P18391: Grinder Gizmo
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Integrated System Build & Test

Table of Contents

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

Team Vision for Integrated System Build & Test Phase

PRI: Katie Berus Rev:01 Date:3/27

Plans for this phase continued to build the subsystems and begin to integrate the subsystems together. We also planned to test some of out components in this phase.

Test Results Summary

The test plans documentation can be found be clicking on the link here

Document

Bun Holder Test

PRI: Katie Berus Rev:01 Date:3/27

A "bed of nails" was created to stabilize the bun on the image creation device so that it does not move when the soldering iron moves across it.

Bun Holder

Bun Holder

Bun Holder Test Video

Ice Pack Temperature Test

PRI: Scott Eisele Rev:01 Date:3/29

The burgers will be stored in a cooler mounted underneath the burger elevator until they are ready to be dispensed. This cooler will be kept cold with standard ice packs, which can be re-frozen. The image below demonstrates a temperature reading of one Ice Pack, demonstrating its ability to reach the temperature our burger have been specified to be kept at (40 deg Fahrenheit) in our requirement.

Ice Pack Temperature Reading

Ice Pack Temperature Reading

Photo of the cooler which has been mounted to the table

Photo of the cooler which has been mounted to the table

George Foreman Motor Test

PRI: Scott Eisele Rev:01 Date:3/29

The George Foreman grill will be actuated via a DC electric motor mounted to the 80/20 which supports the vacuum rail. A 12V DC motor was tested, to ensure it had sufficient torque to lift the grill lid. The linked video demonstrates the motor lifting the grill lid.

https://drive.google.com/file/d/1vfGhIJwgB8ZqB-Ouy8uYQcA5HeeS9v6A/view?usp=sharing

Subsystem and System

Improvements have been made on the subsystems and the entire system as a whole through this phase. The new additions and improvements are shown below.

Bun Etcher

PRI: Katie Berus Rev:01 Date:3/27

A plate has been created in order to hold the bun at the same height throughout the printing process. The final plate is shown below and the drawing can be found here.

Plate

Plate

Plate

Plate

Assembly Document

Burger Elevator Status Update, Drawings, and Assembly Documents

A functional test of the burger elevator's actuation system was completed on 2/18/18. This test verified that the elevator's actuation will be slide with minimal play, and translate at a speed of at least 1.25" in 10 seconds.

https://drive.google.com/file/d/1EM5Lr--ttzm0t45zzEhKpKyLqZJCpLzr/view?usp=sharing

Since then, minimal changes have been made to the burger elevator. The burger elevator was mounted to the working table via 4 socket head cap screws. In addition, a cooler was mounted to the table underneath the elevator to manage burger temperature.

This subsystem is fully complete, barring final adjustments to flag positions which will be completed once the grill and spatula systems have been installed. Additionally, one cutoff sensor still needs to be mounted and wired. Scripts to allow the RasPi to operate the elevator are also in progress.

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Part Status Document Owner
Top Plate R02 1 Machined Part Top Plate R02 Drawing Fabricated Scott Eisele
Bottom Plate R02 1 Machined Part Bottom Plate R02 Drawing Fabricated Scott Eisele
Side Plate R02 2 Machined Part Side Plate R02 Drawing Fabricated Scott Eisele
Side Plate Slotted R02 2 Machined Part Side Plate Slotted R02 Drawing Fabricated Scott Eisele
Front Bumper R02 2 Machined Part Front Bumper R02 Drawing Fabricated Scott Eisele
Actuator Con Block R02 2 Machined Part Actuator Con Block R02 Drawing Fabricated Scott Eisele
Cutoff Sensor Flag Type A R01 6 Machined Part Cutoff Sensor Flag Type A R01 Drawing In Progress Scott Eisele
Cutoff Sensor Flag Type B R01 6 Machined Part Cutoff Sensor Flag Type B R01 Drawing In Progress Scott Eisele
Rail Con Bracket R02 2 3D Printed Rail Con Bracket R02 Model Fabricated Scott Eisele
Extruded Aluminum (16" Length) 4 Machined Part N/a Fabricated Scott Eisele
Extruded Aluminum (12" Length) 2 Machined Part N/a Fabricated Scott Eisele
Extruded Aluminum (4.5" Length) 5 Machined Part N/a Fabricated Scott Eisele
Extruded Aluminum (1.5" Length) 1 Machined Part N/a Fabricated Scott Eisele
Inside Corner Bracket 4 Purchase Part N/a Acquired Scott Eisele
3/4" Long UNC 5/16"-18 Screws 27 Purchase Part N/a N/a Scott Eisele
5/16"-18 Square Nuts 12 Purchase Part N/a N/a Scott Eisele
5/16"-18 Washers 27 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 Elevator 8020 Assy R01 1 Assembly Drawing Elevator 8020 Supports R01 Assembly Drawing N/a Scott Eisele

Last phase overall completion: 83%

New overall completion: 99%

Grill Status Update, Drawings, and Assembly Documents

This subsystem utilizes a George Foreman grill as the method of cooking the burger, so of the three mechanical subsystems responsible for burger cooking, the grill subsystem has the lowest overall risk level. The primary focus during this phase has been the other subsystems. 3D printed parts have been fabricated.

In addition, a test to ensure the motor selected will be able to lift our grill lid has been performed. This is outlined in section "Test Results Summary" subsection "George Foreman Motor Test."

