2.1 Design Proposals

- A very detailed document

- The focus is on the details, they should tell the picture by themselves

- For the content listed below the items should be classified as

i) not applicable,

ii) applicable but incomplete, -> A plan must be provided for completion including dates deliverables.

iii) applicable and complete

- The list below is incomplete, but can be used as a starting point.

- Structural Parts

-- Detailed part drawings.

-- Dimensioned for manufacturing.

-- Tolerances suitable for manufacturing.

-- Justification for tolerances less than 0.005"

-- Hand Calculations for stress concentrations

-- Factor of safety calculations

-- FEA verification of hand calcs

-- A testing plan for part failure

-- A list of fasteners

-- force calculations for all critical members. FBDs required

-- Material selection based upon properties

-- Assembly drawings

-- Kinematics for moving mechanisms

-- Complete parts list inluding minor parts such as fasteners

-- A materials list for parts to be fabricated.

-- Weld specifications

-- Fastener torques

-- Plans for part fabrication and

- Electrical and Controls Design

-- Safety circuitry

-- Panel layout

-- Component selection

-- current calculations for cabinet fuse size

-- Ladder wiring diagram with wire numbers

-- PLC or controller selection

-- Pneumatic/hydraulic drawings

-- Wire management plan

-- Communication layout

-- List of IO with specification for each

-- Ladder logic

- Electronic Design

-- Block diagram

-- Schematic

-- Calculations and/or simulations for critical frequencies, timing, propagation, etc.

-- Board Layouts

-- Connector wiring diagram (with wire colors and numbers)

-- Circuit test points

-- PCBs verified for part dimensions, capacitors, ground planes, trace width, and other design rules.

-- Plans to mount complex parts (e.g., MLF and BGA)

-- links to (or actual) datasheets

- Software Design

-- System architecture block diagram with all software driven hardware shown

-- Modular software design with defined API

-- Control flow using flowchart, state diagrams, and/or data flow diagrams

-- Algorithms for data processing

-- Data structures

-- For scalable systems Order analysis

-- For real-time systems a deterministic analysis of execution

-- For mission critical systems a fail safe plan

-- A built in test harness to allow code testing in sections

-- Code simulation for proof of concept

- Facilities and Production

-- A model of the production flow (before, after, and alternates)

-- Estimates of variability for each process

-- Workstudy of operations

-- Simulation and verification with existing system

-- Process cycle time estimates

-- Estimates of tooling costs

-- Physical layout with distance estimates

-- Ergonomics - ease and stress

- Research

-- A Clear list of objectives

-- A clear list of constriants

-- An experimental proceedure to test for objectives

-- A plan for experimental alternates

-- A sample of an anticipated outcomes and calculations

-- One or more

- User or Graphical Interface

-- An interaction plan (flowchart, state diagram, or script)

-- Drawings of Layout

-- Information required for each ’mode’

-- Inputs and outputs separated as critical, warning, or information

-- A clear set of variables (or circuitry) to interface User Interface to internal system.

- Enclosures and aesthetics

-- A visual look and feel

-- A physical mockup of the design (e.g., scale model)

-- A plan for fabrication (prototype and production)

-- Requirements for interface to functional items

-- Testing, approval, assessment of appearance

- General

-- Detailed budget for prototype, production, testing, or otherwise

-- Shipping costs in the budget

-- Special requirements for parts such as dark room, cold/heat, humidity, fork lift, storage, etc.

-- Itemized parts lists by supplier

-- Plans for testing or proving each of the specifications

-- Project ROI

-- Delivery/pick-up plans

-- Required space for construction and testing

-- A schedule (normally a Gantt chart) that includes time for failures

-- A realistic assessment of the risk of failure. For substantial risks a backup plan is needed.

-- List of special needs such as power (e.g. 3ph. 440Vac), air (90psi), fume hood, drains, water supply, etc.

-- Plans for limited resources such as CNC machines or surface mounting equipment.

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