Conceptual Design Review Senior Design

Overview Material Flow –Remove cartridges from tray –Presentation of cartridges in front of camera Inspect cartridge –Capture image of cartridge –Software Inspection Future focus Budget Schedule

Minimal change in height desired from 500ct to 50ct tray Minimize risk of incurring incidental and other defects while processing product Cost of x-y positioning systems Material flow considerations

Remove cartridges from tray Gravity feed from 500ct tray –Freefall acceleration velocities are sufficient for 600parts/min requirement –How do we get them back up higher in elevation? Vertical ascent out of 500ct tray –Vacuum and air blast alternatives considered –Air is readily available –Experimental results

Vertical ascent: Air jet and tube array Remove cartridges from 500ct tray –20 tube array, 1-D positioning system –500ct tray gets positioned, tubes are stationary –Varied length tubes, cartridges arrive at different times –Ten cartridges pulsed every 1 second with an air jet array below the tubes

Where the tubes end Cartridge queue –Accepts cartridges from feed tube –Advances cartridges to inspection area –Provides better advancement control than gravity feed tube

Presentation of cartridges in front of camera Dropping Contact Rolling –Single Roller –Multiple Roller

Dropping Image: 3 images within one picture Pros –Gravity is consistent and does work for us –Gravity produces proper orientation Cons –Scaling issues, consistency in falling distance –Mirrors in place to give 360 degree view

Image: 3 images taken 120 o apart Pros –Consistent image in front of camera –Multiple parts within picture window Cons –3 images taken 120 o apart cause long process time –High transfer rates, rotational and linear Single Roller

Multiple Roller Image: 1 unrolled image of entire cartridge Pros –Consistent image in front of camera –Multiple parts within picture window Cons –High transfer rates, rotational and linear –Complex apparatus

Multiple Roller

Lighting Options 1.Front lighting 2.Back lighting 3.Structured lighting

Things to Consider Metallic reflective surface Curved shape of case Surface defects on case Measurements of dimensions of entire bullet

Lighting Applications

Front lighting Brightfield illumination Darkfield illumination

Front lighting Diffused Front light Omni-directional illumination Shiny Object Reflective surface

Back lighting Optical Diffuser

Structured lighting

Lighting options for material flow

Schweitzer Inspection Systems Led lighting configurations Finding center of chip to place on boards XY system for placing Covering to protect from dust and pinch points Mirrors not commonly for automated systems

Software Inspection Three ways to use software to inspect bullets –Intensity –Edges –Shapes

Software Inspection Intensity - Use multiple polygons to look for dark areas (flaws) on the cartridge surface. This sensor is looking for the amount of “white space” inside the red box

Software Inspection Intensity –Pros Easily detect major defects Checks areas Easily manipulate intensity values –Cons Smaller sensors are better, but more work to make them Hairline fractures can cause problems if intensity settings aren’t sensitive enough

Software Inspection Intensity Pass

Software Inspection Intensity Fail

Software Inspection Edges - Use multiple sensors to look for edges (flaws) inside areas that are white on the cartridge surface. These sensors are looking for edges on the red lines

Software Inspection Edges –Pros Easily detect major defects Checks for all edges Easy to make multiple sensors in different places –Cons Smaller sensors are better, but more work to make them Hairline fractures can cause problems if edges are too far apart

Software Inspection Edge Pass

Software Inspection Edge Fail

Software Inspection Shapes - Use a single or multiple sensors to look for “perfect” cartridges or parts of the cartridge. This sensor is looking for the “white” shapes on the cartridge

Software Inspection Shapes –Pros Easily detect major defects Checks for all white “blobs” larger than a specified size. –Cons Smaller sensors are better, but more work and more processing time Smaller defects including hairline fractures and small dents are difficult to see

Software Inspection Shape Pass

Software Inspection Shape Fail

Other Ideas Gage Wheel 50-ct Tray Package Machine

Gage Wheel Pros –Gages parts for proper diameter –Outputs bad parts to separate bin –Produces timing interval between parts Cons –Limited to one type of defect –Allows minor defective parts to pass

Gage Wheel

50-ct Tray Package Machine Existing Prototype to be utilized for project Electromechanical device that can be controlled by camera processor Built for existing tray configuration

50-ct Tray Packaging

Future Focus Phase 1: Focus on successful inspection –Part orientation Falling –Lighting Combination of front and back lighting –Software inspection Combination of intensity and edge sensors

Part Orientation Falling with current camera –Pros Simple mechanical design Utilization of gravity –Cons Complex use of mirrors and lighting Processor intensive Falling with additional cameras –Pros Less processor intensive Eliminates mirrors –Cons Money Camera communication

Lighting Combination of front lighting and back lighting –Pro Cheaper Works well with dropping –Cons Hard to adjust Reflection

Software Combination of intensity and edge sensors –Pros Both sensors work well on different sections of the cartridge Inspects entire cartridge –Cons Multiple sensors Increased processing time

Phase 1 Budget Expected expenses –Materials –Controls Motors Microcontroller –Lighting Expected date for budget approximation –December 6, 2004

Short Term Schedule Experiment (to be completed by December 3 rd ) –Take pictures Different lighting Different transfer methods –Detect defects Implement different sensors Minimize processing time Deliverables (December 17 th ) –Preliminary design of phase 1

Questions