senior design ii final report

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ENGR 4482 Senior Design II ASU College of Engineering Display/Box Assembly Project Final Report Written By: Taylor Barnhill Robert Bise Kevin Muñoz Jed Schales Submitted on: April 20 th , 2015

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Page 1: Senior Design II Final Report

ENGR 4482

Senior Design II

ASU College of Engineering

Display/Box Assembly Project

Final Report

Written By:

Taylor Barnhill

Robert Bise

Kevin Muñoz

Jed Schales

Submitted on: April 20th

, 2015

Page 2: Senior Design II Final Report

REK’M Engineering

Arkansas State University-Engineering Department

105 N. Caraway Rd.

State University, AR 72467

Tel: (870) 972-2088

April 20, 2015

Attention: Dr. Tanay Bhatt

Subject: Display/Box Assembly

To Dr. Bhatt:

On August 26, 2014, REK’M Engineering was assigned the task of designing a system

capable of increasing the production rate of cardboard displays created by American

Greetings Corp as well as improving the comfort and safety of all parties involved in the

process. This report covers the material the students have studied, fabricated, and tested,

as well as the process used to develop the final design and a cost estimate for the designs.

A complete list of man-hours and Gantt chart for the fabrication and testing process is

also included.

Feel free to contact us if any questions should arise.

Sincerely,

Taylor Barnhill

Electrical Engineer

Robert Bise

Mechanical Engineer

Banthi Munoz

Mechanical Engineer

Jed Schales

Mechanical Engineer

Page 3: Senior Design II Final Report

ii

TABLE OF CONTENTS

Section Title Page

TABLE OF CONTENTS

ii

LIST OF TABLES

iii

LIST OF FIGURES

iv

I EXECUTIVE SUMMARY (JS)

1

II INTRODUCTION 2

Background (TB) 2

Constraints (BM)

Task Management (RB)

3

4

Methodology (RB)

5

III FINAL DESIGN ALTERNATIVE (RB) 6

Folding 6

Filling 7

Packaging 8

IV FABRICATION AND TESTING (RB) 10

Folding

Finalizing Bill of Materials (JS)

Prototype Construction (RB)

Physical Testing and Modification (JS)

SolidWorks Testing (JS)

Filling

Prototype Construction (RB)

Testing and Modification (BM)

Load Testing (BM)

Assembly Line Testing (BM)

Packaging

Prototype Construction (TB)

Assembly Line Testing (TB)

Redesigning and Construction (TB)

Packaging Chute (TB)

Box Stopper (BM)

10

10

11

15

17

21

21

24

24

26

26

26

28

29

29

30

V FINAL DESIGN (TB BM JS) 32

General Description 32

Folding Table (JS-T3) (JS)

Retractable Cart (BM-F1) (BM)

Packaging Chute (BM-P1) (TB)

32

32

33

Structural Components 33

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Folding Table (JS) 33

8020 Framing (BM)

Sandwiched Acrylic Table Top (JS)

33

35

Retractable Cart (BM) 37

8020 Framing (BM)

Retractable Shelf (BM)

37

37

Packaging Chute (TB) 38

Metal Framing (TB) 38

Mechanical Components 39

Folding Table (JS) 39

Linear Actuators 39

Packaging Chute (BM) 40

Spring System 40

Electrical Components 41

Folding Table 41

Arduino Uno (TB)

H-Bridge System (TB)

Joystick User Interface (TB)

Accelerometer (TB)

Rechargeable Battery (TB)

41

42

44

45

47

VI DESIGN IMPLEMENTATION 48

Cost Estimate (RB)

Safety Precautions (TB)(JS)

Operation and Maintenance Procedures (TB)(JS)

48

49

52

VII CONCLUSIONS/RECOMMENDATIONS (TB)(BM)(JS) 55

VIII LIST OF REFERENCES (TB RB BM JS) 58

IX APPENDICES

Man-Hours Table (RB) A-1

Gantt Chart (RB) B-1

Descriptive Diagrams (TB RB BM JS) C-1

Control System Code (TB) D-1

Personal Resumes (TB RB BM JS) E-1

Page 5: Senior Design II Final Report

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LIST OF TABLES

Table 1. Cost Estimate for Folding Table 48

Table 2. Cost Estimate for Retractable Cart 49

Table 3. Cost Estimate for Packaging Chute and Box Stopper 49

LIST OF FIGURES

Figure 1. Cardboard Display 2

Figure 2. Folding Table (JS-T3) 7

Figure 3. Retractable Cart (BM-F1) 8

Figure 4. Packaging Chute (BM-P1) 9

Figure 5. Constructed Folding Table 13

Figure 6. Actuator Position 13

Figure 7. Position of Control System 14

Figure 8. Control System Materials 15

Figure 9. Folding Table with Braces 15

Figure 10. Completed Fabrication of JS-T3 17

Figure 11. Acrylic Tabletop 18

Figure 12. Stress Visualization of Acrylic Tabletop 18

Figure 13. Deformation Visualization of Acrylic Tabletop 19

Figure 14. First Draft of JS-T3 19

Figure 15. Final JS-T3 Model 20

Figure 16. Final Model Stress Visualization 20

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Figure 17. Final Model Deformation Visualization 21

Figure 18. Drawer Shelf 23

Figure 19. Finished Retractable Cart 24

Figure 20. Static Testing 25

Figure 21. Cart Shelf Clearance 26

Figure 22. 4 Hole 90° Joining Plate 27

Figure 23. Top and Bottom View of Chute Redesign 29

Figure 24. Final Packaging Chute Design 30

Figure 25. Box Stopper Implementation 31

Figure 26. 7-Hole 90̊ Joining Plate 34

Figure 27. Truss Attachments 34

Figure 28. Actuator Attachment 35

Figure 29. SolidWorks Model of Acrylic Table Top 36

Figure 30. Cart Assembly 37

Figure 31. Retractable Shelf 38

Figure 32. Linear Actuator 39

Figure 33. Box Stopper Spring System 40

Figure 34. Arduino Uno Programmable Board 41

Figure 35. H-Bridge Setup 42

Figure 36. Dual Channel H-Bridge 44

Figure 37. Dual-Axis Joystick 44

Figure 38. Dual-Axis Accelerometer 46

Figure 39. Cart Warning 53

Page 7: Senior Design II Final Report

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I. EXECUTIVE SUMMARY

For factory workers and their employers, safety is of the utmost concern when

designing any manufacturing process that the worker must perform in their daily routine.

Recently brought into consideration is the manufacturing process associated with creating

a display unit for greeting cards and other seasonal goods that can be found at most

grocery stores during the holiday season. An example of the display making process can

be found at American Greetings in Osceola, AR where workers construct display units in

three basic steps. First, flat cardboard sheets are folded into an empty display unit on top

of a table. Next, workers slide the empty unit along a dummy conveyor to a filling

station where products are then placed into the unit. Finally, the unit is moved to the

packaging station where a box is built from a second flat cardboard sheet, fitted around

the display unit, and then sealed and sent on its way to the shipping department via an

automated conveyor. Due to the size of the cardboard displays, the number of

components associated with a filled and packaged unit, and the vastly different worker

profiles of employees, this process is not currently optimized for worker comfort.

The following report by REK’M Engineering details the fabrication and testing of a

proposed solution to the problem that not only increases worker comfort, but also makes

the process safer overall by removing some of the physical strains imposed on a worker’s

body due to the repetitive nature of the process. While the design is based upon research

conducted at American Greetings, the devices fabricated by REK’M Engineering were

designed to be applicable to any manufacturer that uses a similar process.

To produce designs that optimized worker comfort and safety to the fullest extent

possible, the group started by appropriately defining the problem and listing constraints

based on the limitations imposed due to the Occupational Safety and Health

Administration (OSHA), the American National Standards Institute (ANSI), the Code of

Federal Regulations, the National Society of Professional Engineers’ (NSPE) code of

ethics, the physical restrictions that arose from the layout of the factory floor, and the

nature of the manufacturing process. Once this task was completed, and narrowing

techniques were employed, the group was left with the proposed final solution consisting

of a table for folding that features an adjustable height based on user inputs, a cart for

product boxes featuring a slide-out platform that will aid with the filling process, and a

chute that holds packaging boxes in place that will improve the packaging portion.

During the second semester of the Senior Design course at Arkansas State University,

the group manufactured and tested each of these components in order to further optimize

worker safety and other important criteria so that the final design of each of these

components could be fully and properly specified. Some of the solutions required a full

redesign of the proposed solution from the previous semester, while others remained the

same as the proposed solution. Fabrication was made possible through the American

Greetings plant located in Osceola, AR which provided the materials necessary to build

each solution and gave advice on the feasibility of the solutions and construction of each

device. Testing was performed on ASU campus and at the same American Greetings

facility to gather high quality data regarding the usefulness of the solutions and their

potential implementation on the assembly lines at American Greetings. This report

details the fabrication and testing of each of the proposed final solutions from the

previous semester and also the specifications of the final designs by REK’M Engineering.

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II. INTRODUCTION

Background

Over the years, American Greetings (AG) has provided many different ways to

communicate with friends and family through the use of greeting cards. These cards

range from congratulating graduates or wishing someone a happy Mother’s Day. The

market for these cards has spread to many large businesses such as Wal-Mart and Target

along with various smaller businesses. In addition to the large quantities of cards that AG

manufactures, it has started to build cardboard displays and pre-pack the cards into the

displays’ pockets before sending them to stores. Figure 1 shows a typical cardboard card

display that AG builds to send to its buyers.

Figure 1. Cardboard Display

These cardboard displays are built completely by employees standing at a table.

This process requires repetitive movements and muscular endurance by each employee

working at the station. First, a stack of flat cardboard is loaded onto the table from a

separate pile. Then, one employee folds one piece of cardboard into the shape of the

display and pieces together smaller portions to create pockets for the different cards.

After the display has been created, it is passed off to another worker who then inserts the

various cards in their respective pockets. Finally, the completed display with all the cards

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inserted into it is slid into a shipping box and stacked on a pallet waiting to be stretch-

wrapped.

This process of building, filling, and prepping each single display for shipment is

very time consuming. The current setup has also been reported to cause back and

shoulder problems for employees that work on a table that is not at a comfortable height

for them. Workers also have to pick up multiple stacks of flat cardboard to place on the

workspace every shift which can fatigue the body.

The goal of the project is to redesign the process of collecting all the necessary

pieces of a display, building it, stocking it with cards, and finally packaging it. By

designing a whole new process with workplace ergonomics in mind, the group hopes to

lessen the fatigue employees experience by reducing the amount of physical work

required. Another outcome the group is looking for is the increase in the production rate

of display units. This project will be designed and completed in compliance with state

and federal regulations such as OSHA and other agencies and organizations that deal

with worker safety.

Constraints

The conditions that will limit the solution are called constraints. These constraints

need to be met for a successful solution to be developed. The constraints for this project

have been defined as follows:

1. The solution must not create fumes that are hazardous to employee health (OSHA

1910.14(a)(1)(vi)).

