P08351 – Concept Design Review

Agenda

1:00-1:15 Overview of project 1:15-1:50 Mechanical

Engineering subsystems 1:50-2:10 Electrical Engineering

subsystems 2:10-2:25 Proposed integrated

system 2:25-3:00  Open Discussion/ action &

issues

Team members/roles

Team Member Discipline Role Email address

Jim Taylor IE Guide jbteie@rit.edu

John Kaemmerlen IE Consultant jxkpdm@rit.edu

John Bonzo IE Consultant jbleie@rit.edu

Matt Zapotoski IE Project Lead mcz9592@rit.edu

Sharif Hdairis CE CE/EE support sdh6724@rit.edu

Joe Jennings ME ME support jej3689@rit.edu

Bob Shackelford ME ME support rws9132@rit.edu

What's the problem?

Parlec currently manufactures a wide variety of tool holders

The following process currently exists: Manually dip Manually drain Stand on paper towels to dry

Resulting complications: excess labor required (2-3 workers) oil waste part coverage inconsistency

hinder ability to meet throughput

Window of opportunity In response, Parlec has requested a

machine to automate the oiling process.

LOADING

SIGNALS

TOOL HOLDER

CLEANINGAGENT

CLEANING

APPLY OIL

REMOVE EXCESS OIL

UNLOADING

INPUTS

ELECTRICENERGY

CONTROLS

VARIABLE SPEED DRIVE

OUTPUT

OILED TOOL

HOLDER

FUNCTIONAL DIAGRAM

Concept Selection

Concept Generation: Breakdown subsystems even further, develop possible solutions and corresponding pros and cons

Concept Screening: Develop a list of applicable selection criteria and use Pugh’s Method to compare possible solutions

Concept Scoring: Apply weights to each individual criterion in order to confine results to one or two possibilities.

Mechanical Engineering Subsystems

Loading/Unloading Oil Application Part Cleaning Remove excess oil

Loading/Unloading Mechanism

Fixture

Selection Criteria Weight Hooks MagnetsLoose fitting

fixtureTight fitting

fixturePegs None

durability 0.15 0 + 0 0 0 +

part versatility 0.25 0 0 + - 0 +

tolerance protection 0.5 0 0 0 + 0 -

Fabrication cost 0.1 0 - - - - +

Total 0 0.05 0.15 0.15 -0.1 0

SUBFUNCTION SEARCH RESULTS POSITIVES NEGATIVES

LOADING / UNLOADING

Hookseasy to place part,

simple, linear, cheap, most flexible

capacity, prone to damage part, strength

Rackspart versatility (size), offers strength and

stability

bulky, will require/ take up space

Fixtureflexible in design

(custom), holds parts more securely

cost, additional labor/ increased setup time

Magnets durable, part security part versatility? , cost

Oil Application

SUBFUNCTIONSEARCH RESULTS POSITIVES NEGATIVES

ApplyOil

Dip simplestuses excess oil, may not coat

part completely

Spray more uniform coatcontaminates air, requires

energy to apply, may not coat part completely (air pockets)

Poursloppy, difficult to apply full

application, slow

Tumblemore thorough (prevent air

pockets)requires additional equipment,

potential to damage part

Brush cheap, versatilebristles wear out, may brush

off onto part

Apply Oil

Selection Criteria Weight Dip Pour Tumble Brush Spray

Part versatility 0.15 0 - - - -

speed 0.1 0 0 0 0 0

part coverage 0.4 0 - - - 0

running cost 0.05 0 - 0 - -

maintenance 0.05 0 0 0 - -

tolerance protection 0.25 0 0 - 0 0

Total 0 -0.6 -0.8 -0.65 -0.2

Cleaning

SUBFUNCTION SEARCH RESULTS POSITIVES NEGATIVES

CLEANING

Airavailable in facility, low risk of

damaging partexpensive, will contaminate air,

noisy

Brushes cheap, available, singlecould fall apart, not thorough coverage, bristles on part?

