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Accessible Manufacturing Equipment Phase 2

ECE 480 Senior Capstone Design. Accessible Manufacturing Equipment Phase 2. Team 2 Nicholas Neumann Ralph Prewett Jonathan Brouker Felix Adisaputra Li Tian December 10 th , 2010. Contents. Background Design Specifications Final Design Results and Evaluations Conclusion

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Accessible Manufacturing Equipment Phase 2

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  1. ECE 480 Senior Capstone Design Accessible Manufacturing EquipmentPhase 2 Team 2 Nicholas Neumann Ralph Prewett Jonathan Brouker Felix Adisaputra Li Tian December 10th, 2010

  2. Contents • Background • Design Specifications • Final Design • Results and Evaluations • Conclusion • Future Improvements • Demonstration

  3. Background • Basic Purpose of the Project • Former 2008 Machine

  4. Background • Former 2008 Machine (Continued) • PIC Programming • C Code • Timing Loop • Stepper Motors • Parallel Operation (Belt) • Cam Motors • Rotary Cutter • Stationary and Movable Clamps

  5. Background • Major Problems • Programming Interface • No C programmers on staff at location • Difficult Maintenance • Stepper Motors • Inaccuracy • Slow Operation • Motor Drivers • Overheat Issue

  6. Design Specifications • Critical Customer Requirements • Simple Programming Language • Easy Maintenance • High Level of Accuracy • Different Types of Motor • Variable Speed Control • Higher Maximum Speed of Operation

  7. Design Specifications • Secondary Objectives • Visual and Audio Feedback • Reliability and Robustness • Reduce Occurrence of Jamming • Safety • Better Design of Safety Guards • Reduce Noise During Operation • Compact Machine • Aesthetics

  8. Final Design • Mechanical Systems • Pneumatic Guillotine Cutter • Valves Assembly

  9. Final Design • Mechanical Systems (Continued) • Two Capstans Design • Increases the Speed of Operation

  10. Final Design • Mechanical Systems (Continued) • Adjustable Frame

  11. Final Design • Mechanical Systems (Continued) • Tracking Guard

  12. Final Design • Hardware • LEGO NXT Brick as Microcontroller • LCD Screen for Speed Display • Limited I/O Ports • LEGO Servo Motors • High Accuracy • Compatibility • I2C Serial Communication Bus • I/O Expander PCF8574

  13. Final Design • Hardware (Continued) • Input (Buttons) • 8-Segment LED Display • Length Output

  14. Final Design • Hardware (Continued) • Cutter Relay Control • Power Transistor • LEGO NXT Brick Power Supply • Step-Down Converter Circuit • LM7809 Voltage Regulator

  15. Final Design Time • Software • LEGO Mindstorms NXT-G

  16. Final Design Accepts User Input. Executes Commands Starts or Stops Cutting Process Contains Cutting Process Drives 8 Segment Display Displays Length and Speed on NXT Display

  17. Results and Evaluations • Improved Accuracy • 2008: 13.24% defects • 2010: 1.46% defects • Reduced Percentage Error • 2008: -12.99% • 2010: 2.7%

  18. Results and Evaluations • Enhanced Speed of Operation • For 100 Cycle Run: • 2008: 7 min 49.7sec • 2010: 2 min 27sec • 3.19 Times Faster

  19. Results and Evaluations • Capstan Feed Design • Removed Drift Factor • Smaller Size of the Machine • 4.7 Times Smaller in Area • LEGO Servo Motors • Eliminated Overheating Issue • Sources of Error • Susceptible to Ribbon Feed Method • Ribbon at Similar Elevation Improves Accuracy Significantly

  20. Conclusion • Accomplishments • Maintain Simplicity of the Programming • LEGO Mindstorms NXT-G • Better Accuracy and Consistency • LEGO Servo Motors • Variable Speed Controller Implementation • Higher Maximum Speed of Operation

  21. Conclusion • Accomplishments (Continued) • LED Display and Speaker • Reliable and Robust • Tracking Guards Prevent Jamming • Better Safety • Safety Guards • Less Noise • Smaller Size • Aesthetics

  22. Cost *Sponsored by Sponsor Total Cost: $814.65

  23. Future Improvements • Warning Message • Detects Jam • Number Pad • Length • Speed • Speed • Faster • More Range

  24. Future Improvements • Audio (ISD 1400) • Louder • Adjustable Volume Control

  25. Demonstration

  26. Questions

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