P18391: Grinder Gizmo
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Detailed Design

Table of Contents

Project Statement: Automated burger machine with custom imaging to reduce cost and attract customers

Team Vision for Detailed Design Phase

Planned Tasks for this Phase

Completed Tasks for this Phase

Prototyping, Engineering Analysis, Simulation

Feasibility Testing and Prototyping

Scott Eisele

Last Update: 11/27/17

Burger Cooking Tests

Three techniques were tested in our burger cooking test. These methods are outlined in the table below:
Cooking Method Description Initial Predictions
Two-Sided Press Two heated surfaces press into the burger from either side Fast cook time & high power consumption
One-Sided Press The burger is placed on a hot surface, then flipped halfway through cooking Medium power consumption & automated flip would be challenging
Direct Electrocution Two electrodes are placed on either side of the patty, to cook the patty with the electric current Uncertain cook time & power consumption

The three variables we tested for were total cook time, energy consumption, and preheat time. All burgers were cooked to approximately 170 deg Farhenheit, as per industry health standards. The table below demonstrates the results across the various cooking methods:

Cooking Method Cook Time Preheat Time Total Power Consumption Other Comments
Two-Sided Press 2:13 3:30 0.040 kWh Quick grease buildup
One-Sided Press 11:02 3:30 0.065 kWh Flip at 3:30
Direct Electrocution 5:00 0:00 0.020 kWh Horrible smell

The linked video below shows the outcome of our "electrocution" method test: Electrocution Test Video

Bun Etching Tests

To test the capabilities of our various image generation methods, we tested them by hand to establish a baseline for the effectiveness. The table below describes the various methods tested:

Imaging Method Description Initial Predictions
Laser Etching Use a laser to burn the image into the top of the bun. Fast & effective
Soldering Iron Use a soldering iron to burn the image into the top of the bun. Potential to damage bun
Butane Torch Use a butane torch to burn the image into the top of the bun. Potential to burn bun excessively
Adhesive & Sesame Seeds Apply an adhesive layer to the top of the bun, then sprinkle sesame seeds onto the adhesive. Excess seeds will fall off, but seeds will stick where the adhesive is placed. Adhesive recipe may be complex
Flammable Liquid (Alcohol) Drip alcohol onto the top of the bun in the desired pattern, then ignite to burn the image into the top of the bun. Alcohol may absorb into bun
Flammable Liquid (Oil) Drip oil onto the top of the bun in the desired pattern, then ignite to burn the image into the top of the bun. Oil may absorb into bun
Food-Safe Marker Use a food safe marker to draw the image on top of the bun. Marker may be off-putting
Knife Use a knife to carve the image into the bun. Potential to damage bun

The results of our testing are demonstrated in the table below:

Imaging Method Time to complete [s] Other comments
Laser Etching 192 Poor image contrast, laser could not focus
Soldering Iron 26 High contrast, high resolution image
Butane Torch 18 Poor resolution, surrounding areas of bun were burned
Adhesive & Sesame Seeds 15 Good image contrast, low resolution
Flammable Liquid (Alcohol) N/a Did not work
Flammable Liquid (Oil) N/a Did not work
Food-Safe Marker N/a Did not work
Knife 14 Damaged bun
Bun Imaging Test Via Laser Etching

Bun Imaging Test Via Laser Etching

Bun Imaging Test Via Soldering Iron

Bun Imaging Test Via Soldering Iron

3D Printed Sprocket

To test the feasibility of using 3D printed parts for the complex geometries which will be required by some of our actuation mechanisms, we printed out sample sprockets at The Construct. These sprockets were based off of a CAD model for a sprocket on McMaster Carr.

