“Brazing Saddles” ( Team 15) Client: Parker-Hannifin Faculty Mentor: Dr. Kevin Kochersberger Faculty Coordinator: Prof. Paul Stiebitz Critical Design Review May 16, 2003 “Brazing Saddles” ( Team 15) Client: Parker-Hannifin Faculty Mentor: Dr. Kevin Kochersberger Faculty Coordinator: Prof. Paul Stiebitz Critical Design Review May 16, 2003 Project Manager: Melissa Curtin Ethan Bagley (ME) Ethan Bagley (ME) Paul Diedrich (IE) Charles Gullo (IE) Thomas Wild (ME) Brian Belpanno (IE)

2 Agenda  Problem Statement  System Design  Video Demonstration  Testing  Ergonomics/Safety  Conclusions

3 Problem Statement Currently:Currently: –Operator loads and unloads parts every 6 min. –Mechanical system unreliable. Project Goals:Project Goals: –Part removal and handling system: Reduce lossesReduce losses Increase productivityIncrease productivity

4 System Design SubsystemsSubsystems –Pneumatics –Boat –Boat Design –Electronics –Part –Part Handling FunctionsFunctions –Conveyor –Vertical Thruster –Horizontal Thruster

5 Pneumatics Pneumatic circuit diagramPneumatic circuit diagram –Design reuses nearly all components of existing system

6 Boat Design Machinable ceramicMachinable ceramic Sloped front edgeSloped front edge Pins installed for stabilityPins installed for stability Sized to fit existing boats with parts included.Sized to fit existing boats with parts included. Solid BaseSolid Base Holes for vertical pegs Holes for stabilizing pegs

7 Electronics Components: BASIC stampBASIC stamp Retro-reflective sensorRetro-reflective sensor Solenoid valvesSolenoid valves Bell alarmBell alarm Status LED’sStatus LED’s Digital displayDigital display Delay n seconds Open valve 1 Update status LED Close valve 1 and valve 2 Delay z seconds Update count YES Is sensor activated Ring bell intermittently NO YES End Delay x seconds Open valve 2 Update status LED Delay y seconds Initialization Is sensor activated NO Start Update status LED Count = max? Ring bell YES NO End

8 Part Handling System Assumptions:Assumptions: 100% Utilization100% Utilization 250 working days per year250 working days per year Three shifts per dayThree shifts per day $20/hr labor rate$20/hr labor rate Cart System saves 450 hours (time spent walking) per yearCart System saves 450 hours (time spent walking) per year Approximately $9,000 in labor costsApproximately $9,000 in labor costs Cart Furnace and belt Lifting plate

9 Video Demonstration Mechanism in Motion

10 Reliability Testing ExperimentsExperiments –Part removal from belt furnace to vertical lift plate –Part removal from vertical lift plate onto ramp ConditionsConditions –Weight (light / heavy) –Orientation (angle from center)

11 Reliability Testing (Cont.)

12 Ergonomics and Safety Safety CoversSafety Covers –Cover most pinch points Uncovered points noted by signageUncovered points noted by signage Cart SelectionCart Selection –Height of 50 th percentile male (35 in) –Full cart initial push force acceptable to 90% of industrial workers (< 275 N, Cirello et al 1993Maximal Acceptable Push Forces) Audible AlarmAudible Alarm –Meets Patterson’s 1990 good alarm properties 30 db above ambient level30 db above ambient level Not overly startlingNot overly startling Does not disrupt processing of other signalsDoes not disrupt processing of other signals Informative, 2 distinct alertsInformative, 2 distinct alerts

13 Web Site Flash and HtmlFlash and Html Meets Criterion while remaining entertaining for undergradsMeets Criterion while remaining entertaining for undergrads Human factors principals used in designHuman factors principals used in design

14 Conclusions MaintainabilityMaintainability SafetySafety Client Budget: $5000Client Budget: $5000 –Final Cost: $2212 Client concerns addressed:Client concerns addressed: –Boats brazing to furnace –Reliability

15 Special Thanks To: Parker HannifinParker Hannifin Fulya TezerFulya Tezer Brett YoungstromBrett Youngstrom Dave HathawayDave Hathaway Dr. Kevin KochersbergerDr. Kevin Kochersberger Professor Paul StiebitzProfessor Paul Stiebitz Professor Ron AmbergerProfessor Ron Amberger Professor Brian ThornProfessor Brian Thorn

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