Rochester Institute of Technology



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Automated Oiling System

P08351 – Detailed Design Review

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|Team Member |Discipline |Role |Email address |

|Matt Zapotoski |IE |Project Lead |mcz9592@rit.edu |

|Sharif Hdairis |CE |CE/EE support |sdh6724@rit.edu |

|Bob Shackelford |ME |ME support |rws9132@rit.edu |

|Joe Jennings |ME |ME support |jej3689@rit.edu |

8351 Family Support

|Name |Functional Area of Responsibility |Role |

|Dr. Jim Taylor |Industrial |Guide |

|Prof. John Kaemmerlen |Industrial |Consultant |

|Dr. Pratapa Reddy |Electrical |Consultant |

|Dr. Ben Varela |Mechanical |Consultant |

Table Of Contents

Topic Page Number

Design Review Itinerary 3

Project Background 4

Customer Needs 5

Engineering Specifications 5

Concept Overview – Initial Concept Design 6

Concept Overview – Fixture design/ part transport mechanism 7-9

Concept Overview – Cleaning (Air) mechanism 10

Concept Overview – Conveyor system flow/features 11-12

Concept Overview – Oiling Process 13

Concept Overview – Extras/Custom Parts 14

Concept Overview – Variable Speed Drive 10

Concept Overview – Electrical controls 16-26

Concept Overview – Program Screenshot 12

Bill of Materials 14

Current State of Design Specs 12

Needs Assessment for Reference 13

Project Introduction/Background - Matt 5 minutes

Introduction of team members/disciplines

Background on conveyance system

Overview and updates of concept design

Hardware development - Joe 10 minutes

Overview of current state (fixture, air)

Actions taken to mitigate risks

Demonstration of feasibility

Material Handling Concept Selection- Bob 15 minutes

conveyor selection

Oil Flow/circulation

Control system - Sharif 15 minutes

Overview of controls

Results of

Proposed solution for

Bill of Materials - Joe 5 minutes

Summary of budget status

Long lead items

Wrap-up- Matt 10 Minutes

Design specifications complete to date

Additional discussion and comments from panel

1.0 Project Background

Parlec is a manufacturer of tool holders, most commonly used in CNC machines. Before these units are packaged, they must be oiled. In the past, this process has been all manual, resulting in wasted oil, excessive labor required, inconsistency in part coverage, and hindering product flow (extreme bottlenecking) In a growing foreign market which holds cosmetics above all else, Parlec has expressed interest in an automated oiling machine that will consistently oil the tool holders. The goal of this project is to design a machine that will successfully oil Parlec’s most common tool holders.

The team started the project by defining the goal of the project and creating a needs assessment. The majority of this information was obtained by interviewing the customer. The team then determined the specifications that the design must meet. Brainstorming sessions along with QFD analysis led to concept generation. Pugh’s Matrices were used to choose the best possible solution for each individual subsystem.

This review is a follow up to the concept design, and will cover the overall design of the device in the areas of product development, material transport /oiling mechanism selection, control system, enclosure design and project budget. Each engineering discipline will be broken down systematically and every aspect involved in this project will be discussed. Additionally, team members will discuss the risks that have been identified and the steps that have been taken to mitigate each risk in order to ensure smooth implementation of the final design.

2.0 Customer Needs

The establishment and clarification of customer needs is a crucial part of the concept development process. A meeting with the customer was required in order to generate a list of needs. The customer needs were then translated from the voice of the customer to an engineering voice stating what the team will attempt to achieve in order to satisfy each of the individual needs.

N1.0 The product must be safe

N2.0 The product must be durable and robust

N3.0 Maintain cosmetic standards of foreign markets

N4.0 Human application of work fully removed

N5.0 The end product cannot exceed budget

N6.0 The end product will be attractive to customer

N7.0 The product will be easy to operate

3.0 Engineering Specifications

From the list of generic specifications established prior to the concept review, a final list containing modified/more specific specifications was obtained. This list was used to guide the team through the more intricate design of the the machine.

