P16718: Micropen workstation design
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Subsystem Build & Test

Table of Contents

Team Vision for Subsystem Level Build & Test Phase

In the subsystem build and test phase the team focused on finalizing the designs for the operator tooling subsystem. Final designs were sent to Micropen for manufacture. Prototype WIP Fixtures were developed and physical prototypes were machined to begin testing. The Bill of Materials was finalized for each of the other subsystems as well to purchase materials. The team had meetings with Micropen to finish the Operator Tooling designs, and Spectra Services to review the camera and monitor the team plans to purchase.

Customer Interview

Date Location Subject Notes
February 18th, 2016 Micropen Medical Gary Fino and William Grande Interview Notes
February 25th, 2016 Spectra Services Gary Fino and Mike Phillips Interview Notes
February 29th, 2016 Micropen Medical Gary Fino Interview Notes

Test Plan Documentation

The team organized the tests by each subsystem across each test that is required to be completed within the Test Matrix document
 Test Matrix

Test Matrix

The 'Project Manager' will be focusing on documentation, scheduling, planning, and other related tasks while still being connected to each of the subsystem components during testing

The ‘Responsible’ person(s) will be in charge of ensuring the assigned subsystem is tested appropriately, the necessary and required documentation is produced while running the tests, and that all analysis of the data after testing is complete.

 Testing Responsibility Table

Testing Responsibility Table

Documents were organized for the testing of each subsystem to ensure efficiency when orders for products come in. Procedures and tests are outlined for each subsystem within the following documents:

  1. Operator Tooling For the Touchup Procedure
  2. Actuating the Opener (Opening-Closing the Chuck)
  3. Viewing Apparatus Used During Touchup
  4. Arm and Elbow Support During Touchup
  5. Operator Keypad
  6. Proper Seating Position
  7. Stretches and Exercise
  8. WIP Fixture and Tile Stand
  9. Kink in the Wire

Risk and Problem Tracking

 Updated Risk Management

Updated Risk Management

Click on the following link for the latest version of the Risk Management

Functional Demo Materials

Operator Keypad

Click on the following link for the latest information for theOperator Keypad

Viewing Apparatus

Click on the following link for the possible solutions for the Viewing Apparatus

WIP Fixture

 WIP Fixture Testing Prototype

WIP Fixture Testing Prototype

Operator Tooling

Functionality Test

Researched and revised the design in order to minimize the cost and environmental impact during production. To reduce the amount of material needed, we worked to consolidate individual parts so that one component would have more than one purpose. We then tried to predict possible problems that could occur during the touch up process, and modified progressively until we felt confident that I had created the best possible design that was both functional and aesthetically pleasing.

Click on the following link for the complete summary of the Final Operator Tooling Prototype Design

 A three dimensional assembly of the final prototype design was created using Solidwork

A three dimensional assembly of the final prototype design was created using Solidwork

Used the solidwork "Interference Detection" to check the operator tooling assembly for interference of all its components. Results: All of detected interference that were found were due to interference's between fasteners or components with threads. This will not be an issue when the holes are tapped to the exact specifications

Simplified version of the selected design was fabricated in the machine shop to show a physical proof of concept.

 Simplified Rough Prototype made from scrap material

Simplified Rough Prototype made from scrap material

Purchased components of the operator tooling prototype were selected based on the specifications and requirements decided by the team.

Soildwork drawings of components to be manufactured

Stress Test

A theoretical analysis of the operator tooling was completed in order to understand the stresses applied onto the supports. We analyzed the system with an over-estimate of the average operator load.

Click on the following link for the worked out solution and Matlab code of the Operator Tooling Theoretical Stress Test

Shown below are MatLab plots of the Maximum normal stress and deflection with respect to axial location along the shaft as the force applied by the operator varies.

 Matlab Plot of Maximum Normal Stress

Matlab Plot of Maximum Normal Stress

 Matlab Plot of Deflection

Matlab Plot of Deflection

In order to model the worst case scenario, the sliding assembly is placed 92.125 mm away from bearing one. When applying the average operator load to the slide assembly (20 N), the amount of deflection experienced by each shaft is about 5 microns. One can observe that the Maximum normal stress is of the fixture is well below the Tensile strength, 620 MPa, and Yield Strength, 310 MPa, of the 303 stainless steel shaft. This ensures that any deflection of the fixture won’t interfere with the process and the model can withstand the bending stress at the base.

Plans for next phase

During the Integrated Build and Test phase the team plans to acquire the remaining parts and components for testing of the subsystems. The team plans to develop functioning prototypes of the subsystems and to begin integrating them on-site at Micropen for further systems integration testing. The team also plans to work with the operators to begin gathering feedback about the initial changes.


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