2. Moving parts must be concealed in order to prevent employees from experiencing

bodily harm (ANSI B11.19-2003).

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3. The solution must be available for use with different employee physical profiles.

4. The design must optimize the use of industrial floor spacing without exceeding

the floor space that the current process uses.

5. All electric motors must have average full load efficiency specified in the Code of

Federal Regulations (CFR 431.446).

6. The design must be able to compensate for multiple types of folding techniques

for various displays.

7. The solution must be able to work for an entire shift without breaking down or

needing maintenance.

8. The solution must have a minimal learning curve.

9. The design must be moveable by no more than three personnel for slight

relocations and be moveable by forklift for large distances such as during

installation and removal.

10. The production rate cannot fall below that of the current process with the

implementation of the solution.

11. The design must include space to carry all necessary equipment required in the

display making process.

12. There should be justification for return on investment.

13. The solution should not solely be limited to American Greeting’s specifications.

The design should be able to be marketed to any card distribution company so that

potential conflicts of interest are avoided and so that a quality solution is found.

(NSPE Rule #3.1)

14. The process must conform to pre-determined cardboard flat dimensions.

Task Management

Throughout the semester, each member of REK’M Engineering worked with one

another to accomplish the eight project tasks. Each week, the design group met with the

project advisor, Dr. Tanay Bhatt. Each group member kept a logbook to keep record of

the hours and also to record details of the individual work completed. A man hour table

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showing the number of hours completed by each member for each task is located in

Appendix A, and a Gantt chart is shown in Appendix B.

Methodology

The previous semester, REK’M Engineering started the design process to make

the display box assembly at American Greetings more efficient and less hazardous to

employees. The team started by defining the problem. The problem focused on the pain

that many employees have after working on this line for several years. Also, the team

noticed that the assembly of the display boxes could be more efficient with designs that

could assist the employees. The team created constraints that were used for the designing

of alternatives. The team then brainstormed ideas for each section of the assembly line,

folding, filling, and packaging. Each idea met the constraints, and all were considered.

Next, the design group created selection criteria to base the selection of the best

alternatives off of. The group used the criteria to narrow all the entire alternatives down

to four for each of the stages of the display box assembly. The team then created

preliminary designs for each of the remaining alternatives that included parts lists and

3D-drawings. To further the narrowing process to the final alternatives for the each stage,

the group applied weight to each of the criteria. To apply weight to the criteria, the team

created a survey and had employees, management and display box assembly workers,

take the survey in order to receive outside feedback. Based off the surveys, the team

applied weights to the criteria, and from the preliminary designs, chose the best

alternatives for each stage of the display box assembly. The chosen alternative for the

folding stage was a height-adjusting table (JS-T3), for the filling stage was the retractable

cart (BM-F1), and for the packaging stage was the packaging box chute (BM-P1).

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III. FINAL DESIGN ALTERNATIVE

The following designs were created by REK’M Engineering. Each design is to be

used to create the display box assembly more efficient and safer for the employees that

work on this line at American Greetings. There is one design for each stage of the display

box assembly.

Folding Table (JS-T3)

This design allows the employee to fold and construct the display boxes at a

comfortable height. Figure 2 shows a SolidWorks drawing of the originally designed

folding table. The folding table design answers the need for the employee to have safer

way of constructing the display boxes. With a table that can adjust its height, the

employee can put the table height at the appropriate position to where they do not have to

bend their trunks or have to move their arms at a 30-60° angle from the side of their

body.

The initial design of the table had an aluminum tabletop, but this was replaced

with a fiberglass top when the materials were finalized. The legs were to be made with

pneumatic cylinders and were to be supplied with a compressor that was attached to the

underside of the tabletop. However, actuators also replaced these. The cart is to be

controlled by a control system with a joystick used for the employee input. The folding

table is designed to have lockable caster wheels to allow for it to be able to be moved

easily and locked into position when it is being used.

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Figure 2. Folding Table (JS-T3)

Retractable Cart (BM-F1)

To assist the assembly line worker when placing goods into the display box,

REK’M Engineering designed a retractable cart. Figure 3 shows a SolidWorks model of

the originally designed retractable cart. The retractable cart will be able to allow the

employee to receive and carry more goods from the pallet of merchandise to the assembly

line. With the cart full of merchandise, the employee can follow these steps to fill the

display box.

With one hand, the operator pulls the display box down the conveyor line coming

from the folding station.

With the other hand, the shelf on the cart is pulled to its extended position.

Without twisting at the trunk, the operator reaches from the hip area, grabs the

merchandise, and almost sliding it off of the cart, places it into the display box.

This motion requires the arm, as opposed to the torso, to move 10o-90

o in the xy-

plane (parallel to the floor).

Once the display box is filled, it is then pushed down the conveyor line to the

packaging station.

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These steps allow the employee to have proper movement that is safe based on

REBA/RULA. The cart holds up to 20 display box’s merchandise.

The retractable cart is base is a standard service cart. The retractable shelf’s

drawer is made out drawer slides that are attached to metal and the metal is attached to

the top of the service cart. The drawer top is designed to be made out of metal, but any

material may be suitable. The cart includes lockable caster wheels to prevent the cart

from moving while an employee is using it to fill the display boxes.

Figure 3. Retractable Cart (BM-F1)

Packaging Chute (BM-P1)

To assist the assembly line worker when he or she is placing the filled display box

into a packaging box for shipping, REK’M Engineering designed a packaging chute

assist. Figure 4 shows an Inventor model of the originally designed packaging chute. This

design allows the employee to place a shipping box onto the chute. The chute keeps the

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flaps out of the way and helps the employee place the filled display box into it. This

design is expected to reduce the amount of time required to fully complete the display

box assembly. This chute removes the physical pain for the employee that has to struggle

stuffing the display box in the shipping box while trying to hold the shipping box in

place.

This design includes a metal chute made out of two metal plates that the shipping

box fits onto. The distance between the plates can be adjusted based on the size of the

shipping box. The packaging chute can be moved to different parts of the assembly line

as needed. The packaging chute also has a footboard that is placed behind the shipping

box that offers resistance to the shipping box and doesn’t allow it to move when the

employee applies pressure to it by shoving the display box into it.

Figure 4. Packaging Chute (BM-P1)

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IV. FABRICATION AND TESTING

This semester, REK’M Engineering fabricated the final design alternatives that

were designed last semester. American Greetings agreed to fund the fabrication of the

designs on the agreement that they would get to keep the designs. American Greetings

offered their services of their machine shop, available materials that they already had on

hand, and up to $1000 toward materials that needed to be ordered. The team decided to

bring all of the materials back to the machine shop at Arkansas State University to

fabricate the designs at an area that was easier for the team to access. The materials that

were used to construct the designs can be found in the design implementation section.

Once the designs were fabricated, the team proceeded to test the designs and make any

modifications based on the testing.

Folding

The design associated with the folding portion of the display manufacturing

process is JS-T3. The following main tasks were performed during the second phase of

the Senior Design process: Finalizing Bill of Materials, Prototype Construction, Physical

Testing and Modification, and SolidWorks Testing.

Finalizing Bill of Materials

In order to fabricate JS-T3, a more accurate bill of materials needed to be created.

It was deemed by the group during one of the several advisor meetings that changes

should be made to this design in order to alleviate several fabrication, safety, and general

operation issues.

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One of the most troublesome components of the original design was the

pneumatic system that would allow the table to rise and fall to the user’s level of

comfort. The system was originally comprised of two aluminum pipes that would

telescope with each other to create the table supports. Because of the difficulties

associated with the pressurized air and the telescoping system, it was decided to change

the supports to pressure-rated pneumatic cylinders. After running this idea by American

Greetings, their design team suggested that the group do some research over linear

actuators that are relatively the same price and would alleviate several of the group’s

concerns. After deliberation and looking at the benefits of using linear actuators in place

of pneumatic cylinders, the actuators were chosen to provide the support for the table

surface.

Along with this main change, another large design change was made to substitute

acrylic in place of aluminum for the table surface. This would cut down on weight and

cost while maintaining a solid and rugged surface on which to perform folding

operations. Other changes that were made to JS-T3 include removal of the “C-Box”

space due to the limitations of the acrylic sheets and the addition of structural members

between the table supports and within the table surface to provide more rigidity and

stability.

Prototype Construction

Once all of the materials for the folding table was finalized, ordered, and received,

the design team started construction on it. To begin, the base of the table had to first be

constructed. Using the Aluminum 8020 1010, the 1 in by 1in square structural aluminum

that the team received from American Greetings, the team constructed a rectangular base

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for the actuators to connect to. On the four corners of the base were right angle brackets.

The team drilled holes in these brackets for the lockable rotating to screw into and for the

actuators to sit into. Once the base was completed, the actuators were set into the holes on

it and the team then turned their attention to the tabletop.

The tabletop is built from two pieces of acrylic. The team first drilled the holes

into the acrylic where the bolts were to go to connect them together. The team placed 1

inch pieces of PVC pipe between the two pieces of acrylic and bolted them together with

round head bolts. With the tabletop built with two pieces of acrylic that are 1 inch apart,

the table is lightweight compared to using another material and allows the tabletop to be

more rigid than having just one piece of acrylic. Next, the team cut the holes into the

tabletop for the actuators to be placed into and then placed and secured the tabletop onto

them. To add structural support to the tabletop to allow it not to bend as much, pieces of

Aluminum 8020 1010 were placed between the two pieces of acrylic. Figure 5 shows the

tabletop and table base. Figure 6 shows the position of the actuators and how they are

connected to the tabletop and to the table base. When the team first constructed the table,

they noticed that the table swayed and was not very stable. To add structural support to

the table, the team added trusses that extended from the tabletop to the actuators in the

length and width directions. These kept the table from moving as much when it was

bumped and allowed the table to still move up and down. The actuators were connected

to the control system.

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Figure 5. Constructed Folding Table

Figure 6. Actuator Position

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The team constructed a box made of 1010 for the control system to be housed in.

The box has acrylic was that has holes drilled in it to allow air to flow through for the

control system. The team then attached the control box to the bottom side of the tabletop

using 1010 bolts. A 12V DC deep cycle battery powers the control system. To control

each actuator, two dual H-bridges were used. These H-bridges receive an input from the

Arduino that stores the code for that controls the system. The user input is done using a

joystick. Taylor Barnhill was in charge of writing and implementing the code for the

control system which can be seen in Appendix C. Figure 7 shows where and how the

control system is attached to the tabletop. Figure 8 shows the battery, the H-bridges, and

the Arduino that make up the control system for the table.

Figure 7. Position of Control System

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Figure 8. Control System Materials

Physical Testing and Modification

After fabrication of the JS-T3 prototype, the stability of the table and the rigidity

of the table’s surface became design concerns that needed to be addressed. Before

further modification of the design, at the table’s lowest working height, the table would

sway laterally and longitudinally more than four inches away from its designed center

position. The table’s surface also deflected more than previously expected from

SolidWorks simulations. At the table’s ends, the working surfaced dipped two inches

beneath the working surface’s relaxed neutral plane.