3D Printed Sprocket

3D Printed Sprocket

The 3D printed sprockets surpassed our expectations for quality and rigidity from the 3D printer. It demonstrated that utilizing 3D printed parts for generic sprockets, gears, gear racks, and bushings could provide sufficient quality to be utilized in our final device. Considering the 3D printed sprockets costed only $0.18, and the cost of one sprocket from McMaster Carr costs $7.40, there is opportunity for significant cost savings in printing many of our parts. 3D printed parts appearing in our BOM are currently planned on being printed at The Construct.

3D Printed Linear Bearing

Additionally, the feasibility of using 3D printed parts and extruded aluminum with a graphite lubricant as linear bearings was tested. A test bracket was 3D printed at the construct using PLA at 50% fill density.

The linked video here demonstrates the hypothetical guide rail: https://drive.google.com/open?id=1rb-ImZ81foBejBBdgS7IorbeYdc-c45Y

3D Printed Bearing for Linear Guide Rails

3D Printed Bearing for Linear Guide Rails

Our test revealed that a 3D printed part will (likely/not likely) be capable of use as an effective linear bearing for our burger elevator.

Bun Vacuum Testing

To test the feasibility of using a vacuum to pick and place the buns, a quick test was performed using a shop-vac and a pair of hamburger buns. The expectation was that the shop-vac would create enough suction to lift the buns. The test demonstrated that the shop-vac was easily able to pick up the buns, however, after the vacuum was turned off, the bun still remained stuck to the vacuum for a few seconds. We believe this is due to the inertia in the vacuum mechanism continuing to generate vacuum even after it has been turned off.

The linked video here demonstrates the test: https://drive.google.com/file/d/0B_Sv6sWokmLAc2RZSUtJbFJNQTA/view?usp=sharing

As a result of this test, we plan on using a shop-vac as our source of vacuum for bun pickup. A shop-vac from WalMart will cost only ~$20, and provide sufficient suction to pick up our buns.

Drawings, Schematics, Flow Charts, Simulations

Mechanical Modeling

Burger Elevator

Scott Eisele

Last Update: 11/11/17

A specialized "burger elevator" has been designed to store and dispense burger patties onto the grill. The image below shows a CAD model of the current elevator design.

Burger Elevator Isometric View

Burger Elevator Isometric View

The elevator will be actuated via a linear electric actuator taken from an electric wheelchair. The linear actuator has a 7" stroke, and requires a 24V power supply. Since the actuator was a pre-used part, it was tested in the CE labs, which verified its usability. We are confident the linear actuator will be able to lift our elevator, due to it's predicted mass of 2.91 lbs from our CAD model, assuming the material properties of 6061 Aluminum.

Burger Elevator Mass Properties

Burger Elevator Mass Properties

The elevator's position will be monitored via cutoff sensors and a series of flags on either side. On one side of the assembly, the flags will be solid, and on the other side the flags will have a 1/16" slot cut into it. This will enable positioning accuracy of 1/16".

Flag Sensors for Burger Elevator Positioning

Flag Sensors for Burger Elevator Positioning

The burgers will be loaded into the elevator on stackable plates, ideally made of stainless steel for food-safety. However, the plates could hypothetically be made of any material, and the elevator will still function properly, enabling flexibility in usage. The plates rest on M4 screws spaced 1" apart on the elevator. Since the plates will be removable, cleanup of the device will be simple, and access to all the corners and crevices where grease may be trapped within the elevator will be easy.

Removable, Stackable Plates for Burger Loading and Storage

Removable, Stackable Plates for Burger Loading and Storage

The patties will be pushed off of the elevator and onto the grill via a spatula controlled with a pneumatic actuator. The pneumatic actuator will enable precise control over the travel speed of the spatula in both the forward and backward stroke. This will enable us to quickly slide out the spatula from underneath the patties to drop them onto the grill.

