R16601: Glass Fab Wire Saw Integration/Roadmap

“Glass Fab, Inc. is currently looking to replace their wire glass cutting saw with a smaller, more efficient saw. These saws are designed to process hundreds to thousands of parts per run with minimal kerf loss and high surface precision. Currently four MSD teams at RIT are working on components for a replacement saw for Glass Fab. These components need to be refined and brought together to form a cohesive, finished product to meet the production demands of Glass Fab, Inc..” Major Customer Requirements:  Create a machine that protects the operators and itself  Create a machine that can reliably cut glass  Create a machine that operates at a lower cost than current machine  Create a machine that eliminates extraneous features found on current machine

Cut Glass Protect Interfaces Move Workpiece Provide Slurry Control Wire Integrate Subsystems Control Machine Operation

Move Workpiece Provide Information Adjust WorkPiece Feed Indicate Vertical Position Indicate speed Indicate direction Provide Slurry Provide Information Indicate Flow Rate Control Slurry Change Flow Rate Indicate Remaining Quantity Indicate Slurry Used

Control Wire Guide Wire Provide Information Tension Wire Indicate Wire Remaining Warn About Low Wire Adjust Wire Speed Change Spool Speed Change Roller Speed Measure Tension Adjust Tension Support 175 km of wire Control Machine Operation Run Overnight Setup Jobs Provide Wire Thread Control Estimate Run Time Setup Workpiece Feed Setup Wire Feed Display Run Time

Protect Interfaces Protect User Protect Machine Protect Workpiece Shutdown For Faults Provide Access Interlocks Provide Panic Button Hold Cut Pieces Detect Faults Detect Motor Overheat Detect Wire Break Integrate Subsystems Provide Part Replacement Determine Datum Structure Revise Frame Structure Provide Visual Monitoring Provide Cleaning Access Provide Wire Threading Access

Safety & Controls CR’s Cost CR’sGeneral & Subsystem CR’s

Function MethodMethod Detect Wire Break Indicate Wire Remaining/Detect Low WIre Determine Datum Structure Provide for Threading Access Control Wire Tension Current sensor Measure spool RPM with respect to spool size Tolerance stackup at the part level Side access High-precision guide roller speed differential Linear encoder Correlate wire movement speed with guide roller rotation speed CMM measurementsTop access Incorporate an eye- hooked object which can be displacement- controlled to adjust applied force on the wire Stress gauge Detect/measure weight changes of spools Use physical metal pieces of pre- established sizes to fit tolerances Auto- threading Pinch point Wire resonance Correlate wire movement with steady-state run time Measure fluctuations in tension of the wire will the machine is running to determine part tolerances Hinged parts to allow for rotation out of the way of required access space CAM system (bow-like tensioning system) Detect abrupt changes in motor voltage/power draw

Function MethodMethod Detect Wire Break Indicate Wire Remaining/Detect Low Wire Determine Datum Structure Provide for Threading Access Control Wire Tension Current sensor Measure spool RPM with respect to spool size Tolerance stackup at the part level Side access High-precision guide roller speed differential Linear encoder Correlate wire movement speed with guide roller rotation speed CMM measurementsTop access Incorporate an eye- hooked object which can be displacement- controlled to adjust applied force on the wire Stress gauge Detect/measure weight changes of spools Use physical metal pieces of pre- established sizes to fit tolerances Auto- threading Pinch point Wire resonance Correlate wire movement with steady-state run time Measure fluctuations in tension of the wire will the machine is running to determine part tolerances Hinged parts to allow for rotation out of the way of required access space CAM system (bow-like tensioning system) Detect abrupt changes in motor voltage/power draw

Function MethodMethod Detect Wire Break Indicate Wire Remaining/Detect Low WIre Determine Datum Structure Provide for Threading Access Control Wire Tension Current sensor Measure spool RPM with respect to spool size Tolerance stackup at the part level Side access High-precision guide roller speed differential Linear encoder Correlate wire movement speed with guide roller rotation speed CMM measurementsTop access Incorporate an eye- hooked object which can be displacement- controlled to adjust applied force on the wire Stress gauge Detect/measure weight changes of spools Use physical metal pieces of pre- established sizes to fit tolerances Auto- threading Pinch point Wire resonance Correlate wire movement with steady-state run time Measure fluctuations in tension of the wire will the machine is running to determine part tolerances Hinged parts to allow for rotation out of the way of required access space CAM system (bow-like tensioning system) Detect abrupt changes in motor voltage/power draw

Function MethodMethod Detect Wire Break Indicate Wire Remaining/Detect Low WIre Determine Datum Structure Provide for Threading Access Control Wire Tension Current sensor Measure spool RPM with respect to spool size Tolerance stackup at the part level Side access High-precision guide roller speed differential Linear encoder Correlate wire movement speed with guide roller rotation speed CMM measurementsTop access Incorporate an eye- hooked object which can be displacement- controlled to adjust applied force on the wire Stress gauge Detect/measure weight changes of spools Use physical metal pieces of pre- established sizes to fit tolerances Auto- threading Pinch point Wire resonance Correlate wire movement with steady-state run time Measure fluctuations in tension of the wire will the machine is running to determine part tolerances Hinged parts to allow for rotation out of the way of required access space CAM system (bow-like tensioning system) Detect abrupt changes in motor voltage/power draw

 Uncertainties: ◦ Glass Fab needs to finalize their needs with MSD teams ◦ Sufficient design progress for the MSD subsystems  Questions: ◦ Related to uncertainties  Next Steps: ◦ Work with MSD teams on integration & design changes ◦ Determine more-specific customer requirements and verify current requirements and metrics analysis with customer

Questions?