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Preliminary Detailed Design

Table of Contents 1 Design Review Agenda 2 Engineering Requirements 3 Gantt Chart thru Detailed Design 4 10/29 Trip to AATech 4.1 Trip Report 5 Prototyping, Engineering Analysis, Simulation 5.1 Subsystem 1/6: Chamber/Door 5.2 Subsystem 2/6: Fixture System 5.2.1 CF34 Full Fixture Assembly 5.2.2 GE90 Full Fixture Assembly 5.2.3 CF6-80 Full Fixture Assembly 5.2.4 Passport 20 Full Fixture Assembly 5.2.5 GP7200 Full Fixture Assembly 5.2.6 FEA of Yoke Plates 5.3 Subsystem 3/6: Oil Circulation 5.3.1 Motor 5.3.2 Pump 5.3.3 Regulator 5.3.4 Pressure Gauge 5.3.5 Oil Reservoir 5.4 Subsystem 4/6: I/O Peripherals 5.4.1 Start Button 5.4.2 Door Interlock 5.4.3 Red/Yellow/Green LED Panel Indicator 5.4.4 LS2208 Scanner 5.4.5 24V DC Power Supply 5.4.6 Fluid Solenoid 5.4.7 Air Solenoid Valves - 4639K783 5.4.8 115VAC Relay 5.4.9 I/O Wiring Schematic 5.4.10 Power Flow Diagram 5.5 Subsystem 5/6: User Interface 5.5.1 User Interface Flow 5.6 Subsystem 6/6: Control System 5.6.1 Timing Diagram 5.7 Ergonomics 5.7.1 Fixture Weight 5.7.2 Fixture Height 5.7.3 Rapid Upper Limb Assessment (RULA) 6 Bill of Materials (BOM) 7 Test Plans 8 Risk Assessment 9 Plans for next phase 10 Lessons Learned 11 Preliminary Detailed Design Review 11.0.1 Feedback

Design Review Agenda

1. Engineering requirements
2. Project plan through 11/17
3. 10/29 Trip to AATech
4. Subsystem descriptions and feasibility
5. Ergonomics
6. Test plan
7. Risk assessment
8. Next phase project plan
9. Lessons learned
10. Q&A
11. Action item recap

Engineering Requirements

• Fixture weight added as an engineering requirement.

Gantt Chart thru Detailed Design

10/29 Trip to AATech

• The team visited the AATech plant on 10/29 to meet with Dave Dewispelaere and Cory Hollenbeck. The purpose was to update Cory, who will be responsible for the system in production, on our project status, and to get his feedback. Some design changes resulted from the meeting.

Trip Report

I. Controls

• A Micro820 will still be used as stated in our original design, as it has the capabilities and number of inputs/outputs that we need. We can also purchase an expansion pack if needed.
• A PanelView C400 will be used instead of the 300, because it has a larger display. This was recommended by Cory.
• The bar code scanner was recommended as a last priority by Cory. However, to stay consistent with our original design, the team will use bar code scanning as the primary method for part number entry as long as we stay on schedule and unless issues arise during testing. Push buttons on the PanelView are a back up option.

II. Chamber design

• A stainless steel reservoir with glass panel will be used and will be placed outside of the chamber, a change from our original design of an internal oil compartment. The container will be approximately 3 ft³.
• A tray should be located underneath the chamber in order to catch excess oil.
• 1/2 in. x 1/2 in gussets will be added along the sides of the chamber and will be included in our CAD model.
• A door sliding track will be added as part of our CAD model.
• Polycarbonate will be used instead of acrylic for the chamber material.

III. Other

• An oil filter is required. The oil filter part number has already been provided. The team needs to research the filter housing on our own, as Cory was unsure of the part number.
• The door interlock will be the same as the current system. The part number was already provided.
• An ergonomic scoring video for the current system will be provided along with the calculations used.

Prototyping, Engineering Analysis, Simulation

Subsystem 1/6: Chamber/Door

Subsystem 2/6: Fixture System

CF34 Full Fixture Assembly

GE90 Full Fixture Assembly

CF6-80 Full Fixture Assembly

Passport 20 Full Fixture Assembly

GP7200 Full Fixture Assembly

FEA of Yoke Plates

Subsystem 3/6: Oil Circulation

Motor

Pump

Regulator

• Comes as accessory to pump

Pressure Gauge

• Comes as accessory to pump

Oil Reservoir

• Suggested capacity: 3ft^3 = 22 gal
• Capacity of this tank: 20 gal
• Oil filter included

Subsystem 4/6: I/O Peripherals

Start Button

Door Interlock

Red/Yellow/Green LED Panel Indicator

LS2208 Scanner

24V DC Power Supply

Fluid Solenoid

Air Solenoid Valves - 4639K783

115VAC Relay

I/O Wiring Schematic

• Click here for separate tab.

Power Flow Diagram

• Click here for separate tab.

Subsystem 5/6: User Interface

User Interface Flow

Subsystem 6/6: Control System

Timing Diagram

Ergonomics

Fixture Weight

Assumptions

• One operator will process all nozzle types
• Operator will process all nozzles for a program at once and will do each program once per day
• Operator will lift the fixtures at most 8x per hour (30 second cycle time x 30 nozzles each fixture)
• Fixture can be at most 25 lbs (AAT safety requirement)

Weights

• CAD used to predict fixture weights

Fixture Height

• Based on anthropometry

Assumptions

• 5'6 operator places nozzle at a 45 degree angle from vertical

Enclosure Prototype

Changeover Analysis

Rapid Upper Limb Assessment (RULA)

• Quick observational tool
• Measures a snapshot in time

Assumptions

• Tasks with the most ergonomic risk: Connecting/Disconnecting oil and pneumatic lines, placing/removing nozzle from yoke plate
• Connecting/disconnecting lines: done at most 8x per hour
• Placing/removing nozzle from yoke plate: done at most 4x per minute
• Nozzles are between 4 and 22 lbs

RULA worksheets

Bill of Materials (BOM)

To view the final Bill of Materials for this phase, click here

Test Plans

Risk Assessment

To view the risk assessment for this phase, click here

Plans for next phase

Lessons Learned

• Get all stakeholders involved early
• Purchase parts through your customer

Preliminary Detailed Design Review

Feedback

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