1. P11008 ArcWorks Straw Cutting Device May 13, 2011 Ian Balbresky-ME/Pneumatics Lead Tyler Banta-ME/Design Lead Matthew Estock-ISE/Project Manager Mark Vaughn-ME/Fabrication Lead

2. Project Description Mission Statement o Design, build, and deliver a functional straw cutting device which ArcWorks would utilize in their wash bottle assembly production process. Motivation o The current machine used in the production process at ArcWorks is not 100% reliable. With the addition of a more reliable machine, throughput and efficiency can be increased. Background o ArcWorks is a subsidiary of Arc of Monroe that provides jobs to individuals within the developmentally disabled community. This straw cutting device will be used by high functioning operators and will provide another opportunity for them to perform a specialized task.

3. Customer Needs/Engineering Specifications Customer Needs Increase Productivity Safety of Machine Minimize Physical Exertion Reduce Downtime Complete through cut of straws on first actuation with no deformation Straws must lie within desired length tolerance. Minimal debris left in work area Inexpensive replacement parts Utilize cost effective blades. Engineering Specifications Specification (description)Unit of MeasureMarginal ValueIdeal Value Reduce Straw Load TimeSeconds/Straw21 Increase Output of Cut StrawsStraws/Hour7001000 Reduce Cost of Blade$/month$5.00<$5.00 Completely Cut StrawsPercent of Finished Straws90100 Reduce Number of Deformed StrawsBinary95% of Straws Pass Test100% of Straws Pass Test Reduce Time Required to Replace BladeMinutes305 Reduce Time Required to Change Straw Cut LengthMinutes31 Cut Straws to tolerance of ±.02''Quality of Finished Straws1.0 C pk 1.3 C pk Properly Label All Buttons and Switches ClearlyBinary11 Maximum Dimensions allow for fit on specified tableFeet x Feet3x62x3 Comply with OSHA StandardsBinary11 Pass "Extensive Safety Test" for the DevicePercentage90100 Remove Scrap from Cutting AreaBinary11

4. System Architecture Blade Cutting System Pneumatic System Safety System o Two Handed Anti- Tie Down Frame Debris Removal Straw Removal Length Adjustment

5. Final Design Concept Cutting Plate Vacuum Attachment Blade Carriage Trap Door/ Height Adjustment Trap Door/ Height Adjustment

7. Pneumatic System: From Design to Production Three initial designs o Two micro-controlled Single action cylinders Double action cylinders o One fully mechanical/pneumatic Microcontroller/Double action - Chosen initially Professional/professor input resulted in design change o Fully pneumatic/mechanical system o Easier to debug o No programming required o Single power supply (air) rather than two (air and electrical)

8. Pneumatic System: Implemented Design Lid actuated interlock Two-hand anti-tie down (THATD) button actuation Blade cylinder performs stroke (cuts straws) Stop screw actuates trap door system

9. Pneumatic System: Testing Individual part tests o Successful Full system logic tests o Multiple input pressures o Losses from splitters, tube size changes, and length of tube reduce valve actuation pressure Input Pressure (psi)Results 40No actuation 60Slight actuation of blade cylinder 80Actuated completely 95Actuated completely Pressure reduction of blade cylinder to produce slower cuts o Achieved by manipulating exhaust valves o Timing of THATD – shuts off before cylinder completes stroke (when slowed)

10. Production Rate Test Production Rate Straw Holes Straws/ Hr.Cuts/Hr. Cuts/ min Sec/Group CutStraws/Day Days to Fill Box Days to make Safety Current Device10700701.1751.4335001.4314.29 New Device Predicted121000831.3943.2050001.0010.00 New Device Actual Tested1214401202.0030.0072000.696.94 Current + Actual2221401903.1718.95107000.474.67 Assumptions Hours/Day=5 Box= 5,000 Straws Safety Stock=50,000 straws Loading/ Unloading is included Results: The test show that the device is theoretical capable of increasing the throughput of cut straws produced at ArcWorks. This increase in productivity will result in less inventory needing to be stored in the on site warehouse.

11. Performance to Budget Budget which was given = $2,000 Purchases Major Components IncludedCost McMasterFilter Regulator$134.22 Automation DirectCylinders$172.69 McMasterCarriage Components$348.36 MK TechnologiesFrame$150.00 MetalSide Supports$30.00 RoesselPneumatics$549.64 Home DepotCompressed air hose$21.98 McMaster Acrylic and Connectors$65.65 McMaster Height Adjust Components$69.09 Total $1,541.63

12. Project Evaluation SuccessesFailures Designed and manufactured a functional device capable of cutting multiple desired straws. Theoretical production rate increased Number of actuations required by operator reduced Device will not actuate without safety systems engaged Robust/ durable cost effective blade identified Blade changing time minimized/ reduced downtime Ease of use for operator Pneumatic system functional Length of cut straws are within tolerance Debris removal system performs as expected Quality of through cuts unacceptable o Deformation Height Adjustment/ Trap Door System not implemented Manual loading still required

13. High Speed Camera Evaluation A high speed camera was used to view the cutting of the straws in slow motion. These are the results.

14. Recommendations/ Future Work Continued work on height adjustment system Full implementation through further testing Blade testing Determine ideal blade for operation (Possibly thinner blade) Reduce speed of cylinder without sacrificing force generated Pressure was varied to see if acceptable quality of cut at lower psi was possible. Results were negative, future testing should aim to reduce speed but not pressure as previously stated. If two Hand Anti-Tie Down in compromised speed can be adjusted. Manual Loading Device Implementation