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Robot AutomationTEAM 072017-2018
Nathan Casey (ECE)
Josh Tempelman(ME)
Michael Bissetta(ECE)
The Team
Alex Keizer(ME)
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Presentation Outline
Overview
Initial mechanical design
Initial electrical design
Design Change
Final mechanical design
Final electrical design
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The Customer
• Specializes in machining, assembly, inspection
• Serves wide variety of industries: automotive, office, medical, and more
• Currently uses little automation
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Project overview
• Parts are currently being produced in a lathe operated by a worker.
• The pucks are put into a lathe twice, machined to precise dimensions, and measured.
• Our task was to automate this process, decreasing cost and increasing part quality.
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Ethics and Design Norms
Delightful Harmony TransparencyTrust
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Initial design requirements
• Manufacture parts with little to no human interference
• Operate robustly and reliably
• Manufacture 120 parts per hour
• Track dimensions of finished parts
• Comply with safety standards
• All designs are owned by Prefferred Quality Services, not Team07
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Initial mechanical plan - indexing table
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Initial mechanical plan – End of Arm Tool
- Electromagentic Gripping
- Simple Bracket Configuration
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Initial electrical plan - Communication
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Initial electrical plan - Block Diagram
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Anticipated challenges
● Reliable measurements
● Consistent part grabbing
● Lack experience in networking and programming
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Project Change
3+ years of production anticipated on the part created by the cell
November 16 the OEM notified PQS that the part will bediscontinued in Q1 of 2018
PQS has assigned a new project to the team to replace this one
OEM
SUPPLIER
PQS
Old Part New Part
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New requirements
• New heavier part + how to machine it
• New table
• New electrical hardware and requirements
• No measurement system
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Lessons learned
• Scrapped ideas (ex. Gantry robot, two motors for original table design)
• Engineering in industry can be volatile
• Must be able to adapt quickly
• It is important to research deeply as well as broadly
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Safety
• Cage keeps employees away from moving parts
• Three Emergency stop buttons
• Safety Relay connects all E-stops and handles emergency procedure
• Safety mat and speaker ensures no one is near table when it rotates.
• Stack lights indicate machine state
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Finances
• Cost savings was a important factor for our customer
• With the change of project costs increased significantly and that had to be communicated to the
customer
• We updated our budget regularly and kept the customer informed on all changes
• We saved a lot of the cost by going through several robot suppliers
• We can also save cost in the future by using parts that have long lifespans
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New System Design
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Key Components:-HAAS Lathe-Fanuc Arcmate 6-Axis Robot-Rotating Part Loading Table-Part Check Ramp-Finished Part Bin-Velox Safety Caging
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New mechanical plan - indexing table
Key Components:-Oriental Motor-Polycarbonate Shields-E-stop Switch-80/20 Framing
Key Metrics/Decisions:-Modular-Cost Effective-Portability-Safety-Manufacturability
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Part Table Progress
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New mechanical plan - parts slot
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Key Components:-80/20 Framing-Low Friction Polycarbonate Slides-Housing for Electrical Hardware-Touch Screen Display
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New mechanical plan – End of Arm Tool
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Key Components:-Machined Aluminum Plumbing-Venturi Vacuum Pumps-Two Laser Distance Sensors-Proxy sensor-Homing Rods
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FEA and Calcs
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0 0.5 1 1.5 2-60
-40
-20
0
20
40
60
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New electrical design plan - power distribution
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New electrical design plan - Communication
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New electrical design plan - software
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New electrical design plan - software
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New electrical design - Progress
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Lessons learned
- Working with distributors can be difficult
- Software can have a lead time
- Inter-team communication is important
- Don’t assume things about the customer
- Solid plans make work go much faster
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Moving Forward
• Finish programing
• Wire and power all components once drops are installed
• Finish installation of arm and cage
• Begin working through test plan
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Questions
31
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