In order to address these issues, seven excess pieces of aluminum 8020 were

placed longitudinally-oriented into the sandwiched sheets of acrylic. This quick solution

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greatly reduced the amount of sag in the table to a level that is much less noticeable (<

1/2”). Several solutions were proposed to address the stability of the working surface due

to the wobbling of the table supports. One of the first attempts at stabilizing the device

was to expand the base of the table so that the legs would all point inward to the center so

that there would be more resistance to motion that would move the table from its

equilibrium position. While this did solve the problem to an extent, the base would need

to be expanded greatly in order to reduce the wobble to an acceptable level by this

method. A second attempt was made to secure the table by using an assembly consisting

of two set screws, an aluminum cylinder, and a washer at the bottom of each table leg to

firmly clamp the leg to the bracket. This solution did not fix the problem very well, since

movement of the table sometimes caused the set screws to fall from their vertical position

and lose pressure on the clamped joint. A third solution was proposed to brace each table

leg in both the longitudinal and lateral directions. These braces would inhibit the

wobbling since it would effectively act as a second rectangular brace directly beneath the

table. Before implementing any solutions, the table could wobble over a two inch range

in either direction. After adding braces in both the longitudinal and lateral directions, the

table could only wobble over a ¾” range in either direction. A picture of the final version

of JS-T3 is given below in Figure 10.

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Figure 10. Completed Fabrication of JS-T3

Additional testing was planned to take place to determine the speed and sag at

various points along the working surface under 25 lbf increment loads up to 450 lbf. This

was not possible to perform, however, since the H-bridge motor controllers were

damaged during some of the electrical system setup. Additional testing will take place

during the week between completing the final report and giving the final presentation so

that results can be discussed during the presentation.

SolidWorks Testing

During the finalization of the bill of materials for this design, preliminary

SolidWorks studies were performed to analyze how the proposed changes would affect

the operation of the table and to see how the table would react under the design loading

conditions. The newly designed tabletop with all dimensions given in inches is shown in

Figure 11. A stress analysis was performed on the tabletop, and the stress and

deformation visualizations can be seen in Figures 12 and 13 respectively. The first draft

of the completed table is shown in Figure 14.

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Figure 11. Acrylic Tabletop

Figure 12. Stress Visualization of Acrylic Tabletop

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Figure 13. Deformation Visualization of Acrylic Tabletop

Figure 14. First Draft of JS-T3

These preliminary models were further developed into more realistic models

based on the materials acquired from American Greetings. Furthermore, after noting how

much the table sagged under its own weight, it was decided that the “C-Box” bracket

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would not be built. A second stress analysis was performed on the final model of the

table shown in Figure 15, and the results can be seen for the stress visualization and

deformation visualization in Figures 16 and 17 on the following page.

Figure 15. Final JS-T3 Model

Figure 16. Final Model Stress Visualization

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Figure 17. Final Model Deformation Visualization

The results of these studies show that no part of the entire folding table

experiences significant stress and that the edges of the table sag the most in the

longitudinal direction where the maximum is nearly 0.5” under the design load. Since no

part is subjected to forces close to its yield stress or its rated value for operation, the low

values for stress are to be expected. The relative values for resultant displacement shown

in Figure 17 correspond closely to those values found by the group after fabrication.

After fabrication, the group recorded significant deformation of the acrylic sheets in the

middle (~0.25”) and also at the far ends of the folding tables (~0.5”).

Filling

Prototype Construction

The initial design for the retractable cart was to have the cart base be a standard

service cart. However, when the team went to American Greetings for materials, they had

a large supply of Aluminum 8020, a structural aluminum that they were to provide the

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team with. The team decided to build the cart out of the structural aluminum because it

could be fastened in different ways. After discussing more with American Greetings, they

provided a cart that they had built out of Aluminum 8020 1515, which is the 1.5 in by 1.5

in square Aluminum 8020, for a previous project. Originally, the cart had severally small

shelves but being built out of Aluminum 8020, the team was able to customize the cart to

how they wished. The team kept the original top shelf that was built out of plywood and

stripped the cart of all shelving to just have a basic cart. The cart has two non-rotating

caster wheels on the front and two lockable rotating casters toward the back where the

user pushes the cart. The team used to a piece of 1515 to build a handle for the user to be

able to push it around.

Once the base cart was constructed, the team then turned their focus onto the

drawer shelf that would extend over the assembly line. To begin, the team placed two

pieces of Aluminum 8020 1010, which is the 1.0 in by 1.0 in square Aluminum 8020, on

top of the plywood shelf top that the drawer slides would connect to. The team secured

the two pieces by drilling holes into the plywood shelf top and using bolts and 8020 nuts.

The team then placed the drawer slides on top the two pieces 1010 and attached them

with 1010 bolts and nuts. Once the slides were in place, the team extended them to attach

the drawer top. The drawer top was originally a plywood shelf that was on the cart. A 2x4

piece of wood was used to create sides on the drawer top. The drawer top was attached to

the slides using the fastener screws that came with the slides. Figure 18 shows a side

view of the drawer shelf on the top of the cart.

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Figure 18. Drawer Shelf

To prevent the drawer slides from bending when the drawer is completely

extended, the team bolted another piece of 1010 toward the back of the shelf top. The

team used an L-bracket that was connected to the back piece of 1010 to connect the shelf

top to this piece. The L-bracket can be tighten to allow the drawer shelf to be locked into

place and can be loosened to move the drawer in and out. When the drawer is completely

extended, the L-bracket piece adds resistance and holds the back of the drawer down and

doesn’t allow the front of the drawer that is extended from bending. Next, to add more

shelving, the team cut a piece of plywood and secured it on the bottom of the cart with

1515 bolts and nuts. Figure 19 shows the finished retractable cart in its extended position

with materials that would be used at American Greetings. A cost estimate of the cart can

be found in Design Implementation section.

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Figure 19. Finished Retractable Cart

Testing and Modification

The retractable shelf cart was tested for two main functions. The two functions

were the physical and ergonomics aspects.

Load Testing

In order to determine the static properties of the filling design (BM-F1) the team

ran a static analysis. The load testing consisted of a load at the end of the retractable

shelf. This was used to find which would happen first the breaking of the shelf or the

tipping of the cart. Figure 20 shows the results from the static test. The first part, (a),

shows the shelf on the x-axis with point load and its respective reaction forces. Second

part, (b), shows the shear force diagram and the third part, (c), is the bending moment

diagram.

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25

According to the static analysis, the largest moment in magnitude occurs at the

middle, 120 lb. ft. Treating the shelf as a beam, the stress of the shelf was calculated.

Equations 1 and 2 were used to determine the maximum stress on the shelf. The stress

with a 60 lb. load at the end of the extended shelf was calculated at 640 psi. The shear

strength of plywood is about 899 psi [1]

. This test was designed to determine what would

occur first the tipping of the cart or the breaking of the shelf. Since at 60 lb. load the cart

tipped over and the stress did not exceed the shear strength of the plywood, the load on

the shelf will have to be limited.

𝜎 =𝑀𝑦

𝐼𝑥 (Eq. 1)

𝐼𝑥 = 𝑏ℎ3

12 (Eq. 2)

(a

)

(c

)

(b

) Figure 20. Static Testing

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26

Assembly Line Testing

The cart design was taken to American Greetings to put to use on the line to

observe the usefulness. The cart use was compared to the current method of filling the

box displays. Originally, the cart had been built to fit the use of a fairly short box. In the

assembly line test the team realized that the heights of all the different models of boxes

that are use are not the same. To relieve this issue, the team raised the legs of the cart up

8 inches. The 8 inches gave the enough clearance for most if not all display box designs

to pass under the shelf with no problem. Figure 21 (a) shows the shelf height over the

conveyor. Figure 21 (b) and shows the cart prior and Figure 18 shows after the

modification.

Packaging

Prototype Construction

The team started out constructing the cross member that reaches over the

conveyor to allow workers to adjust the width of the chute. This cross member was built

out of the aluminum 8020 material that American Greetings had given to the group. From

(a) (b)

Figure 21. Cart Shelf Clearance

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27

the design that Taylor created last semester, the team made the cross member out of two

rods of 8020. The horizontal shaft had to be attached to the other vertical shaft in a way

that allowed it to be adjustable for multiple box heights. This was solved by using a 4

hole 90° joining plate to fasten the two rods together, shown below in Figure 22.

Figure 22. 4 Hole 90° Joining Plate

This way, a worker would only have to loosen the two screws along the vertical

rod to adjust the height of the horizontal member, then tighten the screws back to lock it

in place. The horizontal member needed to be long enough to stretch out across the

conveyor, which is 18”, so the team decided that 24” was a desirable length for it. At the

time, the team had not found a solid way to attach the contraption to the assembly line, so

they started fabricating the metal flaps for the actual chute.

The flaps were constructed out of the spare sheet metal that was taken from the

American Greetings supply. First, two flaps needed to be traced out and cut with a

plasma torch. These flaps needed to be large enough to hold a cardboard box, yet small

enough to be easily moved by the smaller employees. The team agreed on a 10” tall, 12”

wide surface that had a 3”x3” flap at the bottom that was bent at a 30° angle to make the

flaps act as a funnel. Once the two were traced, the team used a plasma cutters to cut

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them from the sheet metal, and a band saw to make the final precise cuts. To allow the

flaps to move along the cross member, a 1.5”x1.5” square hole was cut 1” from the top to

weld a 2” section of square tubing to. This square tubing acts as a sleeve for the chute,

allowing each plate to be individually adjusted by loosening a bolt between the tubing

and the aluminum rod. With the flaps constructed, the preliminary work for the

packaging chute was completed, and ready to test on some boxes at the AG plant in

Osceola.

Assembly Line Testing

On the 27 of February, the team went to American Greetings to test the

functionality of the packaging chute. Chris Walker took the team to the packaging

department, and the members got a couple boxes to help test the chute. While testing, the

team noted a couple of design flaws:

There were not many places to attach the cross member to: the assembly line was

connected to something else on the back of it, leaving a small number of openings

The cardboard boxes kept slipping off of the chute while the display box was

being pushed inside of it

The flaps protruded over the assembly line on the side of the workers, making it a

hazard for people walking near it

The horizontal arm was pretty heavy, and hard to adjust with just one person

The horizontal arm was not long enough to allow the flaps to widen enough for

the bigger boxes

Chris did say that he liked the idea of something holding a box while a worker

pushes the display into it, but the team needed to make some adjustments to the design to

fix the noted issues

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Redesigning and Construction

Packaging Chute

Mr. Barnhill came up with a new, simpler design that consisted of a plate that sits

on top of the assembly line and has smaller funnel plates. He created an Inventor file to

show the group, and a picture of it is shown below in Figure 23.

