Table of Contents
Our team is developing the guide roller assembly of an industrial glass cutting wire saw. It is being designed to replace 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.
Future Design Changes
Replace Polycarbonate Viewport
The current viewport, which allows the machinist to view the workpiece as it is being cut by the wire saw, is designed to be made out of polycarbonate paneling. The angle plates have a gap between them, and the polycarbonate paneling covers this entire area. Because of the large quantity of abrasive slurry that will be passing over these panelings, the polycarbonate will quickly turn opaque and prevent the machinist from clearly looking into the machine. The ideal solution to this problem would be to replace the polycarbonate paneling with a metal mesh fencing. This will then need to be covered by a sliding door to prevent slurry from leaving the machine. Additionally, the hole cut in the panelling is meant to take out the catch basket. If there is a large part, it may not fit through this hole. Future changes should enlarge this hole.
Add Water Lines for Slurry Removal
Because there is so much slurry running through the system, there is a high possibility that it will begin to build up in areas that are flat or have a small slope angle. To prevent this slurry build up, we recommend adding water lines for slurry removal. This is not an urgent need because it is currently unknown where these locations may be. Specifically on the Guide Roller assembly, the areas of concern are on the base plate, in the catch basket, and on the top of bearing yoke covers.
Structural Support of Baseplate
After conducting a sufficient amount of finite element analysis to prove that our baseplate is structurally sound, we are confident that the plate (if placed on a table) will hold our system with no concerns. As more components come together to form the full system, the baseplate will see significantly more stress. Because of this, we recommend creating a support system underneath the baseplate to ensure its strength. This will be a key design change as the integration of all the systems begins.
Replace Motor with Newer Model
Due to the end of the life cycle of our current motors, we have left off looking for a new motor that has similar features but a longer warranty and service period. When a new motor is found, the motor shaft design will have to be adjusted to fit the specifications of the new motor. Additionally, the mounting features, such as the motor locating feature and the bolt hole, on the inboard angle plates will need to be adjusted.
Determine Required I/O Modules for Machine
The PLC for the machine has been chosen, but the I/O modules (Analog, Digital, Input,Output, 8 vs. 16 channels, etc.) have yet to be chosen. Essentially, a rough estimate for the safety interlocks on the machine for doors will need to be determined and if those interlocks will be in series or individual. Then analog I/O will have to be determined for the entire system. Essentially, work needs to be done to start interconnecting the mechanical and electrical components together.
The document describing these design changes can be downloaded by clicking here
The full assembly instructions document can be downloaded by clicking here
The full test plan document can be downloaded by clicking here
Bill Of Materials
The full bill of materials to date can be downloaded by clicking here