Wyman Gordon Forging LocatorJohnathan Knight – Team ManagerMin Han Zhao – Team FacilitatorShimona Gorelick – Lead Electrical EngineerNick Perrotte – Lead Mechanical Engineer 1

Overview• Project Background• Detailed Design Output

• Bill of Materials• Drawings• Schematics

• Risk Assessment• Customer Needs and Test Plans• Feasibility Analysis• MSDII Schedule

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Background Info - Customer

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A Precision Castparts Corporation Company, is a global leader in the manufacturing of titanium, steel and nickel-based forgings primarily for the aerospace, energy, and military markets.

50,000 ton press National Historic Mechanical Landmark

Background – Customer Process & Justification

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Current Process• Mult heated until “red hot,” 1700-2100°F• Oil soaked carbon paper is applied to the die to prevent the mult

from sticking• About 60 seconds of operating time to position forging• Operator controls the piece with a fork truck and other simple tools

until it is aligned properly• Final alignment is based on operator judgment

Project Justification• Current alignment process is conducted visually• Experienced workers are approaching their retirement years• Cost approximately $1M annually to rework• Proper alignment in the die could reduce this figure by 30%

($300,000).

Engineering Metrics

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Previously Designed System

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Senior Design P12556 • Bought 6 lasers from Micro Epsilon (OPTONCDT ILR1181)• Built a track for adjustable positioning• Built cases for the lasers to be able to withstand the conditions.

• The cases are made of aluminum and have been drop tested to check for durability

• Thermal insulation inside the cases allows the lasers to be as close to the process as possible

• A mirror has been set up so that no lasers will be in the direct path of the fork truck

• A user interface has been set up and coded in Visual Basic

System Layout

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How the System Works• Similar to layout, lasers calibrate off of each other and

machined faces of the die, measure mult and provide instantaneous feedback to the display

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Upgrades• Overview of the following slides

• Laser aperture enclosure• Protect the laser from any outside debris during the forging process• Replace manual shutter system that would involve added steps to the

forging process• Die locating bars

• Give a known distance from the laser to the die to replace the need for two calibrating lasers; in turn, one of the lasers can be used for rotational measurements

• Display box • Add rotational indicators, input connectors, and a mounting mechanism

• Microcontroller interface• Replace pure hardware logic with microcontroller processing to allow

flexibility for different parts and to optimize the speed of the system• Magnet mounting

• Improve the strength of the magnets with the capability to be turned on and off when needed

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Bill of Materials - Electrical

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System Sub System Part Description Vendor Unit Price Qty. Ordered Total Cost

Input Power DC Power Adapter - 9V or 12V Digi-Key $18.60 1 $18.60Connector on board Digi-Key $1.67 1 $1.67

Voltage Regulation Voltage Linear Regulator LDO Digi-Key $0.66 7 $4.62

Laser Inputs RS232 input Digi-Key $3.90 6 $23.40Mux Digi-Key $0.26 4 $1.04Demux Digi-Key $0.26 4 $1.04

Output to LED Power transistor Digi-Key $0.88 7 $6.16LED Lightbulb Home Depot $10.97 7 $76.79Red Film Ebay $23.00 1 $23.00Green Film Ebay $23.00 1 $23.00Directional Cover - Black stock paper Paper and More $18.99 1 $18.99

Microcontroller TI MSP430 TI $26.00 1 $26.00Oscillator Clock Digi-Key $3.90 2 $7.80Op-Amp Digi-Key $0.51 4 $2.04JTAG Cable Digi-Key $63.75 1 $63.75

Board 2-layer PCB ExpressPCB $335.00 1 $335.00

General Resistors Digi-Key $0.10 50 $5.00Capacitors Digi-Key $0.10 50 $5.00Diodes Digi-Key $0.46 50 $23.00

Cabling/Connectors 20 ft DB9 M/F Black Box $17.99 1 $17.99DB9 to USB US Converters $34.95 1 $34.95DB9 Bulkhead mount Digi-Key $4.23 8 $33.84

$752.69

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Electrical Total

Bill of Materials - Mechanical

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Laser Glass Windows CAD name 'GlassEnclosure1' 3/8" x 3" DIA. McMaster $55.45 1 $55.45CAD name 'Glassenclosureback' 5/8" x 1' x 3' McMaster $120.12 1 $120.12O-Rings 3/32" thick OD 2" SAE 133 QTY. 50 McMaster $9.03 50 $9.03Actual Glass 1/8" x 2" DIA Heat Resistant Silica Glass McMaster $34.08 6 $204.4818-8 SS Blind Rivet with 18-8 SS Mandrel Domed, 3/16" Dia, .251"-.375" Material Thickness McMaster $13.00 50 $13.00

Alignment Feature Mechanical Locating Bars 3/8" x 1' x 3' 6061 McMaster $72.41 1 $72.41Magnet Mounts: Multipurpose Aluminum (Alloy 6061) .125" Thick, 24" X 24" McMaster $76.28 1 $76.2818-8 SS Button Head Socket Cap Screw 5-40 Thread, 1/2" Length McMaster $3.19 50 $3.19Easy on-Off Encased Neodymium Magnet 95 lbs Breakaway Force McMaster $37.14 9 $334.26

