CLIENT: SPECIALIZED TRAINING FOR ADULT REHABILITATION, INC. (S.T.A.R.T.) CONTACT: KATHY BAUMAN, EXECUTIVE DIRECTOR TEAM MEMBERS: BEN BLAIR LINDEN EASON JOHN HUGHEY JORDAN JOHN (PM) FACULTY TECHNICAL ADVISERS: DR. FARHANG Cardboard Bumper Assembly Jig Ref: SEC F11-75-NISH

Outline Executive Summary – Jordan Subsystem Description  Racking System – Jordan  Clamping System – Ben  Mechanical Analysis – Ben  Sensors – John  Logic Control Circuit – John  Containment and Ventilation – John  Light Emitting Diodes (LED) – Linden  Power Supply – Linden Overview of Device Operation – Ben Responsibilities – Jordan Costs – John and Jordan Time to Build – Ben Potential Improvements – John and Jordan Summary – Linden

Executive Summary Background  Current System  Client’s new production needs Design Challenge  History  Rules

Project Description Create a jig to increase production of cardboard bumpers, while also allowing for a wider range of employees to use the device Features:  Low cost to build and maintain  Provides mechanical advantage to operator  Simple notification system

Diagram of Systems Carboard Banding System Electrical System AC to DC Power Supply LogicCircuitOverflow LEDFill LEDUnderfill LEDFill Sensor Overflow Sensor Ventilation Mechanical System Racking Jig Clamping Mechanism Taping

Subsystems Mechanical  Racking System  Clamping System Electrical  Sensors  Indicators  Sensor control logic  Power Supply  Ventilation

Racking System

Clamping System Two Part System o U-Bolt Lock o Connective Pin

Mechanical Analysis UserRun 1 (sec)Run 2 (sec) Force Analysis Speed Analysis Max: 25, Min: 11, Avg: Max: 63, Min: 44, Avg: 53.1

Sensors Single unit with LED and phototransistor

Sensor Control Logic Circuit

Gate Level Logic

Containment and Ventilation Clear acrylic box cut to size  Cheap  Effective Running temperature nearly indistinguishable from room temperature while outside the box Positioned small vent holes on sides and top to allow for moderate airflow

Indicator LEDs Indicators are RGB LEDs  Low cost and long life Indicators use a well-known pattern

Power Need the jig to be able to use standard 120 volt alternating current Components require a 5 volt direct current

Overview of Device Operation

Responsibilities Ben – Construct and integrate clamping system Jordan – Construct and integrate racking system John – Construct sensor controller, calibrate sensors, mount components in the case, attach the case to the jig Linden – Solder the power supply, attach power supply to the control logic circuit

Cost (Mechanical Subsystems) Mechanical Subsystems Costs Part NumberMaterialUnit PriceQuantityTotal Price 1Leg$6.812$ Leg Separator$ Base Plate Arm Long$ Base Plate Arm Short$ End Plate Arm$2.382$4.76 6End Plate$ Fall Arm$ Electrical Housing Under Plate$ Electrical Housing$ Hinge Assembly$ Hinge Plates 2 12 Hinge Pin 1 13Base Plate$ Moving Plate$ Connective Pin$ U-Bolt$ U-Bolt Attachments$0.832$ ANSI B NO /4 Bolt$0.432$ ANSI B / /4 Bolt$0.521 Total$44.77

Cost (Electrical Subsytems) Part NumberMaterialUnit PriceQuantityTotal Price 1Optical Detector/Phototransistor$1.132$2.26 2Breadboard Power Supply 5V/3.3V$ Multicolor RGB LED w/ White Diffused Lens$1.753$5.25 8LM311N High Performance Voltage Comparator$7.462$ Rosin Core Solder$ AC Adapter 9V 1.5A$ L Adaptaplug$ Solder Iron$ PCB Standoff$ Universal PC Board$ De-soldering Braid$4.191 Total$91.69

Time Required to Build Prototype Step of ConstructionHrs. Machining base components0.5 Welding base components0.75 Machining jig components2 Welding Jig components2 Welding base to jig0.5 Installing Latch system0.5 Installing pin system0.25 Mounting electrical components to circuit board2 Soldering Components to Circuit Board5 Preparing Container for Electrical Components2 Mounting and Aligning Sensors0.5 Mounting and Aligning LEDs0.5 Total Time to Construct16.5

Potential Improvements Mechanical Improvements  Adjustable Base  Machined Parts  Width Adjustment for Feed Slot Electrical Improvements  Adjustable sensor mounting  Better Case

Summary Electronic jig Clamping system User friendly Cheap to build and maintain Small improvements can be made

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