Figure 23. Top and Bottom View of Chute Redesign

This design would be able to be placed anywhere on the assembly line, and

moved around easily. Also, nothing would hang over the line to pose a threat to anyone,

and allowed a larger area for the flaps to adjust. Two 3”x3” squares were welded onto the

bottom of the base plate on each side to keep it from moving around once placed on the

assembly line. The original plates were cut down to 5” tall, 2” wide still with the existing

3”x3” inner flaps kept at a 30° angle. The plate itself was cut into an 8”x20” rectangle,

with an 8” slot cut out for the adjustable flap. One flap was screwed tightly onto the plate

to keep it stationary, while the other flap was welded to a small 2” piece of angle iron,

and then screwed to the base plate through the slot. This allowed the flap to be able to

move to make the chute wider or narrower. A picture of the final design is shown in

Figure 24 on the next page.

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30

Figure 24. Final Packaging Chute Design

After the team finished the chute redesign, they needed to figure out how to keep

the cardboard box on the chute while a worker slides the display into it.

Box Stopper

The team’s end goal with the packaging chute was to prevent the associate

working the line from handling two boxes at once. An observation that was made during

the testing of the first chute design; it was that the chute did not have a method of

securing the packaging box. To secure the box to the chute the team designed and built a

stopper with a spring system. Figure 25 shows the box stopper under implementation

with the packaging box secure (a) and resealed (c) in the assembly line. The pedal in

Figure 25 (b) is the release mechanism for the box stopper.

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(a)

(c)

Fig

ure

25

. B

ox

Sto

pper

Im

ple

men

tati

on

(b)

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32

V. FINAL DESIGN

General Description

Folding Table (JS-T3)

The folding table was a design created and developed by Jed Schales and built by

every member of the REK’M Engineering Team. It began as an aluminum table that

would use a pneumatic system to lift and lower a flat, level surface so that a worker could

comfortably work throughout the day without leaving the factory with aches and pains.

The final design still accomplishes the goal, but does so in a much more controlled and

efficient manner by minimizing the weight of the device and implementing a more

sophisticated lift system. The user manipulates a joystick controller to send a signal

through various electrical components in such a manner that four linear actuators act in

unison and the table rises or lowers while remaining level. The table is relatively light

since it is made of acrylic and PVC in place of heavier alternatives such as aluminum or

wood. JS-T3 consists of 25 different types of components, features a four foot by eight

foot working surface which adjusts to elbow level for 95%+ of the human population,

weighs 172.3 lbs., and costs just under $1,600 to fabricate.

Retractable Cart (BM-F1)

The retractable cart is 2 ft. wide by 3 ft. long by 46 in. tall cart that will be used to

decrease the ergonomically discomfort that employees experience while working on an

American Greeting’s assembly line. It works under the foundation that the cart will carry

everything and the employee will do minimal bending at the torso.

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Packaging Chute (BM-P1)

The packaging chute was a design created by Banthi Muñoz, worked on by Taylor

Barnhill, and built by the REK’M Engineering Team. At first, it started with the idea of

funneling a filled display box into a packaging box that was stationary in order to cut

down on time spent by a worker trying to hold the box down while simultaneously

pushing the 15+ pound display into it. The final design does just this. It holds a

packaging box in place, keeps it from slipping with the addition of the box stopper, and

allows a worker to seamlessly slide a display box into said packaging box. All the worker

has to do next is press down on the foot pedal to lower the box stopper and allow the

finished box to slide to its next location.

Structural Components

Folding Table

The folding table, JS-T3, consists of two very important structural components

that form the working surface and standing base of the design. The standing base has

been named “8020 Framing” and consists of twelve of the twenty-five components that

comprise the entire table. The working surface is named “Sandwiched Acrylic Table

Top” and consists of seven of the twenty-five components that comprise the entire

device.

8020 Framing

The frame of the folding table consists of 52”X 28” frame of 1010 joined with 7-

hole 90̊ joining plate and a 26” section of 1010 in the middle of the 52” sides. The legs,

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linear actuators, sit in the 7-hole 90̊ joining plate. The 7-hole 90̊ joining plate had a 7/8”

hole milled out to inset the ends of the legs, as shown in Figure 26 below.

Trusses were a key point in the design of the table; these gave stability to the

table. The team had to figure out a special method to attach trusses to the linear actuators

in a manner that did not damage the interior components. The team designed a truss brace

that acted much like a C-clamp and used a hex nut and bolt to tighten around the surface

of the linear actuator, Figure 27.

Since the actuators were only set inside the 7-hole 90̊ joining plate. The team

needed to find a method of securing the actuators to the bottom frame. A 2” aluminum

Figure 26. 7-Hole 90̊ Joining Plate

(b) Figure 27. Truss Attachments

(a)

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rod was lathed down to 31/64” to fit inside the horizontal hole shown in Figure 28 (a). A

34 size drill bit was used to mill holes on both ends of the pin and the holes were

threaded with a 6-32 tap, Figure 28 (c). With the table being a big unit a custom washer

needed to be fabricated. This prevented the pin from turning and releasing the set screws.

Sandwiched Acrylic Table Top

The working surface of the folding table consists of two 4’ x 8’ acrylic sheets that

have sixteen 1” long slices of 1-1/4” schedule 40 PVC tubing fastened between them to

act as spacers. Through these PVC spacers, there are screws that attach the two pieces of

acrylic together and maintain a relative position for the PVC to support. At the bottom of

(c)

Set Screws

Figure 28. Actuator Attachment

(a) (b)

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the lower acrylic sheet, several other important components are fastened such as the

actuator trusses of the 8020 framing and the electrical component box which is attached

at the center of this lower sheet. Four 1.5” diameter holes were cut in a central 2’ by 4’

rectangle shape from this bottom sheet so that the linear actuators can sit in these holes

and support the table firmly. With only the PVC spacers, the group noticed that the table

sagged significantly along its longest dimension, but with the addition of more 8020 1010

members parallel to the table’s longest side, the sag was greatly lessened and the working

surface became a much more solid surface to work upon. A SolidWorks rendering of this

tabletop is given in Figure 29 below.

Figure 29. SolidWorks Model of Acrylic Table Top

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Retractable Cart

8020 Framing

The cart frame was made from 1010 extruded aluminum. From the bottom shelf is

26” above the top shelf. The width and length of the cart are 24” and 36” respectively.

The corners use 4-hole 90̊ joining plates as shown in Figure 30 (a). The entire frame sits

on top of 5” casters the front two have 360̊ rotation and the rear two do not rotate. Figure

30 (b) displays the modeled frame, the actual frame is shown in Figure 30 (c).

Retractable Shelf

For the retractable shelf the team used a set of Richelieu 18” Drawer Slides. The

slides attached each to a 12” section of 1010 that then attached to the 8020 Frame. The

sliding section of the drawer slides were screwed onto the bottom side of a 24” by 36”

section of ¾” plywood; the plywood served as the retractable shelf that hovered over the

(a) (b)

Figure 30. Cart Assembly

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box display on the conveyor. To prevent the back end of the shelf from lifting when a

load was added, the team incorporated a third 24” section of 1010 at the rear of the shelf.

A lose was sliding nut in the 1010 section that could be tightened to enable the shelf to be

locked in any position needed, Figure 31 (a). Two sections of 2”X4” were used as an

elevated edge to prevent items from falling off of the opposite side that the employee is

operating on, Figure 31 (b).

Packaging Chute

Metal Framing

The packaging chute is made out of 1/8 inch sheet metal that is rigid and will not

bend under normal use. It sits on top of the conveyor and is easy to pick up and place

somewhere else if needed. It is mostly welded together, and the flaps are fastened onto

the base plate with 1010 screws for easy disassembly.

(a) (b)

Figure 31. Retractable Shelf

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Mechanical Components

Folding Table

The folding table, JS-T3, consists of one main mechanical component that forms

the leg supports of the overall design. This main component is the set of linear actuators

that work together to change the table’s height. This component is just one of the twenty-

five that comprise the entire device.

Linear Actuators

The four linear actuators are pre-fabricated devices that came from Firgelli

Automations. They are specified to operate under a static or dynamic force of 400 lb.,

operate at 0.4”/s under this full load, and draw a maximum of 5A of current at 12V DC.

On its own, the device weighs 7.4 lbs., and its length is 30.88” while retracted and 54.88”

while extended. In their configuration within JS-T3, these devices allow the table to sit at

its lowest at 36” and its highest at 50”. Within the device, there is a factory preset limit

switch that will shut off operation if it reaches either of these limits. A SolidWorks

rendering of the actuators is given in Figure 32 below.

Figure 32. Linear Actuator

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Packaging Chute

Spring System

The spring system of the box stopper consisted of one compression spring and

two tension springs. The compression spring resides inside a cylinder to prevent

buckling. The compression spring as well as the two tension springs attach at the same

vertical position but are 1 ½” apart in the horizontal direction. The opposing end of the

tension springs are attached to a chain that follows to the floor level. At the floor level

there is a foot pedal that used body weight to compress the compression spring, lower the

stopper, and release the packaging box. The tension springs are necessary to prevent

excessive force from being used on the pedal. For example, a person presses the pedal

beyond the compressed length of the compression spring. Instead of breaking the welds

or bringing the conveyor system down the tension springs will elongate. This could

happen with the pedal getting out of place as well. Figure 33 (a) displays a diagram of the

spring system, and (b) shows the tension springs and the incased compression spring.

Tension

Springs

(a) (b)

Figure 33. Box Stopper Spring System

Stopper

Compressi

on Spring

Pedal

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Electrical Components

Folding Table

The folding table, JS-T3, consists of five electrical components that together form

the control system for the table. These components are the Arduino Uno, the H-bridge

system, the joystick user interface, the accelerometer, and the rechargeable battery.

These are five of the twenty-five total components that make up JS-T3.

Arduino Uno

The Arduino Uno is a programmable board that handles multiple analog and

digital inputs, and sends digital and PWM outputs to whatever devices are being used in

conjunction with the board. For the table, it has two inputs, a joystick and an

accelerometer, and four outputs, four individual actuators. It is programmed in a language

resembling the C language and is fairly easy to use. The Arduino website has an array of

sample code to look at for many different devices. The board runs off of a 9V battery,

AC/DC outlet converter, or the USB that is connected to the PC or Mac used to upload

the code. A picture of the board used for the project is shown below in Figure 34.

Figure 34. Arduino Uno Programmable Board

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H-Bridge System

The H-Bridge has been the number one way to control both the direction and

speed of a motor ever since the transistor was created. The concept behind it is extremely

simple, and it can be applied to almost all typed of DC powered motors. It all has to do

with the four transistors that are in the circuit. A transistor is a semiconductor device used

to amplify and switch electronic signals as well as electrical power. Depending on the

type of transistor (bipolar junction transistor, metal oxide semiconductor field effect

transistor, or other types) they can perform many different functions, however, they all

have one similar quality – they act as a switch. When current flows into a certain one lead

of the three they have, they allow current to flow through the other two. For example, in

the case for the BJT, its three leads are the emitter, base, and collector. When placed in a

circuit, it will not allow current to flow from the collector to the emitter until it detects

current in the base lead. From then on, it allows the circuit to be complete. By using this

idea, engineers came up with the idea of placing four transistors in a circuit in order to

control the direction and speed of a motor. The circuit looks something like the figure

below in Figure 35.

