Wyman Gordon Forging Locator

1. Wyman Gordon Forging Locator Johnathan Knight – Team Manager Min Han Zhao – Team Facilitator ShimonaGorelick– Lead Electrical Engineer Nick Perrotte – Lead Mechanical Engineer

2. Overview • Project Background • Detailed Design Output • Bill of Materials • Drawings • Schematics • Risk Assessment • Customer Needsand Test Plans • Feasibility Analysis • MSDII Schedule

3. Background Info - Customer 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

4. Background – Customer Process & Justification 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).

5. Engineering Metrics

6. Previously Designed System • 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

7. System Layout

8. 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

9. 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

10. Bill of Materials - Electrical

11. Bill of Materials - Mechanical

12. Bill of Materials - Total Specific details for each upgrade will be addressed in upcoming slides

13. 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).

14. Mechanical Calibration • Mechanical Calibration will be done with Locating bars that attach to the rails being used with bolts.

15. Mechanical Calibration Railing to Locating Bar Mounting Bracket

16. Mechanical Calibration Locating Bar

17. 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

18. 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

19. 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.

20. 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”

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

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

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

24. 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 Aperture Enclosure Glass Enclosure

25. Laser Protection

26. Laser Protection

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

28. Risk Assessment • Update risk assessment to final design • Lead time risk • Manufacturing risk

29. Safety and Usage • 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.

30. Engineering Metrics

31. 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

32. 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)

33. 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 meter Ideal: 10 meter

34. 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

35. 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 system 1.Different ages: 20-55 years old 2.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

36. 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

37. 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.

38. Feasibility • Everyone do your own shit

39. 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

40. MSDII Schedule

41. Questions & Comments • Self explanatory

42. MicroEpsilon Lasers • 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) EDIT THIS SLIDE

43. Laser Enclosures • 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 EDIT THIS SLIDE