Rags cheap, available, singlemust be maintained, manually

operated

Solvent/Chemicals will remove all debrismessy, lengthen process

(drying time req'd), may not remove all debris

Cleaning

Selection Criteria Weight Air Brushes Rags chemicals

Part versatility 0.2 0 - 0 0

speed 0.2 0 0 0 -

part coverage 0.4 0 - - 0

running cost 0.1 0 - 0 - -

maintenance 0.1 0 - - -

Total 0 -0.80 -0.5 -0.5

Remove Excess Oil

SUBFUNCTION SEARCH RESULTS POSITIVES NEGATIVES

REMOVE EXCESS OIL

Spin quick, reliability of result, versatileexpensive, potentially dangerous,

additional equipment required

Hang/Dip simplest, cheapest slowest, requires space

Wipe simplest, cheapest slow, unreliable

Air quick, consistent, low maintenance req'd

messy, noisy, expensive

Heat decreases viscosity costs money to produce heat

Remove excess oil

Selection Criteria Weight Air Spin Wiping Drip

Part versatility 0.2 0 0 0 0

speed 0.2 0 - 0 -

part coverage 0.4 0 0 - 0

running cost 0.1 0 - 0 +

maintenance 0.1 0 - - +

Total 0 -0.4 -0.5 0

Electrical Engineering Subsystems

Variable Speed Drive System

Control Panel

Electrical Control System

Mixed Signal Input

U 1

TC L O S E = 1

1 2

R 11 k

V 15 V d c

0

V R 21 KS E T = 0 . 5

D 1D 1 D L 4 1 A

D 2D 1 D L 4 1 A

0

V 25 V d c

V

Discrete variable Continuous variable

Variable Speed Drive System

SUBFUNCTIONSEARCH RESULTS

POSITIVES NEGATIVES

VSD System

AC Motor w/ prebuilt drive

Cheaper, better power efficiency, easy to replace parts

and maintain.

More expensive than custom drive solution.

AC Motor w/ custom drive

Cheapest, better power efficiency.

Wiring and quality of drive components is lower. Harder to interface with processing unit.

Replacing drive is harder.DC Motor w/ prebuilt

driveBetter acceleration, comparable

maintenance to AC/prebuiltHigh power DC drives are very

expensive.

DC Motor w/ custom drive

Better acceleration.expensive, harder to maintain and replace parts, design time

of custom drive.

Drive System

Selection Criteria Weight AC/Custom AC/prebuilt DC/prebuilt DC/custom

fabrication cost 0.25 0 - - -

maintenance cost 0.25 0 + 0 -

reliability 0.2 0 + + 0

ease of implementation 0.2 0 + + 0

start/stop performance 0.1 0 0 + +

Total 0 0.4 0.25 -0.4

Integrated Solution

Loading/Unloading : hooks, tight fitting, loose fitting fixture

Oiling: Dip and spray Cleaning: Air and rags Remove excess oil: Air and drip VSD System: AC/DC with prebuilt

drive and AC with custom drive

Integrated Solution

System loading/unloading cleaning apply oil removing excess oil VSD

1 hooks air dip air ac/prebuilt

2 tight fitting air dip air ac/custom

3 loose fitting rags spray air ac/prebuilt

4 hooks rags spray drip dc/prebuilt

5 tight fitting air spray drip ac/custom

6 loose fitting air dip drip dc/prebuilt

7 tight fitting air dip air ac/prebuilt

Criteria/ Machine # 1 2 3 4 5 6 7

ease of manufacture 0 - - - - 0 0

fabrication cost 0 - - - - - +

ease of use for user 0 + + 0 + + +

durability 0 + - - 0 + +

consistency 0 0 - - - 0 0

safe 0 + + 0 + + +

maintenance 0 - - - - + 0

TOTAL 0 0 -3 -5 -2 3 4

Final Concept

QUESTIONS????