Figure 35. H-Bridge Setup

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In this setup, one can control the direction of the motor in the middle by allowing

current to flow into certain transistors. To go forward, current needs to flow into the

transistors at the top left and bottom right. That would turn the transistor “on”, and allow

the circuit to be completed. Conversely, the motor can turn in reverse by taking the

current away from the two previously stated transistors, and connected to the top right

and bottom left ones instead.

Also, one can control the speed of the motor. This is done by applying a pulse

width modulated (PWM) signal to the transistors instead of a constant flow of electricity.

A PWM is a square signal that varies its duty cycle (ratio of how long the signal stays

high in a single period over the entire period) based on the input to the system. For

example, a duty cycle of 75% means that the signal is on for three-quarters the time, and

off the rest of the time. The reason a PWM signal is needed for the H-Bridge is that, by

connecting the PWM to the transistors, the motor will only be supplied its needed voltage

at a rate desired by the user. Otherwise, the motor will run at full speed the entire time the

transistors detect current. The higher the duty cycle, the closer to full speed the motor

will run, and it will turn slower and slower while the duty cycle reaches 0%.

The actual H-Bridges used in the project are dual channel, and built to withstand

up to 30A peak current, which is more than enough to support two 5A actuators per

board. Each board can support two different motors connected to the same power source,

and able to control both motors’ speed and direction individually. The project required

two boards to control all four actuators at once. A picture of the H-Bridge is located on

the next page in Figure 36.

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Figure 36. Dual Channel H-Bridge

Joystick User Interface

The ability to adjust the table height seamlessly lies with the easy-to-use 2-axis

joystick from Parallax Inc. This joystick is simple to use, and requires very little

instruction to learn the basics. A picture of the joystick used in the project is shown in

Figure 37.

Figure 37. Dual-Axis Joystick

In technical terms it has two different outputs that operate on a binary system. The

two different outputs deal with the orientation that a user presses the joystick: up versus

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down, and left versus right. The output for both directions is a number ranging from 0 to

1023, or 0000000000 to 1111111111 in binary. The binary is sent to the Arduino board,

which is programmed to convert the binary numbers into decimal numbers that are easy

to code with. In the L/R output, 0 means the joystick is pushed all the way to the left, and

1023 means it is leaning right. For the U/D situation, 0 is all the way down and 1023 is

all the way up. For both directions, a number of 511 means that it is in the resting

position, meaning nobody is pressing it in any direction.

With this information, it is easy to get the Arduino to output both PWM and

direction signals to each H-Bridge. Based on the direction and magnitude the joystick is

pressed, the Arduino can tell the actuators to go up or down at varying speeds. The code

was written to handle four situations that the joystick will operate in:

1. If nobody is tilting the joystick, the board sends a PWM signal of “0” to each H-Bridge,

making each actuator stop.

2. If someone tilts the joystick in the up direction, the board will send out a “High” signal to

the direction pins and a PWM signal that is mapped between 0 (always off, stop) and 255

(always on, full speed) depending on the magnitude the joystick is pressed, telling the

actuators to extend at a certain speed.

3. If the joystick is tilted down it will do the same as the previous situations, but the

direction output will be “Low”, telling the actuators to retract, making the table go down.

4. When a user presses the joystick all the way to the right, the accelerometer will initialize,

and start to stabilize the table automatically until the user lets go of the joystick.

Accelerometer

An accelerometer is a device that measures the tilt, speed, and acceleration of an

object. In this case, it is used to measure the tilt of the table, in the case of one of the

actuators not rising/falling at the same rate as the other three. It is a very small device,

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and the group used the product from Parallax Inc. for the project. A picture of the

accelerometer used is shown below in Figure 38.

Figure 38. Dual-Axis Accelerometer

For this project, the accelerometer is used to determine the direction that the table

is tilting if there is any, and the Arduino uses that information to stabilize the table. It is

called dual-axis because it reads the tilt on the horizontal x and y axes. It sends a signal, a

number in between -4000 to 4000 for each axis, to the Arduino board, and the board is

programmed to convert that number to the amount of g’s the device is experiencing.

Based on the tilt that the board reads, it will do one of 9 actions:

1. No tilt – nothing is sent to the actuators, device does not move

2. Tilts forward – back two legs go down

3. Tilts backwards – front two legs go down

4. Tilts left – right two legs go down

5. Tilts right – left two legs go down

6. Tilts forward-right – front left and back two legs go down

7. Tilts forward-left – front right and back two legs go down

8. Tilts back-right – back left and front two legs go down

9. Tilts back-left – back right and front two legs go down

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There is a 0.1 second delay in readings, so the accelerometer will wait for the legs

to move for 0.1 seconds before making another reading in case the situation changes.

Rechargeable Battery

The power source for the actuators is a deep cycle 12V 35Ah rechargeable

battery. It is able to supply an entire Ampere of current to a device for 35 straight hours

before needing to be recharged. In this case, the four actuator use 5A a piece under full

load conditions, so that is 20A total. The battery will be able to power the four actuators

for a total of 1 hour and 45 minutes. At first, that doesn’t sound great at all, but that isn’t

how the setup works. The actuators only use the battery’s charge to operate when there is

a signal coming from the Arduino telling the H-Bridges to turn on. Otherwise, the circuit

is not complete and the battery is not being used at all. When a person wants to adjust the

table, he or she will only use the joystick for around 10 seconds. With that information,

the battery should have enough capacity to handle 630 height changes.

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VI. DESIGN IMPLEMENTATION

Cost Estimate

Below, Tables 1, 2, and 3, are the cost estimates for the each of the designs. The

team used several different resources to acquire the building materials. These resources

included 80/20 Inc., Lowes, and Amazon. The total costs for each design were $1,592 for

the table, $460.92 for the cart, and $85.04 for the packaging chute. Altogether, the three

designs totaled $2137.96.

Material Quantity Price/Quantity Price

Aluminum 8020 1010 T-Slotted (in) 350 $0.23 $80.50

1010 Bolt and Nut Pair 60 $0.50 $30.00

10 S 5 HOLE 90 DEGREE JOINING PLATE 4 $6.30 $25.20

10 S 7 HOLE 90 DEGREE JOINING PLATE 4 $7.65 $30.60

1-1/4". x 2 ft. PVC Pipe 1 $2.15 $2.15

Round Head 3/8in x 2in Bolt 16 $0.37 $5.92

3/8in Lock Washers 16 $0.23 $3.68

3/8 in Fender Washers 16 $0.55 $8.80

3/8 in Hex Nuts 24 $0.22 $5.28

Flexion Lock Rotating Casters 4 $23.50 $94.00

Firgelli 24 in Stroke Actuator 4 $141.68 $566.72

4 ft x 8 ft Plexiglass Sheet 2 $215.56 $431.12

Dual Channel Motor Controller 2 $32.89 $65.78

Auduino UNO R3 Board 1 $14.49 $14.49

12V 3.5Ah Rechargeable Battery 1 $74.90 $74.90

1in Square Steel Tubing (in) 16 $0.31 $4.96

1in OD Round Steel Tubing (in) 8 $0.27 $2.16

2 Axis Parallax Joystick 1 $4.99 $4.99

2 Axis Parallax Accelerometer 1 $29.99 $29.99

10 S 2 HOLE JOINING STRIP 2 $3.40 $6.80

2'x2' Acrylic 1 $11.98 $11.98

1'x1' Plywood 1 $6.29 $6.29

10 S 2 HOLE INSIDE CORNER BRACKET 8 $2.90 $23.20

2" ID Aluminum Rod (in) 16 $1.49 $23.84

1'x1'x1/4" Aluminum Plate 1 $25.22 $25.22

Set Screws 10 pack 1 $13.43 $13.43

Total Cost= $1,592.00

Table 1. Cost Estimate for Folding Table

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Safety Precautions

Safety Precautions

JS-T3 is designed to support a 500 lbf load imparted to the table’s working

surface. Although the load ratings for the linear actuators and caster wheels are

significantly greater than this (400 lbf per leg and 250 lbf per wheel), the expected

Material Quantity Price/Quantity Price

Aluminum 8020 1515 Lite T-Slotted (in) 425 $0.45 $191.25

Aluminum 8020 1010 T-Slotted (in) 57 $0.23 $13.11

1515 Bolt and Nut Pair 66 $0.60 $39.60

1010 Bolt and Nut Pair 5 $0.50 $2.50

15 S 5 HOLE 90 DEGREE JOINING PLATE 4 $7.10 $28.40

15 S 4 HOLE 90 DEGREE JOINING PLATE 4 $5.60 $22.40

15 S 4 HOLE INSIDE GUSSET CORNER GUSSET 4 $6.25 $25.00

15 S 2 HOLE INSIDE CORNER BRACKET 6 $2.95 $17.70

Flexion Lock Rotating Casters 2 $23.50 $47.00

Flexion Rigid Casters 2 $13.08 $26.16

23/32 x 4 x 8 Plywood 1 $28.72 $28.72

2'x4'x96" Stud 1 $3.11 $3.11

Richelieu 2-Pack 18in Drawer Slides 1 $15.97 $15.97

Total Cost = $460.92

Table 2. Cost Estimate for Retractable Cart

Material Quantity Price/Quantity Price

11ga 1'x2' CR Steel Sheet 2 $25.39 $50.78

1010 Bolt and Nut Pair 4 $0.50 $2.00

1" OD Aluminum Tubing (in) 6 $0.55 $3.30

Hillman Compression Spring 11/16"x3" 1 $3.49 $3.49

Hillman Tension Spring 5/8"x3-1/4" 2 $4.57 $9.14

Gate House 3-1/2" Hinge 1 $2.78 $2.78

Blue Hawk 15' #3 Double Loop Chain 1 $6.97 $6.97

Quick Link 1/8" 3 $1.78 $5.34

Chain S-Hook 1/8" 1 $1.24 $1.24

Total Cost= $85.04

Table 3. Cost Estimate for Packaging Chute and Box Stopper

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50

deformation along the acrylic sheets with loads greater than 500 lbf causes a significant

problem for a worker who intends to use this device for an extended period of time. The

table will not keep a level surface and will be difficult to perform accurate folding

operations upon. The table was not tested for impact tests. From analysis of the

components of JS-T3 during physical testing and SolidWorks studies, it appears that

upon failure, the table’s acrylic sheets will be the first to fail by shearing, but remain

stationary since there are multiple layers and several underside brackets. Since the entire

table can move, a crushing hazard exists if any part of the worker is rolled upon by the

caster wheels while they are not locked in place. There should be no pinching hazards

present while using the device due to the configuration of the linear actuators and their

trusses. There may be the danger that a worker could scrape their hands or knuckles on

the working surface due to the bolts that were left exposed on the top sheet of acrylic that

forms the tabletop. This can be addressed by drilling small sections out of the acrylic

surface so that the screw heads can sit at the same level as the working surface. As of

now, there are no barriers between the electrical components and a worker, so a shocking

hazard may also exist if the worker attempts to disconnect or tinker with any electrical

components while the device is powered.

