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What is available to teachers and students
July 2009

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July 2009
Moshe Kam
D.G. Gorham
Ship the Chip
Sort It Out
Critical Load
Pulleys and Force
Rotational Equilibrium
Understanding Bar Codes

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Package design and the engineering behind shipping products safely

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Ship the Chip
Objectives
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Learn about engineering product planning and design
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Learn about meeting the needs of the customer and society
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Learn about teamwork and cooperation
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Ship the Chip
Students will learn…
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Package design, manufacture and test
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Material properties and selection
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5

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Ship the Chip
The Challenge

Design a package that will securely hold a potato chip and protect it from breaking when dropped
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Construct the lightest package to get the highest score
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Overall score based on:

Weight of the package


Volume of the package
Intactness Score
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Ship the Chip
Procedure
1.

Sketch a design on the worksheet
Label your worksheet with Table # and Team Name
2.
3.
4.
Construct a model of your package
At a test station, drop the package from a height of 1.5 meters
Open your package and examine the chip
5.
Calculate and record your score
6.

Using a second kit, redesign and construct a new package
Record the second design on the worksheet
7.
8.
Label your package with Table # and Team Name
Submit your worksheet and package to the Test Team for overnight testing
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Ship the Chip
Materials

Cardboard – 22 cm x
28 cm
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10 Craft sticks
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6 Cotton Balls
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String – 91 cm
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Plastic wrap – 1 sheet of 22 cm x
28 cm
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10 Toothpicks
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Foil – 1 sheet of 22 cm x
28 cm
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Paper – 1 sheet of 22 cm x
28 cm
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1 Mailing label
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1 Potato Chip
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Ship the Chip
Tools and Accessories
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Scissors
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Marking pen
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Pencils/Pens
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Calculator
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Rulers
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Digital Scale
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Clear Adhesive
Tape
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Masking Tape
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Ship the Chip
Scoring
_

10
_ _

_ _
3
Intactness score :

100: like new, perfect

50 : slightly damaged; cracked but still in one piece

25 : broken in 2 - 5 pieces
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5 : broken in 6-20 pieces
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1 : broken into more than 20 pieces; crumbled

+ Ship the Chip
Calculating Volume
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We will imbed the package in the smallest-volume rectangular prism that contains it
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We will calculate the volume of the prism;
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Width x Length x Height
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For example : 3cm x 4cm x12cm =144 cm 3 in the prism shown below
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If your package weighed 100g and had a volume of 800 cm 3 and the chip has arrived broken in 3 pieces:
Overall _ Score

_ _

_ _
3
_

25

0.3125
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+ Ship the Chip
Procedure
1.
Sketch a design on the worksheet

Label your worksheet with Table # and Team Name
2.
3.
4.
Construct a model of your package
At a test station, drop the package from a height of 1.5 meters
Open your package and examine the chip
5.
7.
Calculate and record your score
6.

Using a second kit, redesign and construct a new package
Record the second design on the worksheet
Label your package with Table # and Team Name
8.
Submit your worksheet and package to the Test Team for overnight testing
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The engineering behind industrial sorting processes

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Sort It Out

Learn about engineering of systems and about measurements
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Learn about sorting mechanisms
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Get an introduction to Performance
Indices and measures of errors
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Learn about teamwork and cooperation
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Sort It Out
Sorting through History
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Miners panning for gold
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Quality control in food and other industries
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Bottle sorting for recycling
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Sort It Out
Different Types of Sorting
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Image Processing for the operation of Casinos
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Off-the-shelf cameras, frame grabbers, and imageprocessing software used to develop a casino-coin sorting Lighting system
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Frame
Grabber
Digital I/O &
Network
Connection
Camera &
Optics
PC platform
Inspection software
Part Sensor

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Sort It Out
Different Types of Sorting
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Material Properties of
Coin:
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Current run through left coil, creates magnetic field
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Magnetic field passes through and is attenuated by coin
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Right coil receives magnetic field, creates measurable current with different value depending on the coin
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Coin in
Center
Transverse line represents direction of magnetic field

