Revied - OENG 1068 - AD 026 PART A & B - Sem2 2020 - 06 July 2020 PDF

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Coordinator: Pattabhiraman Malavalli Email: [email protected]

SEM2 2020 SoVEHS

PROJECT BRIEF PART A & B For

ENGINEERING PROJECT (OENG 1068) Hydrogen – Electric Hybrid Model Car AD026 – Associate Degree in Engineering Technology (Mechanical) - Mechanical Stream

AD026-Mech

Engineering Project

OENG 1068

Version 1

2020 Page 1

School of Vocational Engineering, Health and Sciences

Project Brief Outline Welcome to the Associate Degree Engineering Project. This Project Brief contains detailed information that supports information outlined in your Course Guide Part B. The Project Brief is prepared to provide you with detailed information and guidelines to undertake the Engineering Project.

Course Details

Progra m Code Progra m Strea Cours e Name Semest er, Year

AD026

Course Code OENG1058

Mechanical

Coordinato r ‘s Name

Pattabhiraman Malavalli

Engineerin g Project

Coordinato r ‘s Phone

+61 3 9925 4080

Semester 1, 2020

Coordinato r ‘s E-Mail

[email protected]. au

Coordinato r ‘s Office

57.5.15

Project Weight

100% of a 24 Credit Point course

Issue Date 12th February 2020 To be Final Report Announce Submissio d on n Date Canvas

AD026 -Mechanical

Engineering Project

OENG 1068

Version 1

2020 Page 2

Table of Contents 1.

Introduction ................................................................................................................................... 5

2.

Course Aims ................................................................................................................................... 5

3.

Learning Outcomes ........................................................................................................................ 6

4.

Hydrogen Powered Automotive Challenge is Project Based Learning ............................................ 7

5.

Project Outcomes ........................................................................................................................... 7

6.

Mentoring ...................................................................................................................................... 8

7.

Reflective Journal ........................................................................................................................... 9

8.

Break Down Structure - Work Schedule ....................................................................................... 10

9.

Resources ..................................................................................................................................... 11

10.

Project Summary ...................................................................................................................... 12

10.1

The Challenge ....................................................................................................................... 12

10.2

Participation in Challenge ..................................................................................................... 12

10.3

Design Requirements ........................................................................................................... 13 10.3.1.....................................................................................Race Car Body and Chassis 13

10.3.2

Cost .............................................................................................................................. 13

10.3.3

Software Analysis ......................................................................................................... 14

10.3.4

Your Tasks ..................................................................................................................... 14



Task 1 – Project Planning, Product Life Cycle Management .................................................. 14



Product Design Team formation ........................................................................................... 14



Identify Resource and allocate resources, assign tasks, MS-Project Gant Chart preparation. 14

10.3.5

Task 2 – Structural Design of the Race Car (Start of Product Life Cycle Management) 15

10.3.6

Task 3 – Electric car concept design review and work on detailed design.....................15

10.3.7

Task 4 - Manufacture of the Race Car Body & Chassis, components, Validation...........16

10.3.8 Task 5 –Redesign Electric racing car for Sustainable engineering applications – Integrate Horizon Hydrogen Fuel Cell ........................................................................................... 16 10.3.9

Task 6 – Horizon Fuel Cell Assembly ............................................................................. 16

10.3.10

Task 7 – Validation System ........................................................................................ 17

10.3.11

Task 8 – FEA and Testing report, Quality Check ......................................................... 17

10.3.12

Task 9 – Performance Testing and Competition ........................................................ 17

11.

Phases of the Project ............................................................................................................... 18

12.

Occupational Health & Safety .................................................................................................. 19

13.

Material Requirements ............................................................................................................ 20

14.

Assessment .............................................................................................................................. 20

14.1

Overview of Assessment ...................................................................................................... 20

14.2

Assessment Tasks ................................................................................................................. 20

14.2.1

Initial Design and Project Plan (10%) ............................................................................ 21

14.2.2

Interim Project Report and Poster (15%) ...................................................................... 21

14.2.3

Final Project Report (50%) ............................................................................................ 22

14.2.4

Participation and Teamwork (10%) ............................................................................... 24

14.2.5

Presentation (15%) ....................................................................................................... 24

14.3 15.