Adjustable Laser Mount Aluminum Metric T-Slotted Framing System Four-Slot Single, 45 mm Hollow Extrusion (4 ft.) McMaster $25.80 1 $25.80Aluminum Metric T-Slotted Framing System 90 Degree Brace, Single, 2-Hole, for 45 mm ExtrusionMcMaster $8.28 4 $33.12Type 304 SS End-Feed Fastener, for 45 mm Aluminum Metric T-Slotted Framing System McMaster $5.25 6 $31.50Minitek Slide LWN 32 X 45 - 45 McMaster $115.00 2 $230.00

3" x 3" rectangle, 1/4" thick Clear Glass with Satin Pencil Polished edgesHooker Glass,

Mirror & Beveling $4.29 3 $12.87

Display AmazonBasics 60-Inch Lightweight Tripod with Bag Amazon $20.75 1 $20.7518-8 SS Button Head Socket Cap Screw 10-32 Thread, 1" Length McMaster $6.41 50 $6.41Back Bracket: Multipurpose Oversize Aluminum (Alloy 6061) 1/4" Thick, 18" X 18" McMaster $86.57 1 $86.57Tripod Mount: Multipurpose Aluminum (Alloy 6061) 5/8" Thick, 2" Width, 1' Length McMaster $14.34 1 $14.34Display Light Baffl es: Multipurpose Aluminum (Alloy 6061) .032" Thick, 12" X 24" McMaster $17.98 1 $17.983M Adhesive Duo-Pak Cartridge DP-100, 1.7 Ounce (50 Milliliter), Clear McMaster $17.11 1 $17.11Water jet cutting for Display Front and Back Bracket (per hour) RIT $95.00 - $285.00

$1,669.67

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Mechanical Total

Bill of Materials - Total

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Site Visits 2 Site Visits $500.00 2 $1,000.00

$2,422.36$1,000.00$100.00$199.84$121.12

$3,843.32

Overal Total For Parts

Shipping (est.)Tax (8.025%) (Minus Site Visits)

Tota

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5% Contingency

Final Total

Site Visits

Specific details for each upgrade will be addressed in upcoming slides

Mechanical Calibration • Currently, two lasers are used to locate the forging die and

create a datum to compare to the position of the mult• By using mechanical calibration, we can eliminate the need for

2 of the lasers, and use them in other applications (proposed layout shown below).

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Mechanical Calibration • Mechanical Calibration will be done with Locating bars that

attach to the rails being used with bolts.

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Mechanical Calibration

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Railing to Locating Bar Mounting Bracket

Mechanical Calibration

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Locating Bar

Programming Choice

Programmable Logic Controllers• After consulting the PLC expert on campus, it was determined

that the PLC was no longer the best approach functionally or fiscally

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Part Description Manufacturer Price

8-channel analog input module for DL05/06 PLCs, range: 4-20 mA current output at 16-bit resolution Koyo $134.00

8-channel analog output module for DL05/06 PLCs, range: 0-10V voltage output at 16-bit resolution Koyo $186.00

DL06 PLC Units Koyo $251.00

DirectSOFT5 PLC Programming Software Koyo $395.00

6 IN. TOUCH PANEL GRAYSCALE, STN, ETHERNET & USB, SUPPORTS COMPACT FLASH Koyo $540.00

C-MORE TOUCH PANEL PROGRAMMING SOFTWARE Koyo $129.00

Sub Total $1,635.00Tax 8.25%

Shipping $0.00Total $1,769.89

Programming Choice

Microcontrollers• System Requirements:

• Serial input capabilities (USART)• 7 outputs for LEDs (N, S, E, W, CW, CCW, and Go Ahead)• 3 outputs for multiplexer control signals

• 5 laser serial inputs & computer serial input is multiplexed to the microcontroller

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MSP430F123• Low-power, 16-bit RISC mixed signal processor.• 11 GPIOs• 1 USART input• Bigger package to allow for cheaper PCB

• However, bigger package calls for bigger PCB.

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Coding Logic• Initialize Lasers• If (laser is close)

• Open • For each lasers

• Obtain distance • While (distance X not equal to Y of each opposite laser)

• Do math to make them equal • Tell operator where to move

• Else • Print “Matched”

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Display Circuitry• PCB drawing• Trace patterns/wiring diagram• Component selection

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Display Lighting• Cutout in front of box• Wiring harness locations• Wire inputs to box• Component selection

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Display Mounting• Back mount to hold display• Mounts to tripod• Component selection

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Laser Protection• The previous design had no way of protecting the laser from

the conditions during the process, this could pose a big problem to the expensive system so we are going to incorporate high temperature glass to protect the laser

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Aperture Enclosure

Glass Enclosure

Laser Protection

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Laser Protection

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Magnet Attachment/Strength• Magnet bracket• Pull force of magnet to dirty surface

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Risk Assessment• Update risk assessment to final design

• Lead time risk• Manufacturing risk

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Safety and Usage

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ILR-1181-30 Time of Flight Sensor manufactured by Mirco-Epsilon

Class II Laser: described as a low-power visible laser that emits above Class I levels but at a radiant power not above 1 mW.

