DESIGN FAILURE MODE AND EFFECT ANALYSIS

(DFMEA)
Project Sand Bed Turnover Monitor Revsion Date
Year 2008-2009 Revision Number 1
Team Members: Amanda, Shannon, Jake, Yogesh
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3D Printer
Material Piece may break
Could affect entire
filter operation 5 --
Part designed
too thin/narrow 1
Ensure all pieces
are thicker than 1/8" 5 25
choose a shape that is well
supported and avoids thin pieces 5 1 5 25 --
Layers may separate
Could affect entire
filter operation 5 --
sand abraision
against part
(over extended
period of time) 1
Change material
(plastic injection). To
detect failure, reading
may stop or slow without
bridging 4 20
Recommend to Blue Water to use
plastic injection molding to have one
solid piece instead of layers. 5 1 4 20 --
Too "springy" to spin
No reading/Filter
functions fine 3 --
Part designed
too thin/narrow 1
Ensure all pieces
are thicker than 1/8" 1 3
choose a shape that is well
supported and avoids thin pieces 3 1 1 3 --
Not enough
support in
design 1
Add support bars in
weak areas 1 3
choose a shape that is well
supported and avoids thin pieces 3 1 1 3 --
3d printer
part
may not rotate
because the body is
too circular get no reading 4 --
part is designed
too circular 1 1 4
choose kind of rectangular shape that
build the pressure up 4 1 1 4 --
Mounting
System
Could prevent the
bearing from free
spinning
No reading/Filter
fuctions fine 3 --
outer race not
fully supported 1
mount outer race in
multiple locations (tack
weld in 4+ spots) 1 3
mount outer race in enough
locations to keep it secure ensure that
it is well supported by top brace 3 1 1 3 --
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inner race not
allowed free
movement 1
do not add any additional
friction/restrictions to
inner race 1 3
ensure that inner race is not
touching top support (adding friction)
and that it is free to rotate 3 1 1 3 --
Shaft Bends out of place
No readings;
broken pieces 4 -- Non-rigid shaft 2
Different materials or
shape 2 16
Test and observe different shafts and
reseach alternatives 4 2 2 16 --
Bearing and
shaft
Shaft slides around
the press fit bearing
Create unsteady-
state conditions for
the encoder 3 -- Un-secure fit 3
Add a metal rod through
the shaft that can be
welded to the bearing to
prevent up-down, side-
side movement of shaft 3 27
Research different ways to secure the
shaft to the bearing 3 3 3 27 --
Bearing
May not spin, or may
hardly spin
could affect the
reading process 3 --
Does not give
actual sand
motion rate 1
keep away from dirt and
water 2 6
choose correst type of bearing, and
be careful while banging on bearing 3 1 2 6 --
Encoder Ecoder fails No data 5 --
Weather/
moisture wears
the components 3
Design an encoder casing
that enables the encoder
to perform consistently
under all weather
conditions 1 15
Research an appropriate design to
keep the encoder in a steady-state (is
this necessary?) 5 3 1 15 --
Encoder Encoder Output Fails No Data Collection 5 -- Too much load 1 Weight of shape 1 5 5 1 1 5 --
Encoder
may not give correct
results Affect the reading 3 --
The frequency
of reading is too
high or too low
for plc to detect 1
ensure that we choose
the right type of encoder 1 3 select right kind of encoder 3 1 1 3 --
POTENTIAL FAILURE
MODE(S)
ITEM AND
FUNCTION
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POTENTIAL
CAUSE(S) OF
FAILURE
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ACTION RESULTS RECOMMENDED ACTIONS R
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CURRENT DESIGN
CONTROLS
POTENTIAL
EFFECT(S) OF
FAILURE
3 --
Vibrational
effect may
dampen the
reading 1
Take the encoder as high
as possible from the sand 2 6 Choose high frequency encoder 3 1 2 6 --
PLC Program Fails No Data Collection 5 -- Poor Coding 3 Frequent Testing 4 60 Test Frequently 5 3 4 60 --
Power Cord Fails No Data Collection 5 -- Shorted Wires 2 Organization of Wires 1 10 Organize Wires 5 2 1 10 --
LCD Fails No Data Collection 5 --
Unfused
input/output 3 Fuse Inputs/Outputs 1 15 Fuse Inputs/Outputs 5 3 1 15 --
DC Power Supply
Fails No Data Collection 5 --
Unfused
input/output 3 Fuse Inputs/Outputs 1 15 Fuse Inputs/Outputs 5 3 1 15 --
PLC Fails No Data Collection 5 --
Unfused
input/output 3 Fuse Inputs/Outputs 1 15 Fuse Inputs/Outputs 5 3 1 15 --
Dropped Carefulness Be Careful
Acrylic
Model
a plastic piece may
break off
stops filteration
process 5 --
dropping the
sand too hard
on the filter 2
ensure that water is
atleast half filled before
sand is jammed inside the
filter 5 50
be careful while filling the filter with
sand 5 2 5 50 --
air pump may stop
working
stops entire
process 5 --
pump gets
water damaged 1
Put the pump unde the
filter 1 5
Ensure that the pump is well covered
so that it doesn't gets soaked 5 1 1 5 --
c:\corresp1\karlrink\designfailure.xls