P16601: Glass Cutting Machine:Guide Rollers
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Build & Test Prep

Table of Contents

Shared Vision for Imagine RIT

Scenarios of Readiness

Best Case Scenario

The best case scenario for team is that we will have our fixture fully assembled, with the controls system we want, and be able to demonstrate all functionality desired. This functionality will be: motors spin at variable speeds based off user input or motion profile, guide rollers match the desired motion profile within tolerance of wire tensile strength, temperature and interlock sensors are integrated within the controls. There will be a means of observing this velocity, as well as confirming that the two motors are in sync. We will have the fixture set up on display and run demonstrations throughout the day. We will have a minimum of two team members present at all times to answer questions.

Moderate Case Scenario 1

The moderate case scenario is that the fixture is completed, but without the desired controls. This downfall may be due to the lead time on the enclosure being insufficient to give the electrical engineers time to develop code for the controls. Some complications could be installing the enclosure, mounting the motors, and having the power distribution complete. Finally, the problems that could have caused these complications are that the code itself wasn’t fully completed.

We will be able to demonstrate that the design is mechanically sound, but are unable to demonstrate the level of control that will be required for the final integration into a finished product. We will have the fixture set up on display and run demonstrations throughout the day. We will have a minimum of two team members present at all times to answer questions.

Moderate Case Scenario 2

An alternative scenario is that the controls may have functionality and the power is set up, but the rollers had complications in design and were not ready. This could be because they do not match the frame, couple with the motors, or had to be redesigned within a limited time frame. The demonstration would consist of being able to monitor the motor’s positions given they can be mounted on a frame. We will have a minimum of two team members present at all times to answer questions.

Worst Case Scenario

The worst case scenario is that we are unable to demonstrate a working fixture. Whether it be because the fixture broke, we were unable to obtain parts, or the electrical components did not integrate with the mechanical system, we are unable to demonstrate a working fixture. Regardless, the team will display the progress they have made. In terms of the exhibit, the team is unable to have multiple people present at all times, due to other commitments or extreme unforeseen circumstances. We will have a minimum of two team members present at all times to answer questions.

Elevator Speech

Our team is developing the guide roller assembly of an industrial glass cutting wire saw. It is being designed to supplement an existing machine which currently cuts high volumes of glass wafers, but consumes a significant amount of power. Our machine is designed to be more energy efficient and will be used for cutting a small number of parts for ease of production. For our specific project, we will be designing the guide roller portion of this machine. These guide rollers will rotate back and forth simultaneously, causing a wire to move with very high precision. The two guide rollers must speed up, slow down, and move at constant velocity without causing the wire to stretch. After our project is complete, it will be integrated with the concurrent two additional projects, having wiring wrap around the guide rollers and a work piece will drop into the wire array. Future projects will add a slurry containing abrasive particles that is sprayed on to the wire, and a team specifically dedicated to integrating all projects. Overall, our senior design project is the heart of the glass cutting machine and will provide the ultimate framework of this multifaceted project.

A link to the live document can be found here

Week 5 Shared Vision

Mechanical

Electrical

Current State of Design

3D Model

Full Assembly

Full Assembly

Guide Roller

Guide Roller

Guide Roller

Insert / Adapter Plate

Front Insert Assembly

Front Insert Assembly

Motorside Insert Assembly

Motorside Insert Assembly

Front Adapter Plate

Front Adapter Plate

Motorside Adapter Plate

Motorside Adapter Plate

Front Insert Plate

Front Insert Plate

Motorside Insert Plate

Motorside Insert Plate

SKF Roller Bearing - Seal purchased separately

SKF Roller Bearing - Seal purchased separately

Adapter Plate Tooth Analysis

After analyzing the worst case, we have concluded:

A link to the hand calculations used to come to these conclusions can be found here

BOM

public/Reviews/MSD2 Week 2 Review/P16601 P1 BOM.jpg

A link to the full bill of materials can be found here

The specified electrical components are below. There are still too many components/items left to keep track off on the same BOM.

public/Reviews/MSD2 Week 2 Review/MSD 2 Phase 1 BOM.png

The excel file of the specified list of EE components can be found here

The guide roller engineering specifications can be found in this PDF taken from Rockwell's website here

Enclosure

Option 1:

The following is a very rough estimate for the manufacturing costs associated with a cabinet our size and scope:

Design: 50 hours x $90 = $4500

Manufacturing: 96 hours x $50 = $4800

Total: $9300

Standard Build Time: 6-8 Weeks after the design is done. Not too mention they most likely will not be able to start right away.

Pros:

Cons:

Option 2:

The EE students can design the cabinet with guidance from Carl and Dave. Although, manufacturing and assembly of the cabinet will also require Carl's help, alot of it can be done by the EE and ME students.

Pros:

Cons:

Option 3:

The EE students are actively engaged in Carl's design and layout of the Cabinet. Carl does most of the manufacturing and assembly.

Pros:

Cons

Enclosure Layout Concept

Enclosure Layout Concept

Above is a really rough concept of what the enclosure could look like. Some critical design decisions that still need to be addressed/researched include the following:

MSD1 Post Mortem

What Did We Miss

ACTION ITEMS

public/Reviews/MSD2 Week 2 Review/P16601 P1 Action Items.JPG

A link to the live document can be found here

What Could We Improve

A link to our full MSD 1 team assessment can be found here

Problem Tracking

public/Reviews/MSD2 Week 2 Review/P16601 P1 Problem Solving Process.jpg

A link to the live document can be found here

Test Plans

Updated Engineering Requirements

public/Reviews/MSD2 Week 2 Review/P16601 P1 Engineering Requirements.jpg

A link to the full bill of materials can be found here

Critical Test Plans

Temperature Testing

public/Reviews/MSD2 Week 2 Review/P16601 P1 Test Plan Bearing Temperature.JPG

Roller Alignment Testing

public/Reviews/MSD2 Week 2 Review/P16601 P1 Test Plan Alignment.JPG

Wire Break Testing

public/Reviews/MSD2 Week 2 Review/P16601 P1 Test Plan Wire Break.JPG

Binary Testing

public/Reviews/MSD2 Week 2 Review/P16601 P1 Test Plan Binary.JPG

A link to the full test plans can be found here

Plans for next phase

Gantt Chart

public/Reviews/MSD2 Week 2 Review/P16601 P1 Project Plan.jpg

The full Gantt Chart in Microsoft Project is available upon request.

Individual Plans

public/Reviews/MSD2 Week 2 Review/P16601 P1 Individual Contributions.jpg

A link to the live document can be found here


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