airbag automaton john bailey hattie hiatt chun hau low jason harwood wayne gallup jason canaday

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Airbag Automaton Airbag Automaton John Bailey John Bailey Hattie Hiatt Hattie Hiatt Chun Hau Low Chun Hau Low Jason Harwood Jason Harwood Wayne Gallup Wayne Gallup Jason Canaday Jason Canaday

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Page 1: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Airbag AutomatonAirbag Automaton

John BaileyJohn BaileyHattie HiattHattie HiattChun Hau LowChun Hau LowJason HarwoodJason HarwoodWayne GallupWayne GallupJason CanadayJason Canaday

Page 2: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Presentation OutlinePresentation Outline

Problem DefinitionProblem Definition Customer Needs SummaryCustomer Needs Summary Project BreakdownProject Breakdown ME Subteam DesignsME Subteam Designs ECE Subteam DesignsECE Subteam Designs How They Fit TogetherHow They Fit Together DeliverablesDeliverables BudgetBudget Work PlanWork Plan

Page 3: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Problem Problem DefinitionDefinition

Problem StatementProblem Statement Autoliv uses a variety of machines to fold Autoliv uses a variety of machines to fold

and package their airbag. These machines and package their airbag. These machines take up space, capital, and require a new take up space, capital, and require a new machine design for each new folding machine design for each new folding process. process.

Page 4: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

ProjectProject Breakdown Breakdown

Customer NeedsCustomer Needs

Plug and play machine that Plug and play machine that supports airbag folding supports airbag folding processesprocesses

1) SMED tool interface1) SMED tool interface2) Move interface and 2) Move interface and

toolingtooling3) Central Hub that supports 3) Central Hub that supports

all operations of folding all operations of folding processprocess

Page 5: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Tool Interface ConceptsTool Interface Concepts

Decision CriteriaDecision Criteria Ease of useEase of use In-house manufacturabilityIn-house manufacturability Cheaper alternative to existing Cheaper alternative to existing

robotic interfacesrobotic interfaces

Important Design AspectsImportant Design Aspects Auto connect/disconnect Auto connect/disconnect

pneumatic connectionpneumatic connection Rocking dockingRocking docking Lock down mechanismLock down mechanism

Design Inspiration

Top to Bottom:Switch Step in Snowboard BindingsWalther Tool Master Robotic Tool ChangerTechno-Sommer Robotic Tool ChangerRobotic Accessories Robotic Tool ChangerApplied Robotics in Use at Autoliv

Page 6: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Tool Interface ConceptsTool Interface Concepts Functional RequirementsFunctional Requirements

Docks tool to machineDocks tool to machine User Locks/Unlocks tool User Locks/Unlocks tool

manuallymanually Hands-free connection of utilitiesHands-free connection of utilities Senses secure connectionSenses secure connection

Design CriteriaDesign Criteria UsabilityUsability CostCost SMEDSMED Two Step Connection Procedure Two Step Connection Procedure

Put onPut on Lock inLock in

Page 7: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Slider Support ConceptSlider Support Concept

Alternatives for Alternatives for Slider SupportSlider Support Roller/Ball BearingsRoller/Ball Bearings Dovetail waysDovetail ways Triangular waysTriangular ways Closed cylindrical Closed cylindrical

bushingsbushings

Slider support using open cylindrical bushings on precision ground shafts

Page 8: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Hub ConceptHub ConceptConceptual Design

-Actuator attached to 12 O’clock arm

-Pivot connection depends on arm design

-Tilt connection mounted to Bobcat (base)

Page 9: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

ME BudgetME BudgetItemItem CostCost

Linear Linear GuidesGuides

Linear BushingsLinear Bushings 200200

Precision ShaftsPrecision Shafts 500500

Aluminum for bracketsAluminum for brackets 5050

Tool Tool InterfaceInterface

Manufacturing MaterialsManufacturing Materials 150150

Power/Data/Pneumatic Power/Data/Pneumatic Connections Connections (Male/Female)(Male/Female)