Presentation of Printed Materials ......................................................................................... 26 Appendix .................................................................................................................................. 27

15.1

Regulations ........................................................................................................................... 27

15.1.1

General Regulations ..................................................................................................... 27

15.1.2

Body Size Regulations ................................................................................................... 28

15.1.3

Wheel Regulations 1 ..................................................................................................... 29

15.1.4

Power Plant Regulations ............................................................................................... 29

15.1.5

Aerofoil Regulations ..................................................................................................... 30

15.1.6

Vehicle Repair Regulations ........................................................................................... 30

15.1.7

Grievances .................................................................................................................... 30

15.1.8

Race Regulations .......................................................................................................... 30

1. Introduction The Engineering Project is a capstone project that encourages a holistic approach for managing the technical and managerial aspects of a project, utilising multiple technologies and topics you have learnt. It provides you with the opportunity to demonstrate your learning and develop skills relevant to the industry for your future employment. It will also provide you an opportunity to integrate and further develop a range of technical and generic skills acquired in the courses completed in the program. You will also undertake a number of activities in this course to enhance communication and project management skills. a. Introducing to the Alternative energy sources, Hydrogen Fuel Cell. b. Application of Hydrogen Fuel Cell power generator in model race cars

2. Course Aims The main aim of this course is to simulate a real engineering environment and provide you with Work Integrated Learning. This course is project based and requires you to demonstrate technical skills, professional capabilities and personal attributes at levels which are commensurate with paraprofessional engineering practice as defined by organisations such as Engineers Australia. It is also designed to develop and enhance critical managerial skills such as planning, developing objectives, managing risks, report writing and time management. The project work in this course is equivalent to a two-month full-time task that a new graduate may be expected to undertake shortly after starting work as an engineering officer.

You will receive supervision from your Coordinator and may also have a mentor. Your mentor could be an academic staf member, an industry representative or/and a student completing a Bachelor Degree program in a similar discipline. You are expected to perform your project work in a group and independently i.e. including minimal guidance from your supervisor and/or mentor. This project will be completed in the final semester of the program.

3. Learning Outcomes: After completion of this course you are expected to achieve the following learning outcomes: 

      

Ability to apply knowledge of basic science, engineering and electric car design fundamentals and extensive knowledge of real electric car technologies In-depth technical competence in at least one engineering discipline Ability to undertake problem identification, formulation and solution Ability to utilise a system approach to design and performance Ability to engage in design and execute designs to an appropriate professional standard Ability to use appropriate techniques and resources Ability to manage information and documentation Ability to apply to creative and innovative capabilities

The course will also contribute significantly to the development of your capabilities as follows:  



  

Ability to communicate efectively, not only with engineers but also with the community at large Ability to function efectively as an individual and in multi- disciplinary and multi-cultural teams, with the capacity to be a leader or manager as well as an efective team member Understanding of the social, cultural, global and environmental responsibilities of the professional engineer, and the principles of sustainable design and development Understanding of and commitment to professional and ethical responsibilities Expectation and capacity to undertake lifelong learning Ability to demonstrate professional attitudes

With regard to technically specific learning outcomes, you will be able to:

     

Develop surface modelling using CATIA-V5&6 or Solidworks Develop virtual wind tunnel model for fluid flow analysis Develop FEA, Model and conduct endurance test on CAD model Develop CNC code from 3D CAD model or 3D printing Develop reverse engineering model and industry standard dimensional report Develop focused engineering skills on sustainable engineering by involving in Hydrogen Fuel Cell and Electric Automotive Challenge

4. Hydrogen Powered Model car limited design and development - Project Based Learning Project Based Learning is centered on learning that emanates from exploring a real Hydrogen Fuel Cell Electric Automobile Technology. You will design and race hydrogen powered RC cars. This 24 credit points course mobilise around renewable energy vision through team work and collaboration. The task involved in this project empowers the students to become problem solvers of tomorrow. In Project Based Learning, you will spend much of your time learning by:    

Identifying: Determining what you need to know Researching: Finding out what you need to know from the library, Internet, colleagues, Industries. Teaching: Teaching yourself, each other and reinforce the understanding with coordinator. Applying: Applying your new knowledge ins design, develop and validate the Hydrogen powered RC car. Also you will apply the knowledge you have developed from previous courses.

The primary aim of the exercise is to complete the project on time. Project Based Learning encourages interdependent learning and reinforce in depth understanding of the product design. This will provide you with an ability to understand in depth of knowledge about the product. Creates an opportunity to defining your own gaps and to solving engineering problems.

