Mag-Lite Report (Team)

Purpose of Laboratory - This laboratory will introduce you to the principles of competitive assessment / reverse engineering. You will dissect a Mag-style flashlight and determine how it works. You will also compare the Mag-style flashlight design with that of another small flashlight. Suggested tasks for team members: electrical circuit diagram, mechanical switch operation, external features and body drawings, parts list, materials of construction, and intellectual property information. Use the Guitar Effects Pedal Competetive Assessment Project from Sophomore Clinic to get more ideas on what you should include in your Mag-Lite Report. All information obtained during the Mag-Lite laboratory period must be recorded in your laboratory notebook in pen and the yellow sheet(s) submitted at the end of the laboratory.

Format of Written Project - Submit one report per team. Reports must be printed and stapled in the upper left-hand corner and have 2.5 cm margins on all sides. The type font must be 12 points. The line spacing should be double-spaced. Each page should be numbered (in Word, use Insert, Page Numbers). For help on report writing refer to the chapters "Representations of Technical Information" and "The logical structure of Technical Reports, Section by section" in the course text. Submit one report per team. The written project must contain the following:

1) A letter of transmittal addressed to your section professor stating the report title, what is in the report and why you are submitting it. It must be signed by all members of your team.

2) Cover Sheet - Use a descriptive title (give the brand and model) include team names, submittal date, and course and instructor name.

3) The body of the report, containing the following sections (see "The logical structure of Technical Reports, Section by section" in the course text for detailed descriptions):

Abstract

Introduction

Methods and Materials - this is called "the procedural section" in your course text.

Results - Include appropriate tables (e.g., specifications, parts list) and figures (e.g., drawings) after their first mention in the text. This should cover the following:

i) Form of Mag-Lite: For example: What does it look like? Is it ergonomic? What is it made of? Include a parts list.

ii) Function of Mag-Lite: Describe how it works. Describe how it is constructed. Incorporate material, mechanical, electrical, and assembly factors into your discussion. See the bottom of this document for some electrical help.

iii) Intellectual Property of Mag-Lite: Describe any patents on the product, including subcomponents. Use http://www.delphion.com/ (you'll need to open a "basic registration" account), http://www.uspto.gov/, or other patent sites. When do the patents run out?

iv) Description of another small flashlight. Follow the general format used for the Mag-Lite (Form/Function/Intellectual Property), but with less detail. No drawings required.

Discussion - It should cover the following:

i) Summary of the desirable characteristics of the Mag-Lite. Use House of Quality.

ii) Comparison of Mag-Lite and another small flashlight. How are they similar? different? Which is best? Are they both designed to fulfill the same function? Use House of Quality.

iii) Proposal to make a flashlight competitive to the Mag-Lite. What desirable characteristics does a competitive flashlight need to have? Will there be problems with patents?

The discussion section is based only on information presented in previous sections, with the exception of the material on the proposed new flashlight.

Drawings - Include drawings in the Results sections (and the Discussion section if you want to include a drawing of the proposed flashlight). See the "Graphics" chapter of your course text (also called "Appendix C") for help on making engineering drawings. There should be at least a full page of drawings, drawn by hand or using AutoCAD, Solid Works, or a similar drawing program. Mechanicals should learn Solid Works, Civils should learn AutoCAD. Each drawing should be given a title (e.g., Figure 1: Body of Mag-Lite Flashlight). Figures should be referred to in the Body of the Report (e.g., Figure 1). If a figure is not referenced in the body, it doesn't belong in the report! Drawings include:

i) Dimensioned drawings of parts, including an exploded view diagram. Linking an exploded diagram to a parts list is a good idea.

ii) Electrical circuit diagram showing all pertinent parts.

iii) Mechanical/Electrical switch operation.

Electrical Help (also see the "Various Concepts" document linked from the bottom of Dr. Everett's Freshman Clinic II course webpage)

Measure the Voltage across the flashlight batteries. Compare this to the battery ratings. Also measure the current in each flashlight. Calculate the resistance from the voltage and current, for each flashlight. What is the main cause of resistance in a flashlight? Estimate the power used by each flashlight, based on the voltage and current. How much work do the batteries do when each flashlight is on for a minute? Estimate how long the batteries should last in each flashlight by dividing the rated amp hours by the measured current.