Pneumatic Actuator With Spatula for Burger Unloading

Pneumatic Actuator With Spatula for Burger Unloading

Burger Elevator Drawings and Assembly Documents

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Link to .stl file Document Owner
Top Plate R01 1 Machined Part Top Plate R01 Drawing Top Plate R01 Model Scott Eisele
Bottom Plate R01 1 Machined Part Bottom Plate R01 Drawing Bottom Plate R01 Model Scott Eisele
Side Plate R01 2 Machined Part Side Plate R01 Drawing Side Plate R01 Model Scott Eisele
Side Plate Slotted R01 2 Machined Part Side Plate Slotted R01 Drawing Side Plate Slotted R01 Model Scott Eisele
Front Bumper R01 2 Machined Part Front Bumper R01 Drawing Front Bumper R01 Model Scott Eisele
Actuator Con Block R01 2 Machined Part Actuator Con Block R01 Drawing Actuator Con Block R01 Model Scott Eisele
Cutoff Sensor Flag Type A R01 6 Machined Part Cutoff Sensor Flag Type A R01 Drawing Cutoff Sensor Flag Type A R01 Model Scott Eisele
Cutoff Sensor Flag Type B R01 6 Machined Part Cutoff Sensor Flag Type B R01 Drawing Cutoff Sensor Flag Type B R01 Model Scott Eisele
Pusher Baseplate R01 1 Machined Part Pusher Baseplate R01 Drawing Pusher Baseplate R01 Model Scott Eisele
Rail Con Bracket R01 2 3D Printed N/a Rail Con Bracket R01 Model Scott Eisele
Cutoff Sensor Mount R01 2 3D Printed N/a Cutoff Sensor Mount R01 Model Scott Eisele
Extruded Aluminum (16" Length) 4 Purchase Part N/a N/a Scott Eisele
Extruded Aluminum (12" Length) 2 Purchase Part N/a N/a Scott Eisele
Extruded Aluminum (4.5" Length) 5 Purchase Part N/a N/a Scott Eisele
Extruded Aluminum (1.5" Length) 1 Purchase Part N/a N/a Scott Eisele
M3x10 Button Head Cap Screws 24 Purchase Part N/a N/a Scott Eisele
M4x30 Button Head Cap Screws Full Thread 16 Purchase Part N/a N/a Scott Eisele
M4x15 Button Head Cap Screws 4 Purchase Part N/a N/a Scott Eisele
M4x12 Button Head Cap Screws 4 Purchase Part N/a N/a Scott Eisele
M5x25 Socket Head Cap Screws 4 Purchase Part N/a N/a Scott Eisele
M5x15 Socket Head Cap Screws 24 Purchase Part N/a N/a Scott Eisele
M4 Washers 24 Purchase Part N/a N/a Scott Eisele
M5 Washers 28 Purchase Part N/a N/a Scott Eisele
M5 Nuts 4 Purchase Part N/a N/a Scott Eisele
Burger Elevator Assy R01 1 Assembly Drawing Burger Elevator R01 Assembly Drawing N/a Scott Eisele

Burger Cooker

Scott Eisele

Last Update: 11/28/17

To cook our burgers, we selected a setup which utilizes a store-purchased George Foreman grill. This is a low-budget, low-risk cooking method.

Burger Cooker with Single Motor Actuation

Burger Cooker with Single Motor Actuation

The grill will be opened and closed via an electric motor tied to a U-bolt mounted to the lid of the grill. Burgers will be placed into the grill from the burger elevator with the spatula, and removed from the grill with the vacuum transfer system.

Burger Cooker Drawings and Assembly Documents

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Link to .stl file Document Owner
Motor Clamp R01 1 3D Printed N/a Motor Clamp R01 Model Scott Eisele

Vacuum Transfer System

Zach Gastin

Last Update: 12/08/17

To assemble the burger, the top bun need to be picked up from the storage location and placed onto the image generation station and the bottom bun needs to be picked up and then placed into the assembly station. Then the cooked hamburger patty needs to be picked up from the grill and placed onto the bottom bun in the assembly station, and finally the top bun with the image needs to be picked up from the image generation station and then placed onto the hamburger patty in the assembly station. This will all be accomplished by vacuum system on a horizontal axis, actuated by a stepper motor and toothed belt to provide location accuracy. Additionally the vacuum system will be mounted to a vertical linear actuator to allow differing object heights. A vacuum cup will be used to pick up the objects.

