Accessible Manufacturing Equipment Phase 2 by fTMdAM

VIEWS: 0 PAGES: 26

									                   ECE 480 Senior Capstone Design


Accessible Manufacturing Equipment
Phase 2
                                            Team 2
                                  Nicholas Neumann
                                      Ralph Prewett
                                   Jonathan Brouker
                                     Felix Adisaputra
                                               Li Tian
            December 10th, 2010
Contents

   Background
   Design Specifications
   Final Design
   Results and Evaluations
   Conclusion
   Future Improvements
   Demonstration
Background

 Basic Purpose of the Project
 Former 2008 Machine
Background

 Former 2008 Machine (Continued)
   PIC Programming
     • C Code
     • Timing Loop
   Stepper Motors
     • Parallel Operation (Belt)
   Cam Motors
   Rotary Cutter
   Stationary and Movable Clamps
Background

 Major Problems
   Programming Interface
     • No C programmers on staff at location
     • Difficult Maintenance
   Stepper Motors
     • Inaccuracy
     • Slow Operation
   Motor Drivers
     • Overheat Issue
Design Specifications

 Critical Customer Requirements
   Simple Programming Language
     • Easy Maintenance
   High Level of Accuracy
     • Different Types of Motor
   Variable Speed Control
     • Higher Maximum Speed of Operation
Design Specifications

 Secondary Objectives
   Visual and Audio Feedback
   Reliability and Robustness
     • Reduce Occurrence of Jamming
   Safety
     • Better Design of Safety Guards
   Reduce Noise During Operation
   Compact Machine
   Aesthetics
Final Design

 Mechanical Systems
   Pneumatic Guillotine Cutter




   Valves Assembly
Final Design

 Mechanical Systems (Continued)
   Two Capstans Design
     • Increases the Speed of Operation
Final Design

 Mechanical Systems (Continued)
   Adjustable Frame
Final Design

 Mechanical Systems (Continued)
   Tracking Guard
Final Design

 Hardware
   LEGO NXT Brick as Microcontroller
     • LCD Screen for Speed Display
     • Limited I/O Ports
   LEGO Servo Motors
     • High Accuracy
     • Compatibility
   I2C Serial Communication Bus
      • I/O Expander PCF8574
Final Design

 Hardware (Continued)
   Input (Buttons)
   8-Segment LED Display
     • Length Output
Final Design

 Hardware (Continued)
   Cutter Relay Control    DC Power Supply
                                                      Valves
                                                     Assembly

     • Power Transistor           5V

                                              81kΩ
                                                            DC
                                                           Power    24V
                                                           Supply




   LEGO NXT Brick Power Supply
     • Step-Down Converter Circuit
         – LM7809 Voltage Regulator
Final Design

 Software
   LEGO Mindstorms NXT-G




        Time
Final Design
               Accepts User Input. Executes Commands


               Starts or Stops Cutting Process




               Contains Cutting Process



               Drives 8 Segment Display



               Displays Length and Speed on NXT
               Display
Results and Evaluations

 Improved Accuracy
   2008: 13.24% defects
   2010: 1.46% defects
 Reduced Percentage Error
   2008: -12.99%
   2010: 2.7%
Results and Evaluations

 Enhanced Speed of Operation
   For 100 Cycle Run:
     • 2008: 7 min 49.7sec
     • 2010: 2 min 27sec
   3.19 Times Faster
Results and Evaluations

 Capstan Feed Design
   Removed Drift Factor
 Smaller Size of the Machine
   4.7 Times Smaller in Area
 LEGO Servo Motors
   Eliminated Overheating Issue
 Sources of Error
   Susceptible to Ribbon Feed Method
     • Ribbon at Similar Elevation Improves Accuracy Significantly
Conclusion

 Accomplishments
   Maintain Simplicity of the Programming
     • LEGO Mindstorms NXT-G
   Better Accuracy and Consistency
     • LEGO Servo Motors
   Variable Speed Controller Implementation
     • Higher Maximum Speed of Operation
Conclusion

 Accomplishments (Continued)
   LED Display and Speaker
   Reliable and Robust
     • Tracking Guards Prevent Jamming
   Better Safety
     • Safety Guards
   Less Noise
   Smaller Size
   Aesthetics
Cost
                    Part                     Number   Cost
              Guillotine Knife               1        $358.16
               IC LED Driver                 1        $2.80
                LED Display                  1        $1.67
 4 digit LED Driver with I2C Bus interface   1        $3.20

             LED driver w/I2C                1        $1.54
             0.33uF Capacitor                1        $0.83
           A Voltage Regulator               1        $0.70
     I2C interface 8 bit I/O Expander        2        $3.32

            IC I/O Expander                  5        $9.30
                 Tubing                      1        $18.75
                  Valve                      1        $19.75
                  Filter                     1        $11.25
                Regulator                    1        $17.00
         Pneumatic Lubricator                1        $12.25
     Male Straight1/4NPT*1/4 inch            1        $4.50

     Male Straight1/8NPT*1/4 inch            2        $5.00

      Male Elbow1/8NPT*1/4 inch              2        $12.00
               Shipping                               $32.64
      *Lego Mindstorms NXT 2.0               1        $299.99



 *Sponsored by Sponsor
  Total Cost:
  $814.65
Future Improvements

Warning Message
  •Detects Jam

Number Pad
  •Length
  •Speed

Speed
  •Faster
  •More Range
Future Improvements

 Audio (ISD 1400)
   Louder
   Adjustable Volume Control
                                A4 A5 A6 A7
                                0   0   0   1
                                0   0   1   0
                                0   0   1   1
                                0   1   0   0
                                1   1   0   0
Demonstration
Questions

								
To top