Project

Year
Team Members

DESIGN FAILURE MODE AND EFFECT ANALYSIS

(DFMEA)
Mainstream
Revsion Date
2007-2008
Revision Number
Nathan Barrett, Michael Elger, Aaron Gauthier, Linsey Abo, and Cody Newbill

ITEM AND FUNCTION

POTENTIAL FAILURE MODE(S)

POTENTIAL
EFFECT(S) OF
FAILURE

S
E
V

A Frame

Weld Failure

Frame falls

Failure in cross brace

System falls

Cable failure

U-bolt failure
Mounting plate failure
Load Cell

Inaccurate readings
Mechanical failure

Pipes/Transport

O
C
C
U
R

CURRENT DESIGN CONTROLS

D
E
T
E
C
T

R
P
N

Overloading, bad
welding, excessive
dynamic loads

Welding and Bolts

40

Calculate Stresses
at fillet welds at
worst case

Overloading, excessive
dynamics, fatigue

Saftey facros

Make sure the

system isn't
overloaded

No control of
linear slide

Overload, wear on cable

strong cable, good winch

Prototype

Load cell falls in

water

Overload, too much

torque on bolt

Design for worst case

Test

4 bolts, supports

Bolt failure analysis

1000 lb load cell with

much less actual load

45

Load cell falls in

water
Mis-readings,
inaccurate data
LC breaks, misreadings

8
5

POTENTIAL CAUSE(S) OF
FAILURE

March 4, 2008
1

3/16" bolts fail, too much

torsion
Dirty environment,
overload

RECOMMENDED
ACTIONS

Torsion, mis-handling

All load is axial

64

Talk to installation
and users

Poor pipe connections

Proven materials and

parts.

30

Solid Connections
and pressure
calculations

18

Consulted with pipe

specialist.

Pipe Leak

Minor Flooding

Pipe Break

Major Flooding

Funnel

Doesn't
deliver sediment to drum

Weight data
inaccurate

Flume
Section

Falls off

Proper training for

person that
installs/removes
funnel
Inspect flume
periodically

Drum not installed

properly

Tank window

Gate, tank and

flume section fall
into sump

10

Bolts shear,
inadequate attatchment

Accurate bolt/weld
calculations

Severe Leaks

Flow profile
altered

Improperly
sealed

Accurate bolt/weld
calculations

4 112

Inspect flume
periodically

Falls off

Tank, auger,
piping
break/fall into
sump

10

Bad welding/
manufacturing

Accurate bolt/weld
calculations

30

Inspect flume
periodically

Severe Leaks

Sediment leaks
into sump,
flow profile altered

Poorly designed/
manufactured

Accurate bolt/weld
calculations

28

Inspect flume
periodically

Drum

Drum stops
turning

Sediment piles
back into flume
and sump

Agitator fails
Drum Jams

Visual through
tank window

Auger

Clogs

Large sediment
particles

Motor fails

Tank

Stops
Slurry
Pump

Tank fills with

sediment
Tank fills with
sediment

Large diameter piping

6 144

80

3 120

70

Tank window

63

Clogs

Sediment backfills
into tank/flume

Sediment chokes
pipe

Seperator no
longer filling

8 128

Stops

Sediment backfills
into
tank/flume

Motor fails

Seperator no longer filling

8 168

Check drum
periodically