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DECOP Windshield Repair: Critical Design Review

DECOP Windshield Repair: Critical Design Review. Mechanized filling of Syringes for Windshield Chip Repair. Jun Kim Jay Lafond Robyn Paul Chris Pho Harhari Sharma Thejas Srinivasan. Contents. Project Overview WBS and Cost Estimates Capping Update Detailed Design

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DECOP Windshield Repair: Critical Design Review

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  1. DECOP Windshield Repair:Critical Design Review Mechanized filling of Syringes for Windshield Chip Repair Jun Kim Jay Lafond Robyn Paul Chris Pho Harhari Sharma ThejasSrinivasan

  2. Contents • Project Overview • WBS and Cost Estimates • Capping Update • Detailed Design • Module 1: Moulded Tray, Filling Mechanism • Module 2: Table • Module 3: Reservoir • Manufacturing Plans • Risk Analysis • Next Steps

  3. Project Overview • DECO Windshield Repair • Currently fills syringes by hand • Requirements • Cost – <18¢ / syringe • Accuracy – ±0.01mL (ideally less) • Speed – >900 syringes/hour • Reliability • Compatibility

  4. Work Breakdown Structure

  5. Resource Breakdown Structure

  6. Capping Update • No longer mechanizing the capping stage • Difficulty lining up syringe to the caps • Still able to maintain speed requirements • Focus primarily in the syringe filling stage • Time permitting, a separate sealing mechanism will be designed

  7. Possible Solutions

  8. Youtube! http://www.youtube.com/watch?v=xhwR3jEwSwE

  9. Pulling Mechanism

  10. Tray Mould

  11. Support Table • Guided Track • Stopper/locking • mechanism • Material? • Next design step: • Clamp-able • Calibration bar • Channel for drip

  12. Syringe Connection

  13. Reservoir and Piping • Reservoir: To store resin, deliver resin to seal HH LL

  14. Reservoir and Piping • Piping • Vertical (Circular Pipe): Connecting horizontal pipe to reservoir • Stop Valve: Emergency shut-off • Horizontal Pipe ( Square Pipe): Connected to two vertical pipes, has seals attached on surface • Drain Valve – Connected via T-Section to drain system • Vertical 2 (Circular Pipe) – Connected to horizontal pipe, open to atmosphere

  15. Design Criterion - Reservoir • Reservoir: • Enough resin to fill syringes for about 90 minutes • Volume Required = approx 225 ml • So Dimensions Required = Approx 6 cm * 6cm * 6cm • Contingency – 3 cm on top – 2 cm on bottom

  16. Design Criterion - Piping • Horizontal Pipe: - Enough resin to fill 25 syringes = 4ml - Required dimension for radius calculated to be = 0.0026 in - So we chose smallest standard diameter for our pipe - 0.50in

  17. Manufacturing Plans Rapid Prototyping Machining • Support material considerations • Wall thickness • More costly? • Material removal • Material choice – plastic (Delrin?)

  18. Risk Analysis Piece Interface List: Syringe – Cap Syringe – Filling Tube Syringe – Securing Pad Syringe – Mould Mould – Securing Pad Mould – Stopper Tray Mould – Table Mould – Lock Lock – Table Calibration Bar – Table Stopper Tray – Table Filling Tube – Emergency Shutoff Valve Filling Tube – Drainage Vent Filling Tube – Air Vent

  19. Risk Categorization Prerequisites

  20. Categorization Matrix

  21. High Risk Elements & Controls • High pressure at seal expels excess fluid • Minimize fluid head, verify functional seal • Seizure / destruction due to solidified resin • UV shield, include cleaning schedule • Poor seal interface results in excess waste • Minimize seal size and puncture distance • Complete failure; spill of material • Emergency shutoff valves; drainage point with collector

  22. Next Steps • Address seal concern • Refine SolidWorks model • Add DECO suggestions and other modifications • Begin prototyping in early January

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