Vacuum Transfer Sub Assembly Isometric View

Vacuum Transfer Sub Assembly Isometric View

Vacuum Transfer Sub Assembly Side View

Vacuum Transfer Sub Assembly Side View

Horizontal and vertical location will be monitored through the stepper motors, with a home switch for each axis. The horizontal axis will be a carriage riding on an extruded aluminum beam. The vertical axis will be mounted to the carriage. The vacuum cup will be fixed to the bottom of the vertical linear actuator. The vacuum system will be comprised of a vacuum generator feeding a vacuum manifold. From the manifold a tube will run to the vacuum cup and an additional port will run to a solenoid valve vented to atmosphere, to allow the vacuum to be shut off and the object dropped.

Vacuum System Pneumatic Circuit

Vacuum System Pneumatic Circuit

Part Name Planned Manufacturing Method Link to .stl file Document Owner
Rollers Printed Part Roller.stl Zach Gastin
Rod Support Printed Part RodSupport.stl Zach Gastin
Coupling Printed Part Coupling1.stl Zach Gastin
Vertical Linear Actuator Middle Printed Part VerticalLinearActuatorMiddle.stl Zach Gastin
Vertical Linear Actuator Top and Bottom Printed Part VerticalLinearActuatorMiddleTop_Bottom.stl Zach Gastin
Part Name Machined From Link to print file Document Owner
Rollers Bracket 1 6061 Al RollersBracket1.pdf Zach Gastin
Rollers Bracket 2 6061 Al RollersBracket2.pdf Zach Gastin
Vertical Axis Motor Bracket 6061 Al VerticalAxisMotorBracket.pdf Zach Gastin
Vacuum Manifold 6061 Al VacuumManifold.pdf Zach Gastin

Bun Hopper

Zach Gastin

Last Update: 12/08/17

Hamburger buns will be stored by stacking vertically in a tube. The prototype tube will be constructed from PVC pipe with a round base plate that is actuated vertically with a linear actuator. The bun hopper will be inset into the table, and the vacuum pickup system will pick each bun component from above.

Bun Hopper Sub Assembly Isometric View

Bun Hopper Sub Assembly Isometric View

Bun Hopper Bottom View

Bun Hopper Bottom View

Part Name Planned Manufacturing Method Link to .stl file Document Owner
Rod Support Printed Part RodSupport.stl Zach Gastin
Coupling Printed Part Coupling1.stl Zach Gastin
Vertical Linear Actuator Top Plate Printed Part VerticalLinearActuatorMiddle.stl Zach Gastin
Vertical Linear Actuator Bottom Plate Printed Part VerticalLinearActuatorMiddleTop_Bottom.stl Zach Gastin

Bun Etcher

Katie Berus

Last Update: 12/4/17

The bun etcher will be created using a 3D printer which will have the heater and filament extruder removed. In its place will be a soldering iron which we will use to etch the images onto the buns. This will allow us to have accurate images and will be a low risk method. The dimensions of the new printer are close to the printer we were previously looking to use which will allow us to keep the old CAD files in the assembly as a place holder. The new dimensions of the printer are 16.9" L x 16.1" D x 16.5" H.

3d Printer Image

3d Printer Image

Using this printer we will add the soldering iron holder which will attach to the x carriage.

