““Brazing Saddles”Brazing Saddles”

((Team 15)Team 15)Client: Parker-HannifinClient: Parker-Hannifin

Faculty Mentor: Dr. Kevin KochersbergerFaculty Mentor: Dr. Kevin KochersbergerFaculty Coordinator: Prof. Paul StiebitzFaculty Coordinator: Prof. Paul Stiebitz  

Critical Design ReviewCritical Design ReviewMay 16, 2003 May 16, 2003 

Project Manager: Melissa CurtinProject Manager: Melissa Curtin Ethan Bagley (ME)Ethan Bagley (ME)

Paul Diedrich (IE)Paul Diedrich (IE)Charles Gullo (IE)Charles Gullo (IE)

Thomas Wild (ME)Thomas Wild (ME)Brian Belpanno (IE)Brian Belpanno (IE)

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AgendaAgenda

Problem StatementProblem StatementSystem DesignSystem DesignVideo DemonstrationVideo DemonstrationTestingTestingErgonomics/SafetyErgonomics/SafetyConclusionsConclusions

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Problem StatementProblem Statement

• Currently:Currently:– Operator loads and Operator loads and

unloads parts every 6 unloads parts every 6 min.min.

– Mechanical system Mechanical system unreliable.unreliable.

• Project Goals:Project Goals:– Part removal and Part removal and

handling system:handling system:• Reduce lossesReduce losses• Increase productivityIncrease productivity

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System Design System Design

• SubsystemsSubsystems– PneumaticsPneumatics– Boat DesignBoat Design– ElectronicsElectronics– Part HandlingPart Handling

• FunctionsFunctions– ConveyorConveyor– Vertical Vertical

ThrusterThruster– Horizontal Horizontal

ThrusterThruster

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PneumaticsPneumatics

• Pneumatic circuit diagram Pneumatic circuit diagram – Design reuses nearly all components of existing systemDesign reuses nearly all components of existing system

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Boat DesignBoat Design

• Machinable ceramicMachinable ceramic• Sloped front edgeSloped front edge• Pins installed for Pins installed for

stabilitystability• Sized to fit existing Sized to fit existing

boats with parts boats with parts included.included.

• Solid BaseSolid Base

Holes for vertical pegs

Holes for vertical pegs

Holes for stabilizing pegs

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ElectronicsElectronics

Components:Components:• BASIC stampBASIC stamp• Retro-reflective Retro-reflective

sensorsensor• Solenoid valvesSolenoid valves• Bell alarmBell alarm• Status LED’sStatus LED’s• Digital displayDigital display

Delay n seconds

Open valve 1

Update status LED

Close valve 1 and valve 2Delay z seconds

Update count

YES

Is sensor activated

Ring bell intermittently

NO

YES

End

Delay x seconds

Open valve 2

Update status LED

Delay y seconds

Initialization

Is sensor activatedNO

Start

Update status LED

Count = max?

Ring bellYES

NO

End

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Part Handling SystemPart Handling System

• Assumptions:Assumptions:• 100% Utilization100% Utilization• 250 working days 250 working days

per yearper year• Three shifts per dayThree shifts per day• $20/hr labor rate$20/hr labor rate

• Cart System saves Cart System saves 450450 hours (time spent hours (time spent walking) per yearwalking) per year

• Approximately $9,000 Approximately $9,000 in labor costsin labor costs

Cart

Furnace and belt

Lifting plate

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Video DemonstrationVideo Demonstration

Mechanism in MotionMechanism in MotionMechanism in MotionMechanism in Motion

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Reliability TestingReliability Testing

• ExperimentsExperiments–Part removal from belt furnace to Part removal from belt furnace to

vertical lift platevertical lift plate–Part removal from vertical lift plate Part removal from vertical lift plate

onto ramponto ramp

• ConditionsConditions–Weight (light / heavy)Weight (light / heavy)–Orientation (angle from center)Orientation (angle from center)

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Reliability Testing (Cont.)Reliability Testing (Cont.)

Angle Weight7 L7 H

0 L

0 H353 L353 H

Angle Weight7 L

7 H

0 L0 H

353 L353 H

No FailuresNo Failures

Experiment 1

Experiment 2

No FailuresDue to the heaviness of the part, temporary displacement of the vertical lift plate occurred. This did not allow the part to be pushed off onto the ramp. Once the maximum height of the vertical plate was adjusted and the edge of the ramp filed down, no further failures occurred.No FailuresNo Failures

No FailuresNo FailuresNo Failures

Results

ResultsNo FailuresNo FailuresA failure occurred due to the mock setup. After adjustments were made to the mock conveyor, no further failures occurred.

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Ergonomics and SafetyErgonomics and Safety

• Safety CoversSafety Covers– Cover most pinch pointsCover most pinch points

• Uncovered points noted by signageUncovered points noted by signage

• Cart SelectionCart Selection– Height of 50Height of 50thth percentile male (35 in) percentile male (35 in)– Full cart initial push force acceptable to 90% of industrial Full cart initial push force acceptable to 90% of industrial

workersworkers (< 275 N, Cirello et al 1993Maximal Acceptable Push Forces)(< 275 N, Cirello et al 1993Maximal Acceptable Push Forces)

• Audible AlarmAudible Alarm– Meets Patterson’s 1990 good alarm propertiesMeets Patterson’s 1990 good alarm properties

• 30 db above ambient level30 db above ambient level• Not overly startlingNot overly startling• Does not disrupt processing of other signalsDoes not disrupt processing of other signals• Informative, 2 distinct alertsInformative, 2 distinct alerts

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Web SiteWeb Site

• Flash and HtmlFlash and Html• Meets Criterion while remaining Meets Criterion while remaining

entertaining for undergradsentertaining for undergrads• Human factors principals used in Human factors principals used in

designdesign

http://www.rit.edu/~bpb4413/sd/p02015/

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ConclusionsConclusions

• MaintainabilityMaintainability

• SafetySafety

• Client Budget: $5000Client Budget: $5000– Final Cost: $2212Final Cost: $2212

• Client concerns addressed:Client concerns addressed:– Boats brazing to furnaceBoats brazing to furnace– ReliabilityReliability

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Special Thanks To:Special Thanks To:

• Parker HannifinParker Hannifin• Fulya TezerFulya Tezer• Brett YoungstromBrett Youngstrom• Dave HathawayDave Hathaway• Dr. Kevin KochersbergerDr. Kevin Kochersberger• Professor Paul StiebitzProfessor Paul Stiebitz• Professor Ron AmbergerProfessor Ron Amberger• Professor Brian ThornProfessor Brian Thorn

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