P16602: Glass Cutting Machine Wire Supply, Movement and Takeup

Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

Phase V Plan

Phase V Review Goals

  1. Outline design work and plans moving forward
  2. Gain explicit approval on designs and parts purchasing

CAD Package

Questions investigated during this phase regarding CAD include how do we locate components in 3D space and how do we fully define the dancer pulley subsystem. The pulleys are fully defined and the guide pulley support has been determined. Several options have been modeled for the dancer pulley system.

public/Detailed Design Documents/P16602_CAD_DDR.PNG

Bill of Material (BOM)

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Fixture Subsystem Designs

Dancer Pulley Subsystem

For a complete summary of research please click here

Dancer Pulley System Component List



Pneumatic Components

Pneumatic Components

Dancer Pulley Mounting System

For a complete summary of research please click here



Option 2 Mounting System

Option 2 Mounting System

Option # 1
Option # 3

Option #1 Option #2 Option #3
Sliding Door Glide
Option 1 Slide Component
Linear Bearing for T-Slotted Framing
Option 2 Slide Component
Track Roller Carriage for T-Slotted Framing
Option 3 Slide Component
Component Price=$2.89 Component Price=$43.51 Component Price=$56.67
Dancer Pulley System Cost Summary

Dancer Pulley System Cost Summary

Next Steps:

  1. Gain approval
  2. Order components
  3. Integrate components into frame design
  4. Receive parts
  5. Test design

Take-up Spool Subsystem


Take-Up Spool Proposal:

Schematic showing the basic casting design of the take up spool

Schematic showing the basic casting design of the take up spool

Recommended Spool Dimensions

Recommended Spool Dimensions

Mounting and Locating

Key Features:

Take-Up Spool Removal Process:

  1. Attach handcart lifting strap to take-up spool (Full spool weighs about 220 lbs)
  2. Remove clamp plate bolts
  3. Slide clamp plate and removable locator cone through the hole in the frame
  4. Slide take-up spool over until it clears the fixed locator cone
  5. Pull spool straight out
  6. Use angle grinder to cut used wire off the spool

Next Steps:

Pulley Solutions

Our system contains 6 pulleys, a traversing pulley, indexing the wire on the spool, a dancer pulley, controlling the tension of the wire by controlling the wire path length, and a pulley to locate the wire on the rollers, on both the supply and take-up sides of the system.
CAD Model of the Traversing Pulley

CAD Model of the Traversing Pulley

The plan is to manufacture the pulleys in house at RIT using the CNC machines available there.

As for the bearings to be used on the pulleys, with a shaft of 0.5 inches, Mcmaster Carr provides a range of possible solutions such as Permanently Lubricated Ball Bearings, High-Load Ball Bearings or Corrosion-Resistant Stainless Steel Ball Bearings, each with different forms such as open, sealed or shielded. We will not be using positive air pressure for bearings since no slurry is used in our system.
Possible Pulley Bearing Solutions

Possible Pulley Bearing Solutions

Motor and Control System Selection

For the full electrical presentation including details of the different take up spools and the other alternative options, please click here
This is the selected solid takeup spool alternative. The calculations were done by hand and verified with the motion analyzer tool.

The following were the options presented to the customer and are arranged from cheapest and least able to achieve deliverables to most expensive and best able to achieve deliverables.

From the presented options, option 6 was chosen its specific components can be seen below.
public/Detailed Design Documents/Images/Selected Option.PNG

Risk Assessment

Four Main Risks

  1. Design Deadlines for MSD I
    • Due to the complexity of the subsystems in our fixture design is taking longer than anticipated
    • All design should be complete by the end of phase 1 of MSD II
  2. Change in project scope
    • Due to high cost control systems, changes are being made to the project scope
    • Project goals, planning, and design must change as the scope changes
  3. Uneven individual contributions
    • Due to constantly changing demands during the design phase team member contributions are uneven
    • Prior to the Gate Review, the team will discuss ways to eliminate this problem in MSD II
  4. Lack of machining capabilities
    • Multiple large parts must be machined for this fixture, if machines are unavailable or do not have the capabilities needed to meet tolerances these parts may need to be outsourced

For a live risk list document click here.

Plans for next phase

Current Progress

Team Goals Moving Forward

Before the End of the Semester

Individual Focus Areas to Prepare for MSD II

Home | Planning & Execution | Imagine RIT

Problem Definition | Systems Design | Subsystem Design | Preliminary Detailed Design | Detailed Design | MSD I Gate Review

Week 2 Design Review | Week 5 Design Review | Week 8 Design Review | Week 11 Design Review | Customer Handoff & Final Project Documentation