5. Project Outcomes After the completion of this project work, you can achieve the following outcomes:  Ability to apply knowledge learned in other technical courses in the design and implementation of an engineering project  Ability to solve engineering problems utilising sound engineering methodologies  Develop investigative and communication skills with others both in writing and verbally  Appreciation of the range of activities required to initiate, plan and execute a project  Development of project and time management skills  The undertaking of a technical design project in a coherent and logical manner  Writing a project report in a fluent and coherent style  Presentation of a technical project in a fluent and compelling way  Development of teamwork skills

6. Mentoring Mentoring allows for interaction on an advisory basis (for example, teacher-student), by having someone that encourages and assists in the learning process. An efective mentor optimises and develops the project group whilst also encouraging the integration of individual contributions within the group environment. You can learn from a mentor’s expertise and experience. Your mentor could be an academic staf member, an industry representative and/or a student completing a Bachelor Degree program in a similar discipline (Final Year Bachelor Degree students will be requested to be a peer mentor to each team). Guest speakers will also be invited from the relevant industry and/or relevant discipline from the Higher Education School. You will therefore benefit also from the information delivered by the guest Speakers to complete your project. The mentoring and support mechanism is illustrated below:

7. Reflective Journal The purpose of a reflective journal is to record your project related activities to keep on track. Your journal should be a reflective document that provides a personal analysis of your individual participation and progress. Documenting all technical information and your assessment of the group interactions that have occurred during the week. Throughout the project, you will meet with your Project Supervisor weekly two hours to report on progress. You should raise issues and get a resolution. You should ask questions to ensure successful completion of your project. Dot points and actions from this meeting should be recorded in your reflective journal as a weekly entry. You need to access and print of the journal template in the accompanying Resource Package – see Section 9. If unavoidable events prevent an individual in the group from attendance at this weekly meeting, that individual must submit a written copy to ensure their team contribution and accountability is upheld.

AD026 -Mechanical

Engineering Project

OENG 1068

Version 1

2019 Page 10

Prepare action plan and highlight action taken from previous journals and present at the weekly meeting with your supervisor. Discuss your journal entries from the previous meeting typed on the word document and report actions taken. At the end of the semester, you will submit your aggregated all weekly journal entries and actions recorded during the semester. These completed journal will be assessed and graded along with your overall participation and team work. Please note that a failure to complete weekly journal entries will result in a loss of marks.

8. Work Break Down Structure - Work Schedule

AD026 -Mechanical

Engineering Project

OENG 1068

Version 1

2019 Page 11

Week

Project Activity

Week 1

Project work is Phase -1 (refer Develop section 10.3.6 details of Taskcommenced 3) Mile Stone -1 Project planning, Ganttfor Chart, Project Manufacturing Initial andDesign Assembly Week 7 Management, Life Cycle Work, Work Break Down Structure Completed Process Development & Introduction to Mechanical system, Subsystem, review, work on (refer section Hydrogen Fuel Cell,Continue Introduction to Task3 Electrical Goals 10 3 6 for details of Task 3) Principle and applied electronics. Allocation, Team Formation Complete Electric Week 8 Manufacturing components and build assembly. Identified Strategic Assessment & submission. Car Develop Validation of TAMIYA battery Record powered on reflective Commence work on Task1 (refer section 10.3.4) car assembly race car modal testing journal Mile Stone -2 details of Task 1) Task 4(refer section 10.3.7 for details of Task 4) Product Design Phase 1 – Concept Design Week 9comprehensive productPhase 2 Develop Redesign Racing Car for Sustainable definition by defining working principles of the Electric energy application : function, performance and race car. Product Horizon Hydrogen Fuel Cell Fundamentals H specifications, Chassis, Transmission, Hydrogen Fuel Cell safety, Hydrogen C eBody, ll 2.0 Steering, Suspension, Power and Control RC Fuel Cell applications and operations system design and Integration Assembly, Continue work on Task 5 Continue work on section Task 2 (refer 10.3.5 (refer 10.3.8section for details of Task fDesign d t review, il f5) T Develop k 2) component layout Week 10 Hydrogen Fuel Cell Assembly Task 6 and design methodology, Continue work on refer section 10.3.9 for details of Task Task2 Schumacher K151 Mi1v2 - 4WD...