BM-F1 is designed to support 40 lbf of goods when fully extended across the

conveyor, and can support two more boxes of goods on the lower shelf of the cart. The

cart should not be loaded with more than this in order to ensure the worker’s safety. The

criteria for failure for this design is not fracture of a component, but rather the cart

tipping over and not serving its purpose. The cart begins to do so right at 59.4 lbf; this is

why the design is specified to only hold 40 lbf of goods on its top shelf. Since the

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51

retractable cart moves with use, a crushing hazard exists if any part of the worker is

rolled upon by the caster wheels. There should be no pinching hazards since there are

very few moving components, and the clearances between these are less than ¼”.

The packaging chute, weighing 6lbs, consists of an 8”x20” metal base plate, a 5”

tall stationary funnel flap, and another 5” flap that is able to slide across the base plate to

adjust the width of the chute. When placing this device, it is possible to get fingers stuck

in between the plate and the assembly line, so make sure no extremities are under the

base while placing it. Also, the base has a ¼” wide slot for the adjustable flap to move

around, so keep fingers out of the area while moving the flap. Finally, do not slide any

body part across the top of either flap as the flaps are made of metal, and can cause

discomfort along the affected areas.

The box stopper weights around 11lbs and it needs some proper setup before

using. It needs to be placed on top of the assembly line, with the lower half raised up

below the line to screw into the top part. To lower the sliding plate, a worker must press

down on the foot pedal attached to the bottom of the plate. The assembly process will

need a worker with some technical skills, and can pose a threat to those who do not

possess them. Some arm fatigue might occur during installation. Also, there is a ¼” gap

in the top area for the sliding plate to fit into. Make sure to not place any extremities in

the gap during operation. Following these procedures correctly will keep any worker

from experiencing any kind of discomfort.

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52

Operation and Maintenance Procedures

JS-T3 consists of several components that undergo work cycles and as such

require maintenance after an extended period of time. Two primary components that

undergo these working cycles and exhibit a considerable amount of strain because of

them are the linear actuators and the rechargeable battery. No specifications were given

as to the life of the actuators, but Firgelli Automations offers a twelve month warranty.

Since the table legs are not a part that leads to a critical or catastrophic failure of the

device, it is simply recommended to replace the faulty part as it is noticed. The

rechargeable battery can provide enough power to handle 630 height changes. If it is

estimated that a worker will change the height of the table ten times in one shift, then it is

recommended that the battery be recharged twice every month for a five day three shift

work week. To operate JS-T3, two users should position the table into a useable position

at the assembly line and then lock each of the four casters into place. Once this is done,

the battery’s power should be turned on so that the system can operate. These two steps

are part of the initial set up and will not need to be repeated unless the device is relocated.

The user is then to operate the joystick on the underside of the table by pushing it away

from them or toward them to lift or lower the table. Once the table is at a comfortable

level, nothing more must be done to use the table for its intended purpose. To avoid any

injuries due to the previously mentioned safety hazards, it is not recommended to lift the

table to its maximum height, place fingers into any of the devices trusses or electrical

components while the device is powered or raised, or put any force onto the table such

that the resultant load is more than 450 lbf (90% of the rated design load). While

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53

relocating the device, it is recommended to wear steel-toed boots which are

commonplace on factory floors so that workers will not sustain any foot injuries.

BM-F1 consists of one main component that will receive wear and tear during its

useful life. This component is the slide rails which allow the table to extend across the

conveyor belt. No other components should fail during this cart’s lifetime, since no other

parts are fatigued nearly as much as the slide rails are. No information was found

regarding the lifetime of these components, so it is simply suggested to replace them at

the first sign of damage. To operate BM-F1, the user should lock the wheels of the cart

near a product pallet, load the top shelf with one box, and place two more on the bottom

shelf if they desire to do so. They should then unlock the wheels and roll the cart to the

assembly line. The worker must then lock the wheels and then extend the cart across the

line and perform the filling process. Once a box is emptied, the shelf should be retracted

and boxes from the bottom shelf may be placed one at a time on the top of the cart to

continue filling until the cart is completely empty. The worker should then unlock the

wheels, return the cart to a product pallet, and repeat the process. While using this

device, it is recommended to wear protective footwear to avoid any worker injuries.

Figure 39 shows an example of the warning sticker for the cart.

Figure 39. Cart Warning

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54

As for the packaging chute, the one part that may need proper maintenance is the

lock screw that is used to move the adjustable flap. After many shifts and width changes,

the screw might experience some wear and tear, and might strip when too much force is

applied. To avoid this, it is recommended that the lock screw be replaced every six

months.

The box stopper is meant to be stationary. That alleviates the need for

maintenance on all the locking mechanisms. Also, springs do not require any

maintenance, so there is no need for maintenance on the box stopper.

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55

VII. CONCLUSIONS/RECOMMENDATIONS

Regarding JS-T3, the group fell on hard luck since acquiring the materials took

much more time than anticipated. The group did not receive the materials for the folding

table until the middle of Spring Break vacation, and a problem arose with one of the H-

bridges which required another part to be ordered which finally came in on the day that

the final report was due. This meant that the only physical testing mentioned in the final

report took place in the course of one day. Jed Schales spent much of the beginning of

the semester trying to finalize the bill of materials with American Greetings so that the

design could actually be plausible and constructible, but communication problems

between REK’M and AG caused a few weeks of delays as seen in the Gantt chart’s

schedule. Through these less than desirable circumstances of which no one is at fault, the

table was successfully built and serves its purpose. The group concludes that much more

time should have been spent on the testing of the device for different loading conditions

and for testing on the assembly line to gather worker feedback. Without any testing

results to go on besides SolidWorks analyses, the group can recommend little. REK’M

recommends that future groups appropriately plan for the worst and build in some

cushion time within their Gantt charts. The group also recommends to future groups

studying elevating tables, such as American Greetings design teams, that specific

attention be paid to keeping the table’s working surface stationary while the worker is

performing high-motion folding operations. Kevin Muñoz and Ethan Bise worked hard

to address this problem, but a better solution may be realized if this specific aspect is kept

in mind during the design phase instead of as a correction during the fabrication phase.

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56

The retractable cart did exactly what it was designed to do; nevertheless the

design could be improved with noted observations. A recommendation for work in the

future would be to test a prototype of the shelf, where the shelf extended to its side

instead of to the front. This idea was brought up in one of the trips to American Greetings

by Chris Walker. The statics of that design would be different and more in-depth analysis

would have to be conducted. Another recommendation that was also noted in an AG trip

is to incorporate the linear actuator legs into the cart to adjust to any size box that is being

pushed through the line.

Regarding the packaging chute, while testing the final design, the team noticed a

couple of areas that the design was lacking in. First, the base plate was laid on top of the

rollers in the assembly line, so the entire device is about 1/8” above the conveyor. This

might cause a display box to catch on the base plate and force a worker to lift the box

before sliding it into the packaging box. In the future, the design could be altered to allow

the beginning of the base plate to be lower than the top of the rollers to allow the display

boxes to be easily slid across the surface. Also, a floor worker noted that the flaps were

considered to be hazards since the edges were not sanded down. The team could have

sanded down the edges, and made some more intricate cuts to make the design safer if

given enough time. Finally, Chris Walker noted on the difficulty of adjusting the width of

the chute with the Allen wrench. If the design is further implemented, a knob could be

attached to the lock nut, allowing an easier way to tighten and loosen the lock nut.

The box stopper was a key part of the packaging chute that was constructed as a

recommendation in the initial testing. One recommendation that would better the design

would be to add an attachment system to the top platform similar to the rollers on the

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57

conveyor. This would decrease the installation and replacement time marginally. Another

recommendation would be to add a pulley system to the pedal. This would allow the

pedal to be placed at a comfortable location for the user.

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58

VIII. LIST OF REFERENCES

1. 80/20 Catalog. Vol. 18. 2015. Print.

2. "Lowe's Home Improvement Store." Web. 20 Apr. 2015. http://www.lowes.com

3. "Firgelli Technologies - Micro Linear Actuators." Linear Actuators. Web. 20 Apr.

2015. http://www.firgelli.com/

4. "Caster and Material Handling." Flexion. Web. 20 Apr. 2015.

<http://www.flexionmaterial.com/>.

5. "Parallax Inc | Equip Your Genius." Parallax Components. Web. 20 Apr. 2015.

https://www.parallax.com/

6. "Aluminum Tube, Pipe, & Plate | 6061 Aluminum Tubing ..." Web. 20 Apr. 2015.

<http://www.speedymetals.com/c-8342-aluminum.aspx>.

7. "Speedy Metals - Steel." Web. 20 Apr. 2015. http://www.speedymetals.com/c-

8209-steel.aspx

8. http://www.matweb.com/search/datasheet.aspx?matguid=bd6620450973496ea25

78c283e9fb807&ckck=1

9. http://www.gearhob.com/eng/design/drill_eng.htm

10. http://www.farmandfleet.com/products/065494-steelworks-square-tubing.html

11. https://grabcad.com/library/caster-5-inch-wheel

12. http://absurdwordpreferred.deviantart.com/art/Chain-PNG-160294848

13. "Arduino - ArduinoBoardUno." Arduino - ArduinoBoardUno. N.p., n.d. Web. 20

Apr. 2015.

14. "ECE476 Spring 2005 Final Project." ECE476 Spring 2005 Final Project. N.p.,

n.d. Web. 20 Apr. 2015.

15. "Learn.parallax.com." 2-Axis Joystick. N.p., n.d. Web. 20 Apr. 2015.

16. "Memsic 2125 Dual-axis Accelerometer." Memsic 2125 Dual-axis

Accelerometer. N.p., n.d. Web. 20 Apr. 2015.

17. "Robot Check." Robot Check. N.p., n.d. Web. 20 Apr. 2015.

18. Wray, James, Eric Romero, Ethan Clark, and Daniel Brooks. Pedestrian Transport

System Go-By. ASU College of Engineering. Print. 10 Feb. 2014.

19. "Engineering Course Standards." Engineering Course Standards. Arkansas State

University College of Engineering, Fall 2013/2014. Web. 4 Sept. 2014.

20. Bradshaw, Caleb, Jordan Collins, William Marler, Cody Milburn. Portable

Maintenance Lift Time Schedule Go-By. ASU College of Engineering. Print. 25

Apr. 2008.

21. Walker, Chris. "Research Trip to Osceola #1." Personal interview. 6 Feb. 2015.

22. Walker, Chris. "Research Trip to Osceola #2." Personal interview. 27 Feb. 2015.

23. Walker, Chris. "Research Trip to Osceola #3." Personal interview. 17 Apr. 2015.

24. "Dimensions of Socket Button Head Cap Screws." Dimensions of Socket Button

Head Cap Screws. Fairbury Fastener, n.d. Web. 7 Feb. 2015.

Page 65: Senior Design II Final Report

59

25. "Fastener Type Chart." Bolt Depot. Bolt Depot, n.d. Web. 7 Feb. 2015.

26. "Dimensions - Schedule 40 & 80 Pipe - PVC Industrial & Industrial PLUS."

