P16602: Glass Cutting Machine Wire Supply, Movement and Takeup
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Week 5 Design Review

Table of Contents

Team Vision for Week 5 Design Review

Our vision for week five was to:

Live Revision of the BOM can be found here.

Project Progress

Fixture CAD Model

Major changes have been made to the CAD package to coincide with the fixture layout. Frame is fully defined with the exception of a couple dimensions. The layout shown below will have the pulley system mirrored on the other side and two pulleys on the front simulating the guide rollers.
Fixture CAD

Fixture CAD

The following updates have been made:

Frame Update

Frame top view

Frame top view

Frame side view

Frame side view

Pulley Systems Update

A large amount of design work was put into defining the guide pulley system with components shown below. The manufacturability of each part has been checked by Hanzlik. However, because of changes to the fixture frame layout, these parts will have to be redesigned. The final design will look very similar to this.
Guide pulley system

Guide pulley system

Guide pulley system clamp

Guide pulley system clamp

Guide pulley system bracket

Guide pulley system bracket

Guide pulley system bracket flattened

Guide pulley system bracket flattened

The traversing pulley system has been designed very much like the dancer pulley system. The following components are required:

A pneumatic system was chosen due to ease of manufacture and accuracy. A simple, open-loop controller is all that is necessary. Therefore, no sensors are needed. We are seeking a thumbs-up so that we can move forward with this approach to this subsystem.

Dancer System Update

Bracket #1

Bracket #1

Bracket #2

Bracket #2

Machined Bracket #1

Machined Bracket #1

4 Machined Brackets

4 Machined Brackets

Motor Mounting Update

Mounting Considerations

  1. Provide sufficient clearance, heat sink mass, and cooling air so the motor stays within the operating temperature range of 0...40 °C (32...104 °F). Do NOT enclose the motor unless cooling air is forced across the motor, and keep other heat producing devices away from the motor. Heatsink requirements are listed in a footnote to the Specifications on page 22 (in document)
  2. Verify the axial and radial shaft loads of your application do not exceed theose listed in the Motor Load Force Ratings on page 15 (of document)
  3. Position the motor on the machine with its connectors pointing downwards
  4. Insert and hand-tighten the fasteners in each of the four mounting holes in the motor faceplate. The mounting hole diameter is specified in the Product Dimensions
  5. Align the motor on the machine by using the mounting pilot hole to verify the correct alignment
  6. Tighten the fasteners within the recommended torque (8 ~ 20 N-m, i.e. 70 ~ 180 lb-in)
  7. Rotate the shaft to verify for electrical phasing and encoder alignment. The index pulse occurs on a single-turn encoder when the shaft key is aligned with the connectors. Refer to Product Dimensions for a visual reference of this alignment.
  8. Create a drip loop for the wires to move liquid away from the connectors

FE Analysis

Motor Mount Stresses.

Motor Mount Stresses.

Motor Mount Displacements.

Motor Mount Displacements.

Electrical System

Controller Approval

public/Subsystem Build and Test/Controller BOM.PNG

Projected Outcomes:
  1. Code to be used in the end state machine
  2. Creation of a beginner help guide

Cabinet Current State

public/Subsystem Build and Test/BOM related to cabinet.PNG


public/Subsystem Build and Test/Cabinet Concept.PNG


Zeller Meeting Goals:

  1. Zeller completely understands the customers, RIT's, and the students stake in this project
  2. Refine cabinet development
  3. Get an official quote
  4. Discuss a path, that we may learn along this process

Notes from meeting with Carl on 02/09 and 02/11 can be found by clicking here.
Resources Used in Safety System identification can be found here.

Spool Mount Update

Supply Subsystem Assembly
public/Subsystem Build and Test/Supply.JPG
Take-Up Subsystem Assembly
public/Subsystem Build and Test/TakeUp.JPG

Bearing Loads and Life Calculations

Assumptions:


Take-up bearings:


Supply bearings:


NOTE: The chosen bearing is the same for both take-up and supply bearings. The 1 in bore allows for a shaft diameter large enough to withstand shear stress due to torque. Bearings are ready for supplier approval.
public/Subsystem Build and Test/BRG.JPG

Mounting and Locating

Supply Subsystem
public/Subsystem Build and Test/Annotated1.JPG
  1. Supply clamp plate - holds bearing in place, provides clamp force, and supports the supply spool
  2. Plates to represent framing - strong enough to support the full spool wait and some vibration
  3. Taper Roller Bearings - Provide support for the rotating spool
  4. Removable locating cone - locates and centers supply spool
  5. Supply Spool - Stores new wire
  6. Fixed locating cone - locates and centers supply spool while transmitting torque from the motor through a flexible coupling


Take-Up Subsystem
public/Subsystem Build and Test/Annotated2.JPG

  1. Take-Up clamp plate - holds bearing in place, provides clamp force, and supports the take-up spool
  2. Plates to represent framing - strong enough to support the full spool wait and some vibration
  3. Taper Roller Bearings - Provide support for the rotating spool
  4. Removable locating cone - locates and centers supply spool
  5. Take-Up Spool - Stores used wire wire with channels to allow for cutting the wire off
  6. Fixed locating cone - locates and centers take-up spool while transmitting torque from the motor through a flexible coupling


Risk and Problem Tracking

public/Subsystem Build and Test/Process Map highlightes.PNG

Project Outlook

Plans for Week 8

Questions / Approvals for Customer


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