WYMAN GORDON ROCHESTER INSTITUTE OF TECHNOLOGY Multi-Disciplinary Senior Design Team Nick Perrotte (ME)Lead Mechanical Engineer John Knight (ME)Project Manager Shimona Gorelick (EE)Lead Electrical Engineer Minhan Zhao (EE)Team Facilitator FORGING LOCATOR

OVERVIEW Background Customer Needs Engineering Specs Assumptions & Constraints System Design Risks Previous Group Progress Looking Ahead

WYMAN-GORDON A Precision Castparts Corporation Company, is a global leader in the manufacturing of titanium, steel and nickel-based forgings primarily for the aerospace, energy, and military markets.  50,000 ton press National Historic Mechanical Landmark

Heated until “red hot,” °F Oil soaked carbon paper is applied to the die to prevent the billet from sticking About 60 seconds of operating time to position forging Operator controls the piece with a fork truck until it is aligned properly Judgment based on operator’s experience FORGING PROCESS

CUSTOMER REQUIREMENTS Problems Current alignment process is conducted visually Experienced workers are approaching their retirement years Cost approximately $1M annually to rework Proper alignment in the die could reduce this figure by 30% ($300,000).

Able to work properly in heavy industry environment (smoky, hot, dirty, etc.) Accurate to ±1 cm Sensor able to detect both cool and very hot metal surfaces The sensors cannot be negatively affected by infrared radiation Display feedback Easy to use CUSTOMER REQUIREMENTS

FUNCTIONAL DECOMPOSITION

CUSTOMER REQUIREMENTS VOICE OF THE CUSTOMER The importance column ratings are as follows: 1: Desirable 3: Important 9: Critical

ENGINEERING METRICS

HOUSE OF QUALITY The importance column ratings are as follows: 1: Desirable 3: Important 9: Critical

Assumptions The system will be in dismal conditions It will be difficult for the workers to look at a display that is mounted away from where they are working The user interface must be simple to use, so a wide variety of people can be trained Constraints Time – the system must receive input and provide feedback almost instantly to ensure that the part is made properly Lack of interaction with the actual Wyman facility, and not knowing exactly what we are working with at this time ASSUMPTIONS & CONSTRAINTS

SYSTEM DIAGRAM

RISK ASSESSMENT

WHAT HAS BEEN DONE Senior Design P12556 Bought 6 lasers from Micro Epsilon (OPTONCDT ILR1181) Built a track for adjustable positioning Built cases for the lasers to be able to withstand the conditions. The cases are made of aluminum and have been drop tested to check for durability Thermal insulation inside the cases allows the lasers to be as close to the process as possible A mirror has been set up so that no lasers will be in the direct path of the fork truck A user interface has been set up and coded in Visual Basic

WHAT WE WANT TO DO Senior Design P13556 Upgrade the mounting devices to ensure stability in the environment Change the hard wired logic to computer programming to make it easier to change in the future Potentially change the programming language from visual basic to LabVIEW or some form or Programmable Logic Controller (PLC) Optimize the setup of the lasers to keep them out of harms way Possibly incorporate an automatic shutter system that closes the laser cases instantly once the ingot is positioned, so that it will not be harmed by any smoke, dust, or water

SHUTTER SYSTEM Current system: Flat, aluminum shutter that has to be manually flipped on each laser Does not have any seal to properly enclose the laser

SHUTTER SYSTEM Proposed system: Servo motors connected to a switch in the control room open and close a hinged shutter A seal, gasket, or o-ring will be inside the shutter to properly seal the laser from the conditions Some negatives to doing this are that it will cost more money (possibly over $500), more design work will have to be done, and we will have to choose the materials wisely The positives – makes the system a lot easier for the operators and will cut down on the time it takes to close the shutters. It will also, be easier for one operator to flip a switch to close all the lasers at once, than risk someone forgetting to close one of the 6 enclosures.

CONTROL OPTIONS

MOUNTING SYSTEM

SCHEDULE

NEXT STEPS Get feedback from the customer on Programming choice Final budget Compile questions for site visit to Wyman Gordon (October 12 th ) Begin detailed design

QUESTIONS ?