Schedule 40 & 80 Pipe Dimensions. Georg Fischer Harvel, n.d. Web. 7 Feb.

2015.

27. “2.5x24x0.75 DA AIR CYLINDER." 2.5x24x0.75 DA AIR CYLINDER. Surplus

Center, n.d. Web. 7 Feb. 2015.

28. "Occupational Health and Safety." Occupational Health and Safety. Alberta.ca,

n.d. Web. 4 Feb. 2015.

29. "68–95–99.7 Rule." Wikipedia. Wikimedia Foundation, n.d. Web. 4 Feb. 2015.

30. "NCEES: FE Reference Handbook." NCEES. NCEES, n.d. Web. 4 Feb. 2015.

31. "Aluminum Distributor." Aluminum Distributor. ASM Aerospace Specification

Metals, Inc., n.d. Web. 20 Jan. 2015.

32. "Product Details." Product Details. Colson, n.d. Web. 9 Feb. 2015.

33. "3 Gal. 1/3 HP 100 PSI Oilless Pancake Air Compressor." Harbor Freight Tools.

Harbor Freight Tools, n.d. Web. 9 Feb. 2015.

34. "Products & CAD." Original Line® with Adjustable Cushions. Bimba, n.d. Web.

9 Feb. 2015.

35. "Learn How to Cut, Drill and Finish the Edges of Plexiglass (acrylic)." Learn

How to Cut, Drill and Finish the Edges of Plexiglass (acrylic). Basic Car Audio

Electronics, n.d. Web. 4 Feb. 2015.

36. "Fluid Power Cylinders." Unit 24: Applications of Pneumatics and Hydraulics

(n.d.): n. pag. Free Tutorials on Engineering and Science. Free Study. Web. 4 Feb.

2015.

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60

APPENDIX A

Man-Hours Table

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A-2

Table A-1. Man-Hour Schedule

Man-Hour Schedule Individual Hourly Breakdown

Task Estimated

Hours Actual Hours

Percent Complete

Estimated Hours Per

Person

Taylor Barnhill

Robert Bise

Banthi Munoz

Jed Schales

1. Develop Proposal 40 21.25 100 10 4.5 9 2.75 5

2. Fabrication and Testing

Develop Cost and Material Estimate 32 37.5 100 8 7 10 8.5 12

Fabrication 100 249 100 25 66 67 85 31

Testing 100 72.5 100 25 19 16.5 10 30

3. Progress Report 1 24 26 100 6 6 6 8 6

4. Progress Report 2 24 20.5 100 6 6 7 7 0.5

5. Final Design 60 20 100 15 5 8 2 5

6. Final Report 100 60 100 25 14.5 20.5 10 20.5

7. Final Presentation* 40 40 0 10 10 10 10 10

8. Record Keeping/Advising 80 52 90 20 12 12 12 16

Total Man-Hours 600 598.75 150 150 166 155.25 136

* These are just an estimate of the hours each team member will contribute to the Final Presentation

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APPENDIX B

Gantt Chart

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B-2

1/14/2015 2/3/2015 2/23/2015 3/15/2015 4/4/2015 4/24/2015

1. Develop Proposal

Actual Period

2. Fabrication and Testing

Actual Period

3. Progress Report 1

Actual Period

4. Progress Report 2

Actual Period

5. Final Design

Actual Period

6. Final Report

Actual Period

7. Final Presentation

8. Record Keeping/Advising

Actual Period

Figure B-1. Gantt Chart Schedule

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APPENDIX C

Control System Code

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C-2

int legpwm1 = 10; //pwm output to first leg

int legpwm2 = 9; //pwm output to second leg

int legpwm3 = 6; //pwm output to third leg

int legpwm4 = 5; //pwm output to fourth leg

int dir1 = 12; //direction for first leg

int dir2 = 8; //direction for second leg

int dir3 = 7; //direction for third leg

int dir4 = 4; //direction for fourth leg

int joypin0 = A0; //joystick analog input to pin A0

int joypin1 = A1; //L/R input from joystick at pin A1

int value1 = 0; //variable to read the value from pin A0

int value2 = 0; //variable to read the value from pin A1

const int xpin = 2; //x output from accelerometer

const int ypin = 3; //y output from accelerometer

void setup() {

Serial.begin(9600);

pinMode(legpwm1, OUTPUT); //pin10 is an output

pinMode(legpwm2, OUTPUT); //pin9 is an output

pinMode(legpwm3, OUTPUT); //pin6 is an output

pinMode(legpwm4, OUTPUT); //pin5 is an output

pinMode(dir1, OUTPUT); //pin12 is an output

pinMode(dir2, OUTPUT); //pin8 is an output

pinMode(dir3, OUTPUT); //pin7 is an output

pinMode(dir4, OUTPUT); //pin4 is an output

pinMode(xpin, INPUT); //pin13 is an input

pinMode(ypin, INPUT); //pin11 is an input

}

void loop() {

value1 = analogRead(joypin0); //read joystick input, 0 being all the

way down, 1013 being all the way up)

value2 = analogRead(joypin1); //read joystick input on L/R pin

delay(50);

if (value1 < 480) //if reading is less than 480

{

value1 = map(value1, 480, 0, 0, 255); //maps the joystick values to

pwm values

digitalWrite(dir1, LOW); //direction for motor 1 to be down

digitalWrite(dir2, LOW); //direction for motor 2 to be down

digitalWrite(dir3, LOW); //direction for motor 3 to be down

digitalWrite(dir4, LOW); //direction for motor 4 to be down

analogWrite(legpwm1, constrain(value1, 0, 255)); //pwm for motor 1

speed

analogWrite(legpwm2, constrain(value1, 0, 255)); //pwm for motor 2

speed

analogWrite(legpwm3, constrain(value1, 0, 255)); //pwm for motor 3

speed

analogWrite(legpwm4, constrain(value1, 0, 255)); //pwm for motor 4

speed

Serial.print("LOW ");

Serial.println(value1); //print pwm value

}

else if (value1 > 550) //if reading is greater than 550

{

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C-3

value1 = map(value1, 550, 1023, 0, 255); //maps the joystick values to

pwm values

digitalWrite(dir1, HIGH); //direction for motor 1 to be up

digitalWrite(dir2, HIGH); //direction for motor 2 to be up

digitalWrite(dir3, HIGH); //direction for motor 3 to be up

digitalWrite(dir4, HIGH); //direction for motor 4 to be up

analogWrite(legpwm1, constrain(value1, 0, 255)); //pwm for motor 1

speed

analogWrite(legpwm2, constrain(value1, 0, 255)); //pwm for motor 2

speed

analogWrite(legpwm3, constrain(value1, 0, 255)); //pwm for motor 3

speed

analogWrite(legpwm4, constrain(value1, 0, 255)); //pwm for motor 4

speed

Serial.print("HIGH ");

Serial.println(value1); //print pwm value

}

else

{

//initialize all the directions to low and pwm to 0

digitalWrite(dir1, LOW);

digitalWrite(dir2, LOW);

digitalWrite(dir3, LOW);

digitalWrite(dir4, LOW);

analogWrite(legpwm1, 0);

analogWrite(legpwm2, 0);

analogWrite(legpwm3, 0);

analogWrite(legpwm4, 0);

Serial.println("0");

}

int pulsex, pulsey; //variables to read pwm from accelerometer

int accx, accy; //variables to assign the acceleration

while (value2 > 800)

{

pulsex = pulseIn(xpin, HIGH); //read pwm from xpin

pulsey = pulseIn(ypin, HIGH); //read pwm from ypin

accx = ((pulsex / 10) - 500) * 8; //converts pwm into acceleration of

earth's gravity

accy = ((pulsey / 10) - 500) * 8; //converts pwm into acceleration of

earth's gravity

if (accx < -185 && accy < -80 && accy > -105) //if tilting forwards

{

//tell legs 3, 4 to go down

digitalWrite(dir3, LOW);

digitalWrite(dir4, LOW);

///speed of legs are half speed

analogWrite(legpwm3, 127);

analogWrite(legpwm4, 127);

Serial.println("3 4 LOW");

}

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C-4

else if (accx > -160 && accy < -80 && accy > -105) //if tilting

backwards

{

//tell legs 1, 2 to go down

digitalWrite(dir1, LOW);

digitalWrite(dir2, LOW);

///speed of legs are half speed

analogWrite(legpwm1, 127);

analogWrite(legpwm2, 127);

Serial.println("1 2 LOW");

}

else if (accx < -160 && accx > -185 && accy < -105) //if tilting

left

{

//tell legs 2, 4 to go down

digitalWrite(dir2, LOW);

digitalWrite(dir4, LOW);

//speed of legs are half speed

analogWrite(legpwm2, 127);

analogWrite(legpwm4, 127);

Serial.println("2 4 LOW");

}

else if (accx < -160 && accx > -185 && accy > -80) //if tilting

right

{

//tell legs 1, 3 to go down

digitalWrite(dir1, LOW);

digitalWrite(dir3, LOW);

//speed of legs are half speed

analogWrite(legpwm1, 127);

analogWrite(legpwm3, 127);

Serial.println("1 3 LOW");

}

else if (accx < -185 && accy < -105) //if tilting forward left

{

//tell legs 2, 3, 4 to go down

digitalWrite(dir2, LOW);

digitalWrite(dir3, LOW);

digitalWrite(dir4, LOW);

//speed of legs are half speed

analogWrite(legpwm2, 127);

analogWrite(legpwm3, 127);

analogWrite(legpwm4, 127);

Serial.println("2 3 4 LOW");

}

else if (accx < -185 && accy > -80) //if tilting forward right

{

//tell legs 1, 3, 4 to go down

digitalWrite(dir1, LOW);

digitalWrite(dir3, LOW);

digitalWrite(dir4, LOW);

//speed of legs are half speed

analogWrite(legpwm1, 127);

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C-5

analogWrite(legpwm3, 127);

analogWrite(legpwm4, 127);

Serial.println("1 3 4 LOW");

}

else if (accx > -160 && accy < -105) //if tilting back left

{

//tell legs 1, 2, 4 to go down

digitalWrite(dir1, LOW);

digitalWrite(dir2, LOW);

digitalWrite(dir4, LOW);

//speed of motors are half speed

analogWrite(legpwm1, 127);

analogWrite(legpwm2, 127);

analogWrite(legpwm4, 127);

Serial.println("1 2 4 LOW");

}

else if (accx > -160 && accy > -80) //if tilting back right

{

//tell legs 1, 2, 3 to go down

digitalWrite(dir1, LOW);

digitalWrite(dir2, LOW);

digitalWrite(dir3, LOW);

//speed of motors are half speed

analogWrite(legpwm1, 127);

analogWrite(legpwm2, 127);

analogWrite(legpwm3, 127);

Serial.println("1 2 3 LOW");

}

else

{

digitalWrite(dir1, LOW); //direction for motor 1 to be down

digitalWrite(dir2, LOW); //direction for motor 2 to be down

digitalWrite(dir3, LOW); //direction for motor 3 to be down

digitalWrite(dir4, LOW); //direction for motor 4 to be down

analogWrite(legpwm1, 0); //pwm for motor 1 speed

analogWrite(legpwm2, 0); //pwm for motor 2 speed

analogWrite(legpwm3, 0); //pwm for motor 3 speed

analogWrite(legpwm4, 0); //pwm for motor 4 speed

}

Serial.print(accx); //print x accelerration

Serial.print(" "); //print some space

Serial.print(accy); //print y acceleration

Serial.println(); //end line

value2 = analogRead(joypin1);

delay(50);

}

}

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APPENDIX D

Descriptive Diagrams

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D-2

Figure D-1. JS-T3 with Dimensions

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D-3

Figure D-2. Circuit Schematic for Control System

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D-4

Figure D-3. Block Diagram for Control System Flow

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D-5

Figure D-4. BM-F1 With Dimensions

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D-6

Figure D-5. BM-P1 with Dimensions

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APPENDIX E

Personal Resumes

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E-2

Taylor Barnhill 1216 Highway 236 W | Lonoke, AR 72086 | (501) 628–1139 |

[email protected]

Career Summary Recent college graduate with degree in electrical engineering experienced in the design, engineering and quality improvement of electronic components, computer networks, and communication theory. Excellent at multi-tasking with proven ability to handle diverse electrical and mechanical duties.

