Design of a Low Cost and Robust Linkage Position Sensing System

1. Design of a Low Cost and Robust Linkage Position Sensing System Leann Vernon & Phillip Latka Dr. Sanchez November 21, 2013

2. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

3. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

4. Project Summary • Client Relationship: Caterpillar • Project Purpose: Replace existing end implement sensing system • Convergence Project • Mechanical Engineer (3), Electrical Engineer (2), Business (4), Advisors (4)

5. Project Summary • End Implement Location • D8 • System Types • Linkage Position System • Implement Position System

6. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

7. Block Diagram: Overall System Position (From Environment)

8. Block Diagram: Linkage Position System Position (From Environment)

9. Block Diagram: Implement Position Sensor Position (From Environment)

10. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

11. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

12. Design Requirements • Cost • Includes: Cost of sensor, manufacturing, and installation costs • Benchmark cost based on CAT’s current system: $1,000-$1,500 • Robustness/Reliability • Vibration 8 g • Environmental Conditions • Potential for 10,000 operating hours • Accuracy • Location of Linkage: 0.1mm • Location of End Implement: 0.5 in (1.27 cm)

13. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

14. System Specifications • Output of Sensor • PWM signal • Low current ~3.8 mA • Up to 5V • Frequency Range 0.1 Hz to 12.8 Hz • Duty Cycle: 3-97%

15. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

16. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

17. Team Schedule • Mondays 10am • Engineering Group Meeting: Students Only • Wednesday 12pm • Engineering Group Meeting with Advisors • 3rd and 4th week conference call with CAT • Friday 12pm • Team Meeting • Sunday 12pm • Engineering Group Design Meetings: Students Only

18. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

19. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

20. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

21. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

22. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

23. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

24. Other Pertinent Research • Patent • US7757547 Komatsu • Wheel and Encoder • Linkage Position sensor • Other • 1997 Arthur D. Little Consultation Conference • Idea Comparison • Evaluation Criteria

25. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

26. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

27. Initial Brainstorming Session • 30 Designs • Sample Designs • Vision Tracking • Ultrasonic • Flow Meter • Gear Tooth Sensor • Barcode

28. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

29. General Idea Elimination • Mechanical and Electrical Engineers Limited List of 30 Based on Pros and Cons • Pros and cons based on functional requirements • New List of Ideas

30. Design Process • Researching Stage • Existing CAT System • New Sensor Technology • Other Pertinent Research • Brainstorming Stage • Initial Brainstorming Session • General Idea Elimination • Specific Designs

31. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

32. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

33. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

34. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

35. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

36. Specific Designs • Laser Distance Sensor • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

37. Specific Designs • LiDAR • Triangulation • Wheel and Encoder • Sleeve • Push Arm • Magnetometer

38. Outline • Project Summary • Block Diagram • System Overview • Design Requirements • System Specifications • Preliminary Work • Team Schedule • Design Process • Schedule

39. Schedule • Phase 1 - Project Definition • Phase 2 - Design Phase/Research Application • Phase 3 - Advanced Analysis/Prototyping • Phase 4 - Project Delivery

40. Schedule

41. Schedule • Phase 1 - Project Definition • August – Mid October • Phase 2 - Design Phase/Research Application • Phase 3 - Advanced Analysis/Prototyping • Phase 4 - Project Delivery

42. Schedule: Phase One

43. Schedule • Phase 1 - Project Definition • Phase 2 - Design Phase/Research Application • Mid October – January • Top Three Ideas to CAT • Agree on Top Solution • Phase 3 - Advanced Analysis/Prototyping • Phase 4 - Project Delivery

44. Schedule: Phase Two

45. Schedule • Phase 1 - Project Definition • Phase 2 - Design Phase/Research Application • Phase 3 - Advanced Analysis/Prototyping • January – April • Prototyping (Client Approved) • Phase 4 - Project Delivery

46. Schedule: Phase Three

47. Schedule • Phase 1 - Project Definition • Phase 2 - Design Phase/Research Application • Phase 3 - Advanced Analysis/Prototyping • Phase 4 - Project Delivery • April – May • Final Report • Final Presentation

48. Schedule: Phase Four

49. M E Group: Andrew Aubry Chris Costello Ken Ratekin Advisors: Dr. Morris Dr. Sanchez Nick Schmidt E E Group: Phillip Latka Leann Vernon Buisness: Nicole Itschner Scott Roth Kinzie Sellers Rose Wurster

50. Voice of Customer