airbag automaton john bailey hattie hiatt chun hau low jason harwood wayne gallup jason canaday
Post on 15-Jan-2016
214 views
TRANSCRIPT
Airbag AutomatonAirbag Automaton
John BaileyJohn BaileyHattie HiattHattie HiattChun Hau LowChun Hau LowJason HarwoodJason HarwoodWayne GallupWayne GallupJason CanadayJason 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
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.
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
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
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
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
Hub ConceptHub ConceptConceptual Design
-Actuator attached to 12 O’clock arm
-Pivot connection depends on arm design
-Tilt connection mounted to Bobcat (base)
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
Tool Positioning System
Requirements:
Control position of tool within 1/8th inch resolution
Move tool to minimize cycle time but stay within hardware specifications
• Drive
• Position Sensor
• Controllers
Hardware Components
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
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
ControllerCurrently researching:
-Programmable Logic Controller
-Microcontrollers
Tool Controller• Controls tool movements
• Tool identification
• Computer requests tool ID or
• Tool sends ID at interface connect
ECE BudgetDrive $1200
Motor $1000
Controllers $150
Position Sensor $500
Cables $300
Other Discrete Electronics $100___
Total $3250
Putting it all TogetherPutting it all Together
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
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
AIRBAG AU•TOM•A•TONAIRBAG AU•TOM•A•TON Design ScheduleDesign Schedule
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