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Engineering Design Specifications

Document Number: 00001 Title: Keyway machining and component assembly

Revision Date Revision Level Revised By Revision Description

September 23, 2018 00 Uday K. Outlined initial Functional, Non-Functional
specs., and constraints
October 11, 2018 01 Uday K. Detailed requirements and quantified

Intended Application:

This device is intended to be used to mill keyways into steel shafts of known densities. The device also
allows for easy installation of components such as sprockets, bearings, and keys after machining is
completed. It is to be operated indoors, kept away from outdoor elements such as rain, heat, and snow.
This is done to ensure optimum operation of all working components. Electrical components must be
operating at 120V AC.

Requirements Specification:

No. Characteristic Relation Value Units Verification Comments

Real Need
Prevent relative
Ref. > 350 psi Analysis Ref.
Minimize process
Ref. < 2.5 Hours Analysis Ref.
Functional Requirements
Depends on chosen type of key
and keyway. Parallel-sunk keys
are most commonly used since
they prevent axial movement of
key along shaft. Sprocket and
Prevent relative bearings are held using a press fit
1. > 350 psi Analysis
rotation and set screws are used to secure
components in place
Typical keyway must be able to
withstand an avg. shear stress of
350 psi

Based on the weight of a typical

assembly consisting of a shaft,
2. Support shaft > 1800 Lbs. Analysis four sprockets, four bearings.
Safety Factor of 2 is accounted
for in the estimation
Non-Functional Requirements
Machining components do not
Facilitate component hinder the assembly of rotating
assembly * elements and allow for a wide
= 2 Feet Analysis range of motion for the assembler
1. *(Can also be defined
as distance to user This value was chosen to be as
from shaft) armlength, 360 degrees around the
shaft being machined
Based on average manual
2. Calibration time < 15 Mins Analysis calibration time on a CNC
machine table
System Response Depends on the power delivered to
3. < 1 second Examination
Time electric drive motor
Depends on electrical
components, and wear generated
4. Object Life > 20 years Examination with daily operation. Components
more likely to fail are ones in
direct contact with lumber
Component(s) should be easily
Downtime due to replaceable with spare parts,
5. < 2 Hours Examination
system failure without the need to spend added
time on redesign
Sensible modularity when
Installation and setup
6. < 6 Hours Examination designing will dictate easy device
All steel, welded components, and some plastics will be sandblasted and painted for a
7. Aesthetics
consistent finish
RAI Using wear resistant plastic
(Relative (UHMW) on top of steel
8. Abrasion resistance > 5 Analysis
Abrasion components will improve wear
Index) resistance qualities.

Safety must not only be exercised by equipment designers, but also by operators. Guarding
1. Safety must be installed in place as instructed and all warning labels must strictly be followed.
User’s manual must be referred to for proper device operation.
As the average time to machine is
described to be 25-30 mins, most
Minimize process of the time is lost to calibrating
2. < 2.5 Hours Analysis
time the shaft. This should ideally be
only be done once, in the entire
Maximize working Defined area around shaft being
3. < 40 Sq. ft. Examination
area machined (12’ x 3’)

Based on benchmarks and patents

4. Cost < 25,000 CAD Analysis

Maximum shaft Determined by project

5. < 12 Feet Analysis
length requirements

Maximum shaft Determined by project

6. < 2 15/16 Inches Analysis
diameter requirements

The device should easily support add-ons such as laser guides for locating keyways, dust
7. Customizability collection system for metal chips produced during milling, and overhead camera(s) for
improved overhead sight

Material Yield
Strength of framing Yield strength of steel. 44W plate
8. components > 320 MPa Analysis
has a tensile strength of 45,000 psi

User friendliness in
9. Control panel is color coded with areas which provide system feedback and operation

All rotating components need to be

Maintenance, and
oiled/greased, and all sliding
10. serviceability for safe = 1 Week Examination
components need to cleaned for

All components must be able to

operate in the summer, as well as
11. Temperature Range -10-40 °C Analysis in the winter, with the shop doors
opened for a minimum of five