S1.0 The oiling process has to oil 90% of the part (inside negligible)

S2.0 To meet the anticipated throughput, machine will function at an approximate speed of no less than 0.1 mph

S3.0 The machine should accommodate the COMPLETE product line of toolholders ranging from Cat 30 to Cat 50

S4.0

S5.0 The machine will be running for an average of 8 hours per workday

4.0 Initial Concept Design

[pic] Figure 3.1: Side and top view of the initial concept design

A) Overview

The concept shown is the foundation upon which the team expanded on. The operation of manually loading the tool holder onto the suspended pin, which would then be powered through a cleaning phase (air), dipped into oil, cleaned (air) and output from the system.

B) Issues

Issues arising from the concept review include:

- Questions regarding the feasibility of the proposed tray fixture (why not a pin?)

- Inquiries regarding the strategy of the oil retention mechanism (drip pans) for the system

- The inside of the part does not have to be oiled

5.0 Fixture Design

A) Overview

Initially, the team was planning on a carriage-like fixture that would be large enough to hold all of Parlec’s tool holders. Multiple sketches were designed and analyzed by the team. These were proposed at the initial design review. Although deemed a possible alternative, the negative characteristics/qualities associated with the proposed tray like fixture were brought to the team’s attention.

B) Concept Refinement

The resulting concept, which everyone agreed on, was the use of a pin to hold the part. This pin can be seen below. This pin like fixture is a modification of the fixture currently fastened to the storage racks containing the Cat 40’s and Cat 50’s within the Parlec facility.

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Figure 5.1: Front view of pin Figure 5.2: Side view of pin

An additional tip was added to the end (1/2” in diameter and 1” in length) which will allow the accommodation of the Cat 30’s. This will allow for the ability to handle 90% of Parlec’s toolholder assembly, eliminating the need for any changeovers. The fixture will be fabricated from Delrin (POM) plastic, the current material used for the pegs within the facility. The peg will be screwed to a hook suspended from a trolley assembly. The design of a screw in fixture, will allow for simplified maintenance on the machine if any pegs break or become damaged.

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Figure 5.3: Front view of the support Figure 5.4: front view of the trolley

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Figure 5.5: Side view of the complete arm Figure 5.6: Side view of complete arm

C) Risk Assessment & Mitigation

Part versatility:

The risk that exists with choosing the Delrin pin is its ability to successfully handle the wide array of tool holders, ranging from Cat 30’s to Cat 50’s, all having different lengths. If for some reason, the fabricated pin does not work as efficiently as planned during the testing stage, then the design of the pin can be altered as necessary. The fact that the standard pin (without the top extension) is manufactured at Parlec provides the team with the quickest and cheapest way to fabricate the part, and alter if required.

Durability:

These pins are currently used to solely hold the tool holders on racks, and transport them throughout the facility. Using the pin to transport the parts through the oiling machine will apply more stress, but the trolley is designed so the part will always remain perpendicular to the floor, lowering the amount of stress on the pin. If a pin breaks, it can be replaced by simply unscrewing the part from the support and replacing it with a new one.

6.0 Super Air Knife

A) Overview

The Super Air Knife is the best choice for the application in which being used for. It has a low operating cost, if known for its efficiency (in comparison to nozzles and jets), and is guaranteed to adequately remove any excess oil on any part with a length of less than 22 inches (all desired parts).

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Figure 6.1: Air Knife schematic

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Figure 6.2: Air Knife in action

B) Risk Assessment & Mitigation

The Super Air Knife may be more than what is required, the standard air knife ($117 cheaper) may be more than enough, but the team decided that a more efficient air knife would only increase the overall efficiency of the system.

7.0 Conveyor System

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Figure 7.1: Front view of various pieces used to construct the whole frame

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Figure 7.1: Side view of the constructed frame

The conveyor will be made out of steel; it will require 84 square ft (14” x 6”) The diameter of the cable is 3/8’s of an inch and the thickness of the frame is a ¼ inch.