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Sort It Out
Why Coin Sorting is Needed
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Mixed coins come from a variety of sources and must be sorted out before they can be redistributed
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Coins from vending machines
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Coins from parking meters
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Also helpful to identify fake or foreign coins
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Sort It Out
Why Coin Sorting is Needed
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Mixed coins are
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Sorted
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Rolled
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Re-circulated through banks and businesses
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Sort It Out
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Your Turn
Groups of 2
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You are a team of engineers hired by a bank to develop a machine to sort coins that are brought in by customers.
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Must mechanically sort 16 mixed coins into separate containers.
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In our experiment we use washers:
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½ Inch
1 Inch
1¼ Inch
1½ Inch
You will make TWO designs today
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Sort It Out!
Parallel Sorter
Input
Sorting
Mechanism
½”
1”
1½”
1¼”
Output
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Sort It Out!
Parallel Sorter
Input
Sorting
Mechanism
Output
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Sort It Out!
Serial Sorter
Input
Sorting
Mechanism
Output
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Sort It Out
Performance Index 1: “Distance Index”
How good is it?
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1: “Distance” performance index:
1
½ ½
½
½in
1
1
1 1
1in
1
1¼
1¼ 1¼ 1¼
1¼
1¼in
1½
1
1½in
1½
Distance from correct bin here, D error
= 2 bins
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
A washer that does not get sorted has maximum
D error
= 3

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Sort It Out
Performance Index 2: “Percentage Index”
How good is it?
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2: “Percentage” performance index:
1
½ ½
½
½in
1
1
1 1
1in
1
1¼
1¼ 1¼ 1¼
1¼
1¼in
1½
1
1½in
1½
# of washers incorrectly identified
Total # of washers to sort 40
5%
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Sort It Out!
Table Number: Type of Sorter Serial
Team Name:
# of this type in Container for this size washer:
Parallel
Total washers sorted:
16
1" 1 1/4" 1 1/2" each container 1/2"
1/2":
1":
1 1/4":
1 1/2":
Number left unsorted:
Distance Index:
Percentage Index:

Sort It Out!
Table Number:
16
The Perfect Group
Type of Sorter Serial
Team Name:
# of this type in Container for this size washer:
Parallel
Total washers sorted:
16
1" 1 1/4" 1 1/2" each container 1/2"
1/2":
4
1":
1 1/4":
1 1/2":
4
4
Number left unsorted:
0
Distance Index:
4
Percentage Index:
0
0%

Sort It Out!
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Distance Performance Index
 sqrt( 0x1 2 + 0x2 2 + 0x3 2 ) = 0
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A Perfect Score!
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Remember: Lower is better
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Percentage Performance Index
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( 0 / 16 ) x 100 = 0%
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Another Perfect Score!

Sort It Out!
Table Number:
16
Not That Perfect
Type of Sorter Serial
Team Name:
# of this type in Container for this size washer:
Parallel
Total washers sorted:
16
1" 1 1/4" 1 1/2" each container 1/2"
1/2":
4
1":
1 1/4":
1 1/2":
4
1
4
3
Number left unsorted:
0
Distance Index:
Percentage Index:
1
6.25%

Sort It Out!
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Distance Performance Index
 sqrt( 1x1 2 + 0x2 2 + 0x3 2 ) = 1
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A Less Than Perfect Score!
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Remember: Lower is better
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Percentage Performance Index
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( 1 / 16 ) x 100 = 6.25%
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A Less Than Perfect Score!

