Team Vision for Subsystem-Level Design Phase
- What did your team plan to do during this phase?
- Interview Customer
- Finalize answers to feasibility questions
- Update the likelihood and/or severity in our Risk Assessment
- Research controller being used
- Research OSHA/IP Laws
- Research actuators to use
- Electrical Schematic
- Create 3D design of fixture
- Begin creating a BOM
- Create a plan for Phase IV
- Conduct Phase III review
- What did your team actually accomplish during this
- Interviewed customer - 2nd visit to Glass Fab
- Continued updating feasibility questions with new knowledge gain
- Updated Risk Assessment document
- Researched PLCs and linear actuators
- Created a general 3D design of a portion of the overall fixture
- Discretized entire fixture into subsystems
- Started a BOM of high level parts of each subsystem
- Created a plan for Phase IV
- Conducted Phase III review
To view our Subsystem Selection in finer detail, click here.
Bill of Materials (BOM)
To view our Bill of Materials in finer detail, click here.
Feasibility: Prototyping, Analysis, Simulation
To view our Feasibility Analysis in finer detail, click here.
Many of the teams feasibility analysis questions were addressed in the teams second Glass Fab visit. Our findings are summarized in the table below:
To view our Interview Questions and Collected Responses in finer detail, click here.
Subsystem Schematics, Drawings, etc.
Two main requirements of motion: Applying Force and Maintaining Path. To accomplish the applying force part, we chose to use a Linear Actuator
- What is a Linear Actuator?
- A Linear Actuator in this case an all-in-one combination of an electric motor, gearbox and lead screw.
- How does a Linear Actuator work?
- Electric power is converted into mechanical work by the motor which causes the lead screw to rotate.
- A fixed nut on the inside of the actuator creates a purely linear motion of the output shaft.
- Why do we want to use a Linear Actuator?
- Ease of use
- Fewer components to purchase
- When compared to pneumatics/hydraulics, requires less equipment and design complexity.
From this and looking through MSC Direct we came up with a few choices
Currently having difficulty selecting due to the duty cycle parameter, have contacted Duff-Norton about our situation.
Received a reply asking to clarify our operating time on 10/19/2015.
- For Maintaining Path, we plan to use linear shafts to
constrain motion to a single axis.
- Also used to support transverse loads, which can damage the actuator
- Need at least three components:
The shafts, which define our movement range
Shaft supports, which will be mounted to the housing “body”
And the linear bearings, which allow our fixture to move along the shaft. Need to be sized for movement range, and magnitude of forces applied.
Detail View of the Dovetail and the Mounting Plate
Front View of the System
- What is a PLC?
- Programmable Logic Controller (PLC)
- Used for automation of industrial electromechanical processes
- Allows for multiple arrangements of digital and analog inputs and outputs
- System output is based upon input conditions
- Reliable and durable programming equipment
- How does a PLC work?
- Comprised of a power supply, CPU, and I/O ports
- It is a specialized computer used for machine control
- The CPU processes a single program repeatedly
- I/O ports are either digital or analog and the amount vary based on the PLC
- Why do we want to use a PLC?
- A PLC can accommodate three fixtures worth of I/O ports
- A PLC has the programming power to control multiple subsystems at once
- A PLC is used for industrial machine control, which is what we are doing
- PLC Selection Criteria
- System requirements
- What do we want to achieve?
- Break down the task into basic elements
- Application requirements
- Find a device based upon specific function required
- I/O capacity required
- How many inputs do we need for all 3 teams combined?
- I/O types required
- RS 232, Analog, Digital, etc.
- Memory required
- CPU speed requirements (for certain applications)
- Does our system require timing that is
quicker than normal?
- Probably not
- Does our system require timing that is quicker than normal?
- Electrical requirements
- Input/output power/voltage necessary
- Operation speed
- Communication requirements
- This will be determined by what PLC is chosen
- Operator Interface
- How will Ray be able to operate the program/system?
- Physical environments
- Consider where the PLC will be placed
- System requirements
- PLC Benchmarking
To view the PLC Selection data in more detail, click here.
These specifications came from the Rockwell Automation website for Programmable Controllers.
To view our Risk Assessment in finer detail, click here.
Technical Questions for Phase IV
- How many and what type of I/O ports will be needed for each team?
- What additional sensors do the other teams need?
- What sensors are included in the PLC options?
- What sensors will need to be integrated?
- How much memory does the PLC need?
- Will the PLC require an external power supply?
- What materials will be used for the framing of the fixture?
- Based on duty cycle calculations, how many linear actuators will be needed?
Plans for Phase IV
- Add detail to BOM
- Build 3D model of fixture with proper dimensions
- Update Risk Assessment
- Create electrical schematic
- Finalize any remaining feasibility questions
- Propose preliminary detailed design
- Design test plan
- Create a plan for Phase V
- Including beginning Test Plan
- Conduct Phase IV Review