MP4701 DESIGN AND OPERATION OF SUSTAINABLE SYSTEM

Solution.pdf

INSTRUCTIONS 

1. The assignment should be your own original work and should be properly type-written in 

your own words. It will be checked for plagiarism using Turnitin. Any plagiarism or 

copying from others will be dealt with through the university’s plagiarism procedures. 

Similarity (plagiarism) level higher than 10% is highly suspicious. 

2. The whole report should be 1500 words plus any relevant material. Any references to 

materials should be given in standard Harvard or Vancouver form. 

3. Your assignment must be submitted electronically via blackboard by the submission time 

or before. The report should be contained in a Word document or pdf document. No other 

means of submission will be accepted. 

4. Drawings can be done by hand or electronically. They can either be scanned / copied into 

your Word or pdf document. 

5. Any assignment submitted late, but within 5 working days of the deadline, will be given a 

maximum mark of 50%. Assignments submitted more than 5 working days after the 

deadline will not be marked, and a mark of 0% will be recorded. 

6. Students with special needs will be addressed on individual basis. 

(Candidates that may require any special requirement will be dealt with on a one-on-one 

basis which must be discussed with the module tutor/lead before the due date). 

Learning Outcome to be assessed: 

This assignment is structured that students show evidence for partial fulfilment of the following 

module learning outcomes 

1. Understand current development of reliability and condition monitoring methods. 

2. Perform qualitative and quantitative analysis on mechanical systems. 

3. Design a complete conditioning monitoring system for a machine using ISO 

standards. 4. Design of complete structural health monitoring system using SAE/ ISO standards. 

5. Analyse a design for its reliability and maintainability using ISO standard techniques. 

Page 2 of 6 

2019/2020 MODULE CODE: MP 4701 

DESIGN AND OPERATION OF SUSTAINABLE SYSTEMS 

ASSIGNMENT 

REG / ID NUMBER: 

DATE: 

By submitting electronically, I confirm that this piece of submitted work is all my own work 

(unless indicated otherwise within the assignment) and that all references and quotations from 

both primary and secondary sources have been fully identified and properly acknowledged in 

the body of the writing, with full references at the end. 

Page 3 of 6 

ASSIGNMENT 

Ford Motors is planning to introduce a new model to address urban transportation challenge by 

investing in the emerging mobility service with the generation of cleaner vehicles and 

sustainable urban logistics. You have been asked to design the bearing for the rear wheels and 

the suspension system of the New Ford Tourneo Connect. 

https://www.youtube.com/watch?v=0jXnHeH9GNg 

https://www.youtube.com/watch?v=K4JhruinbWc 

There is a trade-off with the size of the bearing, the size should be big enough to last 20 years 

and small enough to reduce the frictional power losses. 

This is an open assignment, the result and viability of the bearings is not known. 

ASSIGNMENT OBJECTIVES: 

? To design and select materials for a reliable shaft/bearing assembly that can be used for the 

above mechanical structure and minimises friction, wear and maintenance. 

? To propose a monitoring system (sensory- actuation system) that can be used to monitor 

system operational condition and prevent system/ sub-systems failure. 

ASSIGNMENT BRIEF: 

You have been asked as an engineer in the ‘Ford Motors’ company to design the bearing for 

the rear wheel, suspension system and to propose a monitoring system for the above prototype. 

Page 4 of 6 

The design process should take into consideration the main dimensions of the mechanical 

structure and materials of the shaft and bearings. You will need to estimate the size and weight 

of the rear wheel and to make realistic assumptions about the driving speed and suspension 

system. You will need to make realistic assumptions about the operating conditions of the 

bearings. Use bearing theory to select the materials for the journal bearings so they will wear 

no more than 2 mm during normal daily operation for 20 years when maintenance would be 

scheduled. 

Provide a detailed, professional report that contains the following items mentioned below: 

1. Review the motor vehicle industry development, summarise the reliability methodologies 

development and condition monitoring techniques in the motor vehicle industry. 

Hint1: You need to read papers/journals/reports to perform this literature review part. 

2. Look thought different online resources to find failure data for various components of the 

Ford motor engine, and construct a reliability block diagram (RBD) analysis for the motor 

engine. List all the assumptions you have made (e.g. failure criterial, failure/repair interval 

etc.) Hint2: Websites like http://reliabilityanalyticstoolkit.appspot.com/mechanical_reliability_data 

and http://www.barringer1.com/wdbase.htm could be useful however you should also search 

for more specific data. Put your findings in a table with references 

3. Perform failure mode effects analysis (FMEA) on the same Ford motor engine. What is 

the advantages and disadvantages of quantitative method like RBD over qualitative 

method like FMEA? 

Hint3: Review the FMEA method and perform the FMEA analysis on motor. 

4. Propose a monitoring system (sensory- actuation system) that can be used to: 

- Monitor system operational condition 

- Prevent system/ sub-systems failure. 

Describe in detail the main elements of the system. Use block diagrams to support your 

discussion. 

Hint4: You have to think about an actuator to prevent failure. 

Page 5 of 6 

ASSESSMENT CRITERIA 

The Department’s Principles of Assessment will be used to determine grading levels. 

1 Review the motor vehicle industry development, summarise the reliability 

methodologies development and condition monitoring techniques in the 

motor vehicle industry. 

20% 

2 Look thought different online resources to find failure data for various 

components of the Ford motor engine, and construct a reliability block 

diagram (RBD) analysis for the motor engine. 

25% 

3 Perform failure mode effects analysis (FMEA) on the same Ford motor 

engine. List the advantages and disadvantages of quantitative method like 

RBD over qualitative method like FMEA. 

25% 

4 Propose a condition monitoring system (sensory - actuation system) that can 

be used to monitor system operational state and prevent system/ sub-systems 

failure. Describe in detail the main elements of the system. Use block 

diagrams to support your discussion. 

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