Sort It Out!
Table Number:
16
The Truly Miserable
Type of Sorter Serial
Team Name:
# of this type in Container for this size washer:
Parallel
Total washers sorted:
16 each container 1/2"
1/2":
1":
1 1/4":
1 1/2":
1
4
1"
1
4
1 1/4" 1 1/2"
1 1
Number left unsorted:
2
Distance Index:
6.16
2
Percentage Index:
56%

Sort It Out!
1/2":
1":
1 1
4
1 1 Number left unsorted: 2
Distance
Index:
6.16
1 1/4": 4
Percentage
Index:
56%
1 1/2":
2
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Distance Performance Index
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 sqrt( 1x1 2 + 1x2 2 + 4x2 2 + 1x3 2 + 2x3 2 ) = 6.16
Much higher score, much lower performance
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Remember: Lower is better
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Percentage Performance Index
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( 9 / 16 ) x 100 = 56.25%
Again, much lower performance

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Sort It Out
Your Turn
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Design (draw) a mechanical sorter that can separate the ½in, 1in,
1¼in, 1½in washers
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Input: either
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Mechanical “shaking” of your device is allowed as part of its operation
Parallel – all 16 washers are inserted at start of your sorter together; or
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Serial – 16 washers are inserted at start of your sorter one at a time
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Materials:
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 glue, tape, paper or plastic plates, cardboard, scissors or hole punch, foil, paper, cardboard tubes washers
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Output: Each size of washer in its own physical container or surface
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Sort It Out
Your Turn
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You will have 45 seconds to allow your sorter to operate
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Predict the value of the two performance indices for your design
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Construct your sorting mechanism
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Test it!
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Can you do better?
You will make TWO designs today: one PARALLEL and one SERIAL
Mechanical “shaking” of your device is allowed as part of its operation
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Sort It Out
Conclusion
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Did your sorting mechanism work? If not, why did it fail?
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What were your performance index values?
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What levels of error would be acceptable in:
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Medical Equipment manufacturing?
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Nail manufacturing?
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What redesigns were necessary when you went to construct your design? Why?
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All about force and how pulleys can help reduce it

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Pulleys & Force
Objectives
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Learn about pulleys and pulley systems
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Learn how using multiple pulleys can dramatically reduce required force
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Learn how pulley systems are used in machines and impact everyday life
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Learn about teamwork and problem solving in groups
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Pulleys & Force
Basics of Pulleys: Two orientations
Fixed Pulley Movable Pulley
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Pulleys & Force
Basics of Pulleys
Compound Pulley
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The tension in the rope, T, is always the same everywhere
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Fixed pulley allows for change in direction of applied force
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Sum of the forces: vertically
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2 T = 100 N
T = 50 N

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Pulleys & Force
Mechanical Advantage
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Mechanical Advantage (MA) is the factor by which a mechanism multiplies the force or torque put into it.
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Ideal MA:

Actual MA:
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This movable pulley system has a mechanical advantage of 2

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Pulleys & Force
Work

Work is the amount of energy transferred by a force acting through a distance

Work = Force x
Distance
Work =
Force x
Distance
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A bigger mechanical advantage decreases the force required, but increases the distance over which it must be applied
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The total amount of work required to move the load stays the same
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Pulleys & Force
Efficiency
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The ratio between Actual and Ideal mechanical advantage is Efficiency
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Frictionless system = 100% Efficiency
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Pulleys & Force
Pulleys in the World
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Pulleys have long been used on sailing ships to handle the rigging and move the sails
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Even with large mechanical advantages, it still takes many people to do the work!
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Pulleys & Force
Pulleys in the World
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Pulleys are used in elevators to change the direction of the tension in the cable, reduce power required of lift motor
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Pulleys & Force
Pulleys in the World
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Industrial cranes lift large loads for construction and transportation
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Pulleys & Force
Measuring Tension
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Spring Scale
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Calibrate: Hold spring scale at eye-level and turn adjustment screw until the internal indicator is precisely aligned with the top zero line
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Measure: Create a loop in the end of the rope you want to measure tension in; attach spring scale to loop. Hold the spring scale steady and read off the tension measurement.
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Pulleys & Force
Your Turn
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Groups of 2
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Develop 2 systems to lift a filled soda bottle 10cm with
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1 pulley
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2 pulleys
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Build your systems
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Measure the distance the soda bottle moves and compare it to the distance you had to pull
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What is the actual mechanical advantage?
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Measure the force you must exert on the string and compare it to the force that is finally transmitted to the soda bottle
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What is the ideal mechanical advantage?
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Calculate the efficiency of each system
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Pulleys & Force
Your Turn
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Now join with one other group at your table
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Develop 2 different systems to lift a filled soda bottle 10cm with all 4 pulleys
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Build both systems
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What are their actual mechanical advantages? Ideal?
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Which one has a better efficiency? Why do think that is?
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Pulleys & Force
Conclusion
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Which system required the least amount of force to lift the bottle? How did this system rank in its mechanical advantage?
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Do you think the size of the pulley makes a difference in the ideal mechanical advantage?
Actual?
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How could you further increase the efficiency of your most efficient pulley system design?
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What other engineering problems were solved with pulleys or pulley systems?
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Spring Scale
 www.arborsci.com
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Structural engineering and how to reinforce the design of a structure to hold more weight.

