Verifying if our design will be easily manufactured is the critical challenge. The hydraulic manifold's various complex internal components make producing it challenging and limit our production options. The manifold must also tolerate a variety of pressures and loads. This is a problem since the shape of the device must be redesigned with no stress-sensitive regions allowed. Figure 1 is an example of how the hydraulic pressure affects the receiver port surface. As shown in Figure 2, the dimensions are very specific. A specific size constraint limits our ability to redesign a smaller or larger device. Lastly, the budget imposed on the project rules out expensive manufacturing processes, and the deadline poses a challenge in the turnaround time when ordering the prototype. Below, Table 1 displays the problem's physical restrictions.
Figure 1. Receiver Port Surface Force
Parameter | Constraints |
Manufacturing | Limited manufacturing options due to complex internal features. |
Strength | The manifold must withstand: Downward piston force of 141,350 lbf Upward wedge press of 74,857 lbf Hydraulic pressures of up to 288,558 lbf Subsea pressures of up to 5,000 psi |
Size | It must be sized as 27.5” x 25.5” x 14” in order to fit within the given interfaces. |
Budget | The client has imposed a budget of $20,000 for the prototype |
Deadline | The client has set a project deadline of 04/22/2023. |
Table 1: Major Project Constraints
Our team has a technical analysis plan that will be used to develop and refine our design. This includes FEAs for all the stresses being applied and an extensive review with the client regarding the internal geometries. The calculations required for the design review consist of determining the best angle for manufacturing purposes while keeping a vast enough distance between the ports. After a design has survived under stress and has the optimal geometry, the manufacturer chosen will need to verify whether or not it can execute. Once the manufacturer approves, the team will continue with the design.
With our project, our team has identified two soft challenges that must be overcome to ensure success. Our team's soft challenge is determining whether we would like to outsource material for our device. We may have to consider materials outside our company, depending on our final design. We will classify success as determining the option that will be of the least cost while maximizing the operating potential of our device.
A second soft challenge would be ensuring that all stakeholders, including the client (HMH) and team members, agree regarding project objectives, requirements, and expectations. To measure success, regular communication and feedback, stakeholder satisfaction, and adherence to agreed-upon project milestones.
*Figure 2. Manifold Insertion
*The green portion is the manifold, the angle at which the ports are shown needs to be altered for manufacturing purposes. The current design shown does not allow for the device to fit into the rest of the stack.
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