Feasibility Analysis

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Figure 7.1: Feasibility/requirement calculations for the conveyor

8.0 Support Frame

The framework of the machine will be comprised of 80/20 steel. This steel is very strong and can support large weights. To guarantee that the machine will be able to support the maximum number of the heaviest parts, the dimensions of the pieces of steel used will be 1.50 inch by 1.50 inch (the largest standalone series available).

Base

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Figure 8.1: Side view of frame with oil pans

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Figure 8.2: specs and illustration of 1515 T-Slotted aluminum

9.0 Extras

RUBBER FLAPS

A) Overview

Rubber flaps will be serve as a safeguard for the machine, hindering the ability of oil vapors to contaminate the outside air. These flaps were designed to completely segregate the oiling area from the rest of the machine. That being said, the proposed design is two flaps side by side, 30 inches long and 6 inches wide. The part will travel in between the two flaps.

B) Risk Assessment & Mitigation

The material for which the flaps will be fabricated must be resistant to oil, and should not diminish over time. The two different types of rubber being considered are skirtboard and nitrile. Nitrile is more of a heavy duty rubber that is more tolerant to oil, but is five times the price. Samples of both have been ordered and will be analyzed with the oil.

The other risk that exists is selecting the width of the flaps. The initial selection is 1/8th of an inch. Flaps that are two thick will require excess energy to move the part through them, but flaps that are too thin will not serve the purpose of isolating the oil from the outside environment.

Oil Pans (Retention system)

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Figure 9.2: specs and illustration of 1515 T-Slotted aluminum

The design will have oil pans that are two feet wide that mirror the overlying conveyor. These drip pans, produced from stainless steel, will have tapers allowing any excess oil from the parts to flow back collects into channel which drains into the oil tank. The channel will contain a trap that will filter the oil before it flows back into the tank. The plan to do this is having the oil pans higher than the tank, which will allow gravity to move the recycled oil back into the tank.

9.0 Oiling System

The stainless steel tub shown below was designed around the proposed conveyor layout. It is a total of 6 ft in length, 2 ft in width, and 2 ft deep. The bottom, flat portion of the tub is a length of two feet, and the inclines are 2.83 ft, resulting in an slope of 45 degrees, at which the conveyor will move the parts through.

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Figure 9.1: Side view of oil bath

10.0 Electric Engineering

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Figure 10.1: Electrical subsystem layout

10.1 Control Panel

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10.1 Control Panel (cont)

10.2 Variable Speed Drive

10.3 DC Motor

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10.4 Internal Sensors

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10.4 Internal Sensors (cont)

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10.5 uController (block)

10.6 Summary

The restrictions and requirements on the electric subsystem were minimal, they included:

• Powered by any combination of the following: 3-Phase 110V or 240V drop, Single-Phase 110v.

• The system shall detect parts going through the machine and control airflow in the cleaning compartments to minimize running costs.

• Max PSI encountered is 125, no filtering required, pipe size assumed to be ½”.

• The Control panel shall contain the controls options provided and described by the customer: a Main ON/OFF switch, 1 START and 2 STOP buttons, a method to control the speed of the machine, an Auto/Manual selector, and a Forward/Reverse selector.

This allowed a good deal of flexibility when selecting the components to build the system, most of which will work directly off-the-shelf after following wiring diagrams. The components directly interfacing with the microcontroller had additional restrictions, and that was to have built-in I/O ports that comply with standard voltage levels that the uController would be using (CMOS or TTL). By doing so, all interfacing circuitry was eliminated, giving fewer components, and relying less on costly custom design solutions and maintenance.

The uController selection was based on a number of criteria, supply voltage, processor speed, number of timers, learning curve, reliability, number of I/O ports, and available A/D converters.

The next section will cover some possibly ambiguous schematic level connections in the system.

10.7 Diagrams

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10.7 Diagrams (cont)

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11.0 Bill Of Materials

[pic] Figure 11.1: BOM for conveyor/frame parts

[pic] Figure 11.2: BOM for controls/wiring devices

12.0 Final Concept

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ANTICIPATED COST: $20,074.90

Markup (Shipping, tax, etc): 20%: 4,014.97

FINAL ANTICIPATED COST: $24,089.80

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