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Critical Load
Objectives
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Learn about civil engineering and the testing of building structure
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Learn about efficiency ratings and critical load
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Learn about teamwork and the engineering problem solving
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Critical Load
Great Structures of the World
Millau Viaduct

Millau, France
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World’s Tallest Bridge
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2460m long
434m pylon height
270m road height
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December, 2004
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Critical Load
Great Structures of the World
Yokohama Landmark Tower
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Yokohama, Japan
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Japan’s Tallest
Office Building
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296m tall
70 floors including office and hotel
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July, 1993
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Critical Load
Great Structures of the World
Beijing National Stadium – “Bird’s
Nest”
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World’s Largest Steel Structure
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258,000 square meters
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5 years to construct
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110,000 tons of steel used in construction
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3,000,000 cubic meters
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Opened June, 2008

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Critical Load
Great Structures of the World
Crystal Cathedral
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Garden Grove,
California, USA
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World’s Largest
Glass Building
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12 stories tall
12,000+ panes of glass
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16,000-pipe organ
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Opened 1980
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Critical Load
Great Card Structures of the World
Skyscraper of Cards

2007 World Record
House of Cards
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Over 7.5 meters tall
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No glue or tape; just cards
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Built by Bryan Berg in
2007
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Bryan Berg at Work
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Critical Load
What is Critical Load?

Force is placed on a structure

Structure can support up to a certain force created by the weight

At a certain point, the structure will fail, breaking

The maximum force the structure can sustain before failure is known as the “Critical Load”
Force
Force
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Critical Load
Efficiency
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A high critical load is not the only parameter to consider
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Is the best bridge made by filling a canyon with concrete?
It certainly would have a high critical load!
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
Consider also the weight of the structure
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Lighter is better, given the same critical load
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These two parameters are combined in an
“Efficiency Rating”:

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Critical Load
Your Turn

Groups of 2
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Up to 12 cards + 1m tape
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Devise a plan to build a load bearing structure
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Should have a flat top
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Support load with base area of
10 x
10cm at least 8 cm above the table
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No altering of cards allowed – just tape!
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No wrap-ups of tape
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Tape is used to connect cards only
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QUESTIONS
 STRUCTURE NEEDS TO BE CONNECTED
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BENDING OF CARDS IS ALLOWED
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CUTTING OF CARDS IS NOT ALLWOED
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YOU CAN ATTACH SEVERAL CARDS
TOGETHER TO MAKE A THICKER CARD
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THE TOP OF THE STRUCTURE SHOULD ALLOW
FOR A LOAD WITH 10X10CM BASE
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HEIGHT SHOULD BE AT LEAST 8CM
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Critical Load
Your Turn

Example:

Supports load
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
Load is at least 8cm above table
Cards failed after load of
2.4kg


Structure made with 4 cards
Efficiency rating:
2.4 kg / 4 cards = 0.6 kg/card
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8.5 cm height

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Critical Load
Your Turn

Your efficiency rating:
[Load at Failure] / [# of cards used]

Predict what the rating of your design will be
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Build your design
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Test it!

Discuss improvements, then repeat exercise for a second design
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Critical Load
Conclusion

What was your efficiency rating?
How close were you to your prediction?

How was your design different from the best design?

How would you change your design? Why?

What other factors would you need to take into consideration if your Card House were a real office building?
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