An additional 3D printed part was necessary to allow the string to spool around the electric motor's shaft. This part is known as the "Spooling Disk" and is shown in the photo below.

Spooling Disk

Spooling Disk

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Part Status Document Owner
Motor Clamp R01 1 3D Printed Part Motor Clamp R01 Model Fabricated Scott Eisele
Spooling Disk R01 1 3D Printed Part Spooling Disk R01 Model Fabricated Scott Eisele
Modified Grill R01 1 Modified Purchase Part Grill Modifications R01 Photo Not started Scott Eisele
U-Bolt 1 Purchase Part N/a Aquired Scott Eisele
Electric Motor 1 Purchase Part N/a Aquired Scott Eisele
Extruded Aluminum (24" Length) 1 Machined Part N/a Not started Scott Eisele
Grill Assy R01 1 Assembly Drawing Grill Assembly R01 Assembly Drawing N/a Scott Eisele

Last phase overall completion: 30%

New overall completion: 75%

Spatula Status Update, Drawings, and Assembly Documents

The burger pusher remains the last subsystem required to meet the "burger cooking" function of our overall design. The actuator has been mounted to the table. The burger pusher will be fabricated and installed in the next phase.

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Part Status Document Owner
Pusher Baseplate R01 1 Machined Part Pusher Baseplate R01 Drawing Fabricated Scott Eisele
Fork Body R01 1 Printed Part Fork Body R01 Model Fabricated Scott Eisele
Cutoff Sensor Mount R01 2 3D Printed Cutoff Sensor Mount R01 Model Fabricated Scott Eisele
Spatula Assy R01 1 Assembly Drawing Spatula Assembly R01 Assembly Drawing N/a Scott Eisele

Last phase overall completion: 20%

New overall completion: 25%

Pick-and-Place System Update, Drawings, and Assembly Documents

When originally designed, the pick-and-place system used a 1/4" vacuum tube connected to a vacuum cup. When it was determined that the vacuum source could not provide enough vacuum pressure but did provide a high flow rate, the system was redesigned to use a 1 1/4" hose. This hose is large enough that it needs to be offset to the side of the vertical actuator. Redesign of the pick-and-place system allows for the larger hose to be used, but also applies a moment to the system due to the loading being off axis to the horizontal guide rail. Remaking the rollers out of aluminum to increase stiffness and provide smoother rolling in the guide rail was completed.

Pick and Place System with Updated Aluminum Upper Rollers

Pick and Place System with Updated Aluminum Upper Rollers

Last phase overall completion: 65%

New overall completion: 75%

Bun Hopper Status Update

The bun hopper is installed in the table using a simple flange. A linear actuator is mounted to the bottom of the tube. A piston will be fabricated and mounted to the end of the linear actuator, acting as a piston in a cylinder with the linear actuator driving the buns upward.

Bun Hopper Mounting Plate

Bun Hopper Mounting Plate

Bun Hopper Linear Actuator

Bun Hopper Linear Actuator

Last phase overall completion: 10%

New overall completion: 75%

Assembly Station Status Update, Drawings, and Assembly Documents

A problem we encountered in the last phase was there is not a wide enough path for the burger to slide when the station was assembled. 2 bolt heads securing the base act as an obstacle. A removable plate was fabricated with a u-shape tab at the end to ensure it will not slide when delivering the burger and a ramp in the front for the delivery.

Height adjustment of the station will be done in the first week of next phase and followed by the final assembly.

Removeable Delivery Plate

Removeable Delivery Plate

Removeable Delivery Plate In Place

Removeable Delivery Plate In Place

Part Number Quantity Planned Manufacturing Method Links to Part Drawing Part Status Document Owner
Removable Delivery Plate R01 1 Machined Part Removable Delivery Plate Drawing Fabricated Jacky Ho
Assembly Station Assy R01 1 Assembly Drawing Assembly Station R03 Assembly Drawing N/a Jacky Ho

Last phase overall completion: 75%

New overall completion: 85%

Bill Of Materials

PRI: Jacky Ho

Rev: 7

Date: 03/30/18

Bill of Material (BOM) & Budget

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 $324.22 $308.98
Burger Cooker $130.78 $111.72
Vacuum Transport System $135.31 $132.9
Burger Assembler $45.14 $19.16
General Items $337.30 $246.93
Total $ 972.75 $819.69
Cost Distribution

Cost Distribution

Bill of Materials & Budget Live Document:

Bill of Materials & Budget Live Document

Risk and Problem Tracking

Problem Tracking

PRI: Katie Berus Rev:01 Date:3/27
Problem Tracking

Problem Tracking

Problem Tracking

Problem Tracking

Problem Tracking

Problem Tracking

Live Document

Risk Management

PRI: Jacky Ho

Rev: 8

Date of Last Revision: 3/22/18

Risk Index and Prediction Chart

Risk Index and Prediction Chart

Revision 1 2 3 4 5 6 7 8
Risk Index 99 164 157 127 98 96 98 69
Prediction 99 150 140 120 100 100 80 80
Risk List

Risk List

All risk items colored green has its index reduce to 0 with the tests performed during this phase.

Risk Management Live Document:

Risk List

Functional Demo Materials

Agenda:

Plans for next phase

PRI: Katie Berus Rev:01 Date:3/27
Schedule

Schedule

Critical Path

Critical Path

Live Document

Priority List

Document


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