Work Experience Industrial Engineering Intern, AMERICAN GREETINGS, Osceola, AR

5/14 – 8/14

Generated a time study analysis on process to ship product to plant in UK ; proposed new plan to save time and money (increased amount of product per shipment by 12%)

Worked with third party contractors to install large scale polyester printer; created startup/shutdown procedures to teach new employees

Farm Field Hand, BARNHILL ORCHARDS, Lonoke, AR

5/06 – 8/13

Handled large equipment such as tractors to move supplies

Supervised workers to obtain maximum efficiency

Calculated the amount of fertilizer and chemicals needed for acreage and dispersed accordingly

Provided irrigation in new fields

Maintained motors in water pumps, ATVs, and tractors

Worksite Maintenance Specialist, UNDERWOOD CONSTRUCTION, Lonoke, AR

5/05 – 8/05

Maintained job site safety by removing materials that were potential hazards to construction workers

Computer & Technical Skills Systems / Languages: Windows XP, Windows 7, Windows 8, Linux Ubuntu, C++ Software: MicroCap, MultiSim, PowerWorld, AutoDesk Inventor, AutoCAD, Microsoft Office 2013 Equipment: Oscilloscopes, multimeters, DC power supplies, function generators, Arduino Skills: Creating circuits, building computers, C++ programming, excellent team player, innovative and

motivated

Education Arkansas State University, Jonesboro, AR (ABET Accredited) May 2015 Bachelor of Science, Electrical Engineering Minor: Mathematics GPA: 3.57 Fundamentals of Engineering Electrical and Computer Exam – Passed December 2014 Technical Projects:

Wireless Directional Speed Motor Controller

• Constructed a Pulse Width Modifier with IC 555 Timer and potentiometer to increase/decrease duty

cycle; Transmitted output signal wirelessly using infrared LEDs; Amplified signal by negative

feedback amplifier, sent to H-Bridge motor controller to power motor in desired direction

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Ergonomic Table

• Designed a table to conform to various worker heights in order to lessen physical pain caused while working on said table; Placed two car jacks on opposing ends of table, welded together to cause synchronous up/down movement, hold up the workspace, while perforated steel tubing lock into a desired height

Marble Sorter

• Built machine and designed control system to sort marbles based on photoconductivity produced by photo resistor when light is shined through said marbles

Honors and Affiliations: Dean’s List – 3 terms Chancellor List – 2 terms Member, Student Chapter of the Institute of Electrical and Electronic Engineering (IEEE) Captain of numerous Intramural Sports, Arkansas State Ultimate Frisbee team

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Robert Ethan Bise

Address: P.O. Box 220, Weiner, AR 72479 Phone: 870-930-0466

Email: [email protected] Looking For: Full-Time

Objective: To further expand and apply my skills, knowledge, and experience by obtaining a full- time job in Mechanical Engineering

Education

Arkansas State University, Jonesboro, AR: Fall 2011-Present

Bachelor’s degree in Mechanical Engineering (BSME)

Minor degree in Mathematics

3.856 GPA

Graduation Date: May 2015 Passed the Fundamental of Engineering (FE) Exam: Nov. 24, 2014

Work Experience

R. Keith Bise Farming, Fisher, AR: 2011-Present

Position: Farm Hand

Maintained and ran farm machinery

Owner: Keith Bise o Phone: 870-930-7385

Student Project, etc. o Senior Design I Project

Involved in an Engineering Design Process to design assists for the process of building greeting card displays at American Greetings

Purpose was to decrease the amount of injuries to employees and increase production rate

Used SolidWorks to model designs

Worked with others to accomplish tasks toward a common goal o Robotics

Sumo robot was designed, built, and programmed

Infrared sensors told robot where to move

Robot was built for a robotics competition

Relevant Mechanical Engineering Courses

Thermodynamics II Intro to Manufacturing Processes

Machine and Mechanical System Design Finite Element Analysis

Process Monitoring and Controls Solid Modeling for Engineers

Mechanical Vibrations Control Systems for ME

Heat Transfer Fluid and Thermal Systems

HVAC Robotics

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Professional Organizations

American Society of Mechanical Engineers (2013-Present) (Chapter Vice-President)

The American Society of Heating, Refrigerating and Air Conditioning Engineers (2013-Present) (Member)

Honors/Awards

Honors College at Arkansas State University (2011-Present)

Who’s Who at Arkansas State University

Riceland’s President Scholarship

Arkansas State University Pride Scholarship

Dean’s List: Fall 2011, Spring 2012, Spring 2013

Chancellor’s List: Fall 2012, Fall 2013, Spring 2014 Technical Skills

o SolidWorks - Design and Simulation

Built and tested assists for the AG Display building process

Designed a water bottle and found the natural frequencies when full and empty.

o MATLAB

Graphed data and solved matrices for several different applications o LabVIEW

Data acquisition software

Created .vi files to analyze signals from transducers and sensors

Preformed vibrations, frequencies, modes, pressure, strain, etc. tests o Proficient in Microsoft Excel, Word, and PowerPoint o PLC and Controller Concepts (Course to be taken in Spring 2015) o Design of HVAC Systems (Course to be taken in Spring 2015

References

Dr. Shivan Haran (Director and Associate Professor, Mechanical Engineering, Arkansas State University, Jonesboro, AR)

o Phone (870) 972-3413, Email: [email protected]

Dr. David Kwangkook Jeong (Assistant Professor, Mechanical Engineering, Arkansas State University, Jonesboro, AR)

o Phone (870) 680-8593, Email: [email protected]

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Banthi Kevin Muñoz

Address: 3600 Northwood Dr., Jonesnoro, AR 72401 Phone: 870-882-9571

Email: [email protected]

Employment Arkansas National Guard: November 2008 – Present

Petroleum Supply Specialist/Team Leader(SGT) o November 2008 – Present o 875th ENGR BN FSC Co. o Supervisor: SFC James Russell o Phone:870-847-1865 o Email:[email protected]

Retention NCO o September 2013 – July 2014 o Supervisor: SFC Wendy Forbs o Phone: 501-212-7060 o Email: [email protected]

ASU-Information & Technology Services: August 2009-Present

Campus Switchboard Operator o August 2009-September 2011 o Supervisor: Dana Slatton o Phone:870-972-3033 o Email: [email protected]

Cellular Customer Services Representative o September 2011-April 2012 o Supervisor: Dana Slatton o Phone:870-972-3033 o Email: [email protected]

Billing Customer Representative o April 2012-May 2013 o Supervisor: Dana Slatton o Phone:870-972-3033 o Email: [email protected]

Assistant Technician o May2013-Present o Supervisor: David Engelken o Phone: 870-972-3033 o Email: [email protected]

Awards

Won “Logistics Warrior Hero” out of 600 soldiers in training

875th

BN Forward Support Company for Soldier of the Year

875th

BN Forward Support Company for NCO of the Year

875th

BN for NCO of the Year

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Education Arkansas State University, Jonesboro, AR: Fall 2011-Present

Seeking degree in Mechanical Engineering

131 Hours Completed

Graduation Date: May 2015 List of Mechanical Engineering Courses Taken

Solid Modeling, Dynamics, Thermodynamics I, Fluid Mechanics, Thermodynamics II, Engineering Economics, Machine Design, Introduction to Manufacturing Processes, Fluid and Thermal Energy Systems, Heat Transfer, Design of HVAC Systems, Mechanical Systems Design, Mechanical Vibrations, Process Monitoring and Control, and Senior Design I, Control Systems for ME, Finite Element Analysis,

Organizations

American Society of Mechanical Engineers (2013-Present

The American Society of Heating, Refrigerating and Air Conditioning Engineers (2013-Present)

ASU’s Men’s Soccer Club (2012-Present) (President) References

Available upon request

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Jed Schales

Address: P.O. Box 1642, State University, AR, 72467 Phone: 870-761-5724

Email: [email protected]

Employment CESUR/ASU Research Assistantship: April 2013-Present

Analytical Study on Photonic Crystals and Waveguiding o April 2013 – April 2014 o Supervisor: Mechanical Engineering Professor Ilwoo Seok o Phone: 870-680-8589 o Email: [email protected]

Simulation of Particle Arrays for Optical Bandgap Control o May 2014 – Present o Supervisor: Electrical Engineering Professor Brandon Kemp o Phone: 870-972-4302 o Email: [email protected]

Hytrol Engineering Internship: March 2014 – June 2014

Configurations Design Engineer o Supervisor: Configurations Design Leader Tiffany Hayden o Phone: 870-935-3700

Education Arkansas State University, Jonesboro, AR: Fall 2011-Present

Seeking degree in Mechanical Engineering

138 Hours Completed

4.00 GPA

Graduation Date: May 2015 List of Mechanical Engineering Courses Taken

Solid Modeling, Dynamics, Thermodynamics I, Fluid Mechanics, Thermodynamics II, Engineering Economics, Machine Design, Introduction to Manufacturing Processes, Fluid and Thermal Energy Systems, Heat Transfer, Design of HVAC Systems, Mechanical Systems Design, Mechanical Vibrations, Introduction to FEA, Process Monitoring and Control, Control Systems for Mechanical Engineers, Senior Design I, and Senior Design II

Organizations

American Society of Mechanical Engineers (2013-present) (Chapter President during Fall 2014)

The American Society of Heating, Refrigerating and Air Conditioning Engineers (2013-Present) (Chapter Vice President from 2014-2015)

The Society of Women Engineers (2013-Present)

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Additional Information

Passed the Fundamentals of Engineering Exam (October 2014)

Two years of High School Education in Spanish, French, and German

Proficient in SolidWorks, MATLAB, Inventor, and COMSOL

Proficient in Microsoft Word, Excel, and Powerpoint

Current Honors College Member at Arkansas State University