Holder Image

Holder Image

CAD Files

Bun Etcher Drawings and Assembly Documents

Part Number Planned Manufacturing Method Links to Part Drawing Link to .stl file Document Owner
SolderingIronHolder 01 Machined Part Holder R01 Drawing Holder R01 Model Katie Berus
TopSolderingIronHolder 01 Machined Part Top Holder R01 Drawing Top Holder R01 Model Katie Berus
SolderingIron 01 Purchased Part N/A Soldering Iron R01 Model Katie Berus
Holder Assembly 01 Assembly Holder Assembly R01 Drawing N/A Katie Berus

Burger Cooker

Jacky

Last Update: 12/07/17

Burger Assembler

Burger Assembler

Detail View of Changes for Burger Assembler

Detail View of Changes for Burger Assembler

Changes are added to the assembly station with the base idea of the station will be controlled by a DC motor with a rack and gear system at the back to move the push plate to deliver the burger. An extra guide rail is added and a roller attached to the motor bracket is added to confirm the rack and the push plate are in place.

Burger Assembler Drawings and Assembly Documents

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Link to .stl file Document Owner
Push Plate R01 1 Machined Part Push Plate R01 Drawing N/A Jacky Ho
Assembler R02 1 Machined Part Assembler R02 Drawing N/A Jacky Ho
Base Plate R01 1 Machined Part Base Plate R01 Drawing N/A Jacky Ho
Motor Bracket R02 1 Machined Part Motor Bracket R02 Drawing N/A Jacky Ho
Guide Holder R01 4 3D Printed Part Guide Holder R01 Drawing Guide Holder R01 STL File Jacky Ho
Roller Bracket R02 1 3D Printed Part Roller Bracket R02 Drawing Guide Holder R01 STL File Jacky Ho

Bill of Material (BOM)

PRI: Jacky Ho

Rev: 3

Date: 12/05/17

Bill of Material (BOM)

Bun Etcher Bill of Materials

Bun Etcher Bill of Materials

Burger Cooker Bill of Materials

Burger Cooker Bill of Materials

Vacuum Transfer System Bill of Materials

Vacuum Transfer System Bill of Materials

Burger Assembler Bill of Materials

Burger Assembler Bill of Materials

General Items Bill of Materials

General Items Bill of Materials

Budget

Sub-System Cost Estimate Actual Cost
Bun Etcher $340.92 $308.98
Burger Cooker $114.67 $82.88
Vacuum Transport System $131.69 $116.02
Burger Assembler $45.14 $19.16
General Items $268.45 $201.84
Total $ 900.87 $728.88
Cost Distribution

Cost Distribution

Bill of Materials & Budget Live Document:

Bill of Materials & Budget Live Document

Test Plans

PRI: Katie Berus

Rev: 1

Date: 12/4

Test Plan Cover

Test Plan Cover

The cover sheet for the test plans shows the correlation to all of the engineering requirements.
test plan parts

test plan parts

test plan parts 2

test plan parts 2

This is an example of the test plan that we are using for each of the purchased parts in order to make sure that each of the parts works as the team needs.

Link to the Entire Test Plan Document

Design and Flowcharts

Electrical Diagrams

Electrical Schematic

Electrical Schematic

Click Here For The Full Electrical Schematic

Click Here For The Full Electrical Schematic

System Architecture

PRI: Murali Srinivasan

Rev: 3

Date Of Last Revision: 12/7/2017

Overall System

Overall System

Overall System

System Flow

Energy Flow

Energy Flow

Data Flow

Data Flow

System Timing

System Timing Diagram

System Timing Diagram

Risk Assessment

PRI: Jacky Ho

Rev: 5

Date of Last Revision: 12/05/17

Risk Index and Prediction Chart

Risk Index and Prediction Chart

Revision 1 2 3 4 5 End of MSD 2
Risk Index 99 164 157 127 98 -
Prediction 99 150 140 120 100 0
Risk List

Risk List

Risk Management Live Document:

Risk List

Design Review Materials

Agenda

Presentation

Plans for next phase

Project plan MSD2

Project plan MSD2

The planned tasks for MSD II are shown above with the critical path shown in red and the assigned team member.

Plan

PDF


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