Human aversion reaction to bright light will protect a person Accident data on laser usage have shown that Class II lasers

are normally not considered hazardous from a radiation standpoint unless illogically used.

Direct exposure on the eye by a beam of laser light should always be avoided with any laser, no matter how low the power.

Sensor will be enclosed, so no protection will be needed.

Engineering Metrics

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Test Plan 1 – System OperationMetrics Tested : EM1, EM2, EM3, EM10, EM11

• System will be set up once all components are built, including coding

• Lasers will be set up on the rails and aimed at different sized and shaped boxes

• Dimensions will be hand measured, as well as calibration• The system will take readings and be compared to the known

dimensions• Actual operational and feedback time will be recorded using a

timer• Sensor range will be verified by moving the lasers away from

the object being measured to determine a max distance where accuracy is within the acceptable tolerance 31

Test Plan 3 – Usability TestMetrics Tested : EM7 - Able to position display relative to press

• Objective: Test each button: North, South, East, west, and Rotate

• Steps:1.Move billet away from the center of the die 2.Then correct arrow will light up and tell operator where to move to the center

• Requirement Should light up the arrow which will lead the billet to the center of the die (North, South, East, and West)

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Test Plan 3 – Usability TestMetrics Tested : EM8 - Visible Distance

• Objective: Clearly visible at variety distance

• Steps: 1. Tester stands away from assign distance 2. Tester with good sight and short sight

• Requirement: Minimum: 5 meterIdeal: 10 meter

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Test Plan 3 – Usability TestMetrics Tested : EM9 - Brightness

• Objective: Able to see in following condition:

1. Bright environment 2. Dark environment 3. Smoky environment

• Steps: Bring the system to the environments list above• Requirement:

Minimum: 15 lumens Ideal: 30 lumens

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Test Plan 3 – Usability TestMetrics Tested : EM12- Easy to use

• Objective:Can an untrained operator use system after minimal instruction*

• Minimal instruction includes:System setup

• Steps:Find numbers of groups to use the system1.Different ages: 20-55 years old2.Different education: High school diploma or lower and College.

• Environment:Heavy industry: Hot, Dirty, and Smoky

• Requirement: • 1.Should not have any main problem by using the system• 2.Should understand what means of arrows on the display box• 3.Should understand numbers in software interface 35

Test Plan 4 – Cost TestMetrics Tested – EM13, EM14

• For Sensor and Software cost to pass the test, a budget will be submitted to the customer, and if approved, the cost of either of these components must stay under the acceptable limit agreed upon

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Manufacturing Plan• Locating bars, aperture covers, display case, and display

mount will all be water jetted at RIT, quoted at $95/hr for 3 hrs of work

• Additional machining will be done by John and Nick for their respective mechanical parts which will include milling and using a lathe.

• Electrical hardware will be put together by Shimona and Min.

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Feasibility• Everyone do your own shit

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Looking Ahead to MSDII• Order long lead parts and finalize any open spots in our design• Begin manufacturing of all components (Electrical and

Mechanical)• Assemble the system• Troubleshoot the system • Bring the system to Wyman Gordon for preliminary testing• Make any changes suggested by the customer• Deliver the finished product to Wyman Gordon Week 9 of

Winter Quarter

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MSDII Schedule

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1 11/25 - 12/12 12/2 - 12/83 12/9 - 12/154 12/16 - 12/22

5 1/6 - 1/126 1/13 - 1/197 1/20 - 1/268 1/27 - 2/29 2/3 - 2/910 2/10 - 2/16 Contingency Time

Finals/ End of MSD

Christmas BreakMSDII

Finish Mechanical and Electrical Hardware

Test ProgramSite Visit 1 (Tentative)

Incorporate Knowledge from Site VisitFinal RIT Review

Site Visit 2

Order remaining parts and begin coding/assemblyContinue building and debugContinue building and debug

Questions & Comments• Self explanatory

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MicroEpsilon Lasers

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• Time of flight sensor

• Data acquisition and interface software available

• RS232 or RS422 serial interfaces

• Has been utilized on measuring red hot materials.

• Class 2 laser (No eye protection) Red 650 nm

output

• Alarm function to supply up to half an amp

• Can reference measurement from any point

• Measuring Range Black Material .4m - 17m

• Resolution .1mm

• Repeatability less than .5 mm

• Linearity ±2mm (+15°C … +30°C), ±5mm (+30°C

… +50°C)

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Laser Enclosures

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• Protective housing for Micro-Epsilon Sensors

• Thermal insulation is primary function• Die Temp 700-900 °F• High temperature insulation for use in fire

protection

• Aluminum Housing• 1/8” thick sheet top• ¼” Al Block bottom support• Weight: 9.5 lbs.

• External Port for Sensor Harness

• View hole for Sensor Optics

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