P16602: Glass Cutting Machine Wire Supply, Movement and Takeup

Systems Design

Table of Contents

Systems Level Design Documents

Team Vision for System-Level Design Phase

Our vision for this phase was to demonstrate critical system level structure. Our critical system level areas were identified as:

Task List for Systems Design Phase

Task List for Systems Design Phase

Functional Decomposition

Functional Decomposition

Engineering Requirements Mapping

Engineering Requirements Mapping

Changes from phase I engineering requirements and phase II engineering requirements. Green represents engineering requirements that stayed the same, yellow represents newly added engineering requirements, and red represents engineering requirements that were not used for the mapping process.

Engineering Requirements comparison


Benchmarking Table


Morphological Chart and Concept Selection

Morphological Chart

Based on the Morphological Chart above, the team was able to produce multiple concept designs with various design goals for each concept. Click on the following links to see the various iterations produced from our Morphological Chart.

Concept Selection

System-Level Selection Criteria:

Pugh Analysis

First Pugh Iteration

Second Pugh Iteration

Take-Away from Pugh Analysis

System Level Concepts

Chosen Design

Chosen Design

Feasible Design Sketch

Feasible Design

User Friendly Design Sketch

User Friendly Design

Systems Architecture

Electrical Overview

Electrical Architecture

Feasibility: Prototyping, Analysis, Simulation

During the Systems Level Design Phase, our team set out to analyze the feasibility of our project through some technical analysis. The following questions were proposed and answered through simple methods of benchmarking and analysis and solving via simple tools:

  1. How much electrical power will our system consume?
  2. What is the force on each pulley at 24 N (slurry) and 45 N (diamond)?
  3. How long can the wire last doing a lower volume of cuts? (How frequently we need to index wire for low volume)?
  4. How much power will our fixture consume?
  5. How would the work piece being pushed onto the wire affects its tension?
  6. How much torque is needed to spin a spool that holds 475 km of wire while maintaining tension at 25 N?
  7. What motor (size/type) will we need to choose to handle all of the fixtures’ components?

For full solutions of these questions please see the following document: Feasibility Analysis

Controls Flowchart

Controls Flowchart

Risk Assessment

Top Ten Risks at this Phase

Top Ten Risks at this Phase

Included below is a link to the full list detailing the teams risk assessment for reference.

Plans for next phase

Critical Subsystems:

  1. Spool subsystem - Hannah
  2. Frame subsystem - Caleb
  3. Mechanics of Tension subsystem - Sarah
  4. Control Subsystem - Joe
  5. Safety Subsystem - JD
  6. Simulation - Fares
  1. What motor selection to pair with spools? What orientation to put spools in relation to each other? What is the best way to spool the wire?
  2. What is the general layout of all components? How will components be mounted in 3D space? How to determine wire path?
  3. How will tension be monitored? Where will tension monitoring system be located within fixture?
  4. What is sequence of our fixture? How do sensors/motors communicate with controls? Faults?
  5. How will the enclosure protect the user? How will safety sensors tie into overall machine controls? What is the method to detect wire breaks? Is it safe?
  6. How will the workpiece effect the tension of the wire? How to simulate guiderollers? How will team account for unpredicted results? Will it work?

Additional Plans for Next Phase:

15 Week Plan:

15 Week Plan

Customer Visit

Customer Visit Questions Answered

Design Review Q&A

What was the point of benchmarking?
To guide with concept selection with quantitative comparison by comparing to the existing DS264 wire saw.

What is unsafe about a wire break?
Safety of user, components and workpiece.

Do you plan on evaluating on higher speeds?
Yes, especially if we consider switching to diamond wire.

What is "Joe"? (Pugh Chart)
Overview of Joe's hand sketched system level design.

How do you change the tension?
Via tensioning arm/dancer pulley. Discussion occurs leading to the conclusion that spools must be involved in controlling the tension. What if the spools are running at different velocities? What about initial startup tensioning?

Where is the power used?
To overcome inertia during acceleration, friction during steady state.

Does your subsystem set the tension for the whole system?
We believe so. It is the tensioning and spooling system, after all.

Master PLC for all groups?
Yes, set up by Joe.

How will Sarah handle team issues?
Bring up issues and talk as a group. Comfortable in her role.

What is the primary concern for scope creep?
Ease of use.

Action Items for Subsystems Design Phase

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