500500

Stainless Steel RodsStainless Steel Rods 5050

HubHub

Pivot bushingsPivot bushings 150150

Steel for Pivot AxlesSteel for Pivot Axles 5050

Various FastenersVarious Fasteners 150150

TOTAL COSTTOTAL COST $1800$1800

Page 10: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Tool Positioning System

Requirements:

Control position of tool within 1/8th inch resolution

Move tool to minimize cycle time but stay within hardware specifications

Page 11: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

• Drive

• Position Sensor

• Controllers

Hardware Components

Page 12: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Drive  Stepper DC servo AC servo

Company Oriental Motors 

Mavilor 

Kollmorgen

Model # AS911AA 

MSS-6 MT306B1

Continuous stall Torque

N/A 

1.83 Nm

3.32 Nm

Max Holding torque

4.0 Nm

N/A N/A

Peak Torque N/A 11 Nm

11.3 Nm

Max speed 3000 RPM

6000 RPM

4000 RPM

Rated current 6.5 A 10.7 A 5.35 A

Rated voltage 100-115 VACsingle phase

67.8 VDC

230 VACsingle phase

Rotor inertia 0.000271 kg-m2

.00040 kg-m2

.000111 kg-m2

Motor weight 6.6 lb 12.79 lb 8.4 lb

Frame size 3.35 in   3.54 in

Cost $1,180.00 

$1,116.00 $930.00

Page 13: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Position Sensor

Optical Laser Ultrasonic Cable Displacement Magnetoresistive Optical Linear EncoderContact No No Yes No NoMeasurement Type Absolute Absolute Absolute Absolute IncrementalAccuracy submicron micron infinite signal resolution micron / submicron micron / submicronLifetime >3.125 million cycles Unlimited 100 million cycles Unlimited 20 million cyclesCost >>$500 $50-$500 ~$500 >$500 ~$500

Requirements:

• Minimum velocity of 15 in/s (0.4 m/s)

• Maximum 1/8th inch (3 mm) resolution

• Measurement range of 600mm

Sensor Options

Page 14: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

ControllerCurrently researching:

-Programmable Logic Controller

-Microcontrollers

Page 15: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Tool Controller• Controls tool movements

• Tool identification

• Computer requests tool ID or

• Tool sends ID at interface connect

Page 16: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

ECE BudgetDrive $1200

Motor $1000

Controllers $150

Position Sensor $500

Cables $300

Other Discrete Electronics $100___

Total $3250

Page 17: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Putting it all TogetherPutting it all Together

Page 18: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Team Design DeliverablesTeam Design Deliverables SMED tool interfaceSMED tool interface Single arm assembly Single arm assembly Hub SystemHub System

Accommodates 3 arms, Linak tilt system and routes Accommodates 3 arms, Linak tilt system and routes utility cablesutility cables

Tool identification systemTool identification system Proof Of Concept tool recognition and automatic Proof Of Concept tool recognition and automatic

program downloadprogram download Tool positioning controlTool positioning control

Page 19: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

Team Documentation Team Documentation DeliverablesDeliverables

Complete set of engineering drawings of Complete set of engineering drawings of custom parts and product information for custom parts and product information for manufactured partsmanufactured parts

Repeatability testingRepeatability testing Failure and Fatigue analysis with predicted Failure and Fatigue analysis with predicted

machine lifetimemachine lifetime Electrical circuit diagrams control modelsElectrical circuit diagrams control models

Page 20: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

AIRBAG AU•TOM•A•TONAIRBAG AU•TOM•A•TON Design ScheduleDesign Schedule

Page 21: Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

AIRBAG AU•TOM•A•TONAIRBAG AU•TOM•A•TONOverall BudgetOverall Budget

ME BudgetME Budget $1800$1800

ECE BudgetECE Budget $3250$3250

Miscellaneous CostsMiscellaneous Costs $400$400

Total CostTotal Cost $5450$5450