P16680: AATech Universal Oil and Bag System Subsystem Design Review 10/20/15

Team P16680 Philip Couturier - Controls Systems (EE) Samantha Orlando - Systems Design (ME) Jessica Reed - Purchasing (ME) Maria King - Project Lead (ISE) Nicole Anklam - Systems Integration (EE) Bryce Mowers - Manufacturing (ME) 2 P16680

Subsystem Design Review Objectives Explain subsystems in detail Show proof of concept for each subsystem Communicate design changes & test plan Show team progress Review action items for both team & customer Get feedback from customer 3 P16680

Agenda Engineering Requirements Systems Architecture Subsystem Descriptions System Flow Diagram Test Plan Bill of Materials Risk Assessment Project Plan Lessons Learned Q & A Action Item Recap 4 P16680

Engineering Requirements 5 P16680 Emergency stop added per last design review

Systems Architecture 6 P16680

Subsystem 1/6: Chamber & Door 7 P16680 DescriptionDesign ChangesProof of ConceptBOM ● Contain oil mist ● Horizontally sliding door ● Electric door- interlock ● Defined door size ● Added two aluminum bars to hold fixture ● CAD model as prototype ● Door size in order to fit fixture and allow for operators to changeover ● Acrylic Chamber ● Acrylic Door ● Electric Door Interlock ● Door Sliding Track

Subsystem 1/6: Chamber & Door 8 P16680

Subsystem 2/6: Fixture System 9 P16680 DescriptionDesign ChangesProof of ConceptBOM ● Locate nozzle ● Secure nozzle ● Engage pneumatic cylinder ● Seal cylinder to nozzle ● Verified a total of 5 fixtures needed ● Each fixture includes base plate, yoke plate, & cylinder with nylon insert ● Prototype using GE 90 nozzle ● Largest nozzle size used to verify chamber size and fixturing capabilities ● Aluminum billets and sheet ● Base plate ● Brass cylinder ● Nylon insert ● Couplers for pneumatic and oil lines

Subsystem 2/6: Fixture System 10 P16680

Subsystem 3/6: Oil Circulation 11 P16680 DescriptionDesign ChangesProof of ConceptBOM Oil from reservoir to be pumped through nozzles at designated pressure Reservoir below fixtures within enclosure Analysis completed on the following two slides for both the pump and the motor Verification that the motor power is large enough for all pressures Verification that the pump is capable of outputting the necessary pressures for the nozzles ● Pump ● Oil lines ● Reservoir ● Pipe fittings ● Drain ● Motor

Subsystem 3/6: Oil Circulation (cont.) Proof of Concept and Analysis - Motor 12 P16680

Subsystem 3/6: Oil Circulation (cont.) Proof of Concept and Analysis - Pump 13 P16680

14 P16680 Subsystem 4/6: I/O Peripherals DescriptionDesign Changes Proof of ConceptBOM Any component that returns or takes in a form of data ● Barcode Scanner (Symbol LS2208) ● LED ● Sensors (proximity/pump) ● Valve/Regulator ● HMI (PanelView C300) ● Pump Control N/A-Scanner connection matches PLC (RS232) -LED’s universal -Example video has valve/regulator working with PLC - Barcode Scanner - LED(s) - Sensors - Valve/Regulator - HMI

Subsystem 5/6: User Interface 15 P16680 DescriptionDesign ChangesProof of ConceptBOM -Compatible with PLC -Placed in junction box with PLC -No longer combined with PLC, two separate units -No touchscreen, now buttons -Extensive catalog documentation -2711R-K3M -RS232 Cable

Subsystem 6/6: Control System 16 P16680 DescriptionDesign ChangesProof of ConceptBOM -4 Analog Inputs -12 Digital Inputs -Previously combined with HMI, now separate -Example videos -Extensive Catalog - Documentation SME’s -Micro LC20-QBB -Turck Wire Receptacle/Cables -Junction Box

User Interface Flow 17 P16680 ● What the operator will see as well as high level overview of the system

Test Plan ● Pump (ER7) --verify the pressure at different points and specifications ● Pneumatics (ER4) --verify cylinder actuation and verify no bleed-off ● Pressure sensors (ER7)--verify they meet specs ● Fixturing alignment (ER2,ER9,ER10) --verify part fit-up with oil injector ● Cycle time (ER8) --different parts and change-over ● Door lock (ER3 & ER6) --verify that the door will not open during operation ● Noise level (ER1) --verify less than 50dB ● Scanner (ER5) --verify communication with PLC and pulls up correct parameters ● LED and HMI (ER5) --verify the system outputs the correct data at the correct time ● User interface (ER5)--verify intuitive controls ● System Control (All)--verify system runs correct parameters and operates as planned 18 P16680

Bill of Materials 19 P16680 List of Functions BOM

Risk Assessment 20 P16680

Project Plan Gantt Chart through 10/20 Next 3 weeks 21 P16680

Lessons Learned Ask questions when we don’t understand something Seek help from professors with pump experience Need to stay ahead of the academic schedule When prototyping fixtures, have to keep in mind machining process 22 P16680

Questions? 23 P16680

Action Item Recap Software and cables Purchase order Get approval of PLC and HMI Oil requirements Nozzle CAD model 24 P16680