1. PECO Group Internal and External Search Results ME 492 Winter 2008 Students: Jeff Bennet jonathan boschiero Kiehl McIntyre Ryan Ernst Advisor: David Turcic

2. Presentation Break Down Brief Overview of Project and Goals (with Analogy Break) Meet the Insert Identification of Materials Assuring Proper Depth Fine-Tuning the Heating Process Purging When Necessary

3. Brief Overview Project: We will be retrofitting this machine. It’s name is Lola. Lola heats up aluminum and steel inserts then pushes them into indentations in nylon panels. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

4. Brief Overview Goals: We will address the following. No process preventing the wrong insert getting pressed. Nothing assures inserts are pressed deep enough. Heating of inserts is inconsistent. Tube full of inserts is a hassle to empty. Overview AnalogyMeet InsertMaterials IDDepthHeatingPurging

5. Analogy Break: The Zipper of Innovation Great idea! Awesome research! Great idea! Awesome research! Great idea! Awesome research! OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

6. Meet the Inserts. Two Types of Inserts: Aluminum and Stainless Steel Same Size: 2.3 cm tall and 1.8 cm wide Pressed into two different makes of panel. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

7. Identification of Materials Differences in materials we tried to exploit: Mass: Scales or spring-activated trap doors Conductivity: Voltage drop or current Emissivity: Surface property detection Magnetism: Attract or repel the inserts OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

8. Identification of Materials Solution: Our external searching turned up capacitive proximity sensors. There is a range of distances where the sensor will detect stainless steel but not aluminum. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

9. Assuring Proper Depth How to push top of insert into panel relative to panel surface: Contact switches on moving platform Ultrasonic sensors for ram and panel Pressure tap for piston’s air line Linear encoder read by moving laser OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

10. Assuring Proper Depth Solution we settled on: Controlling the position of the surface! We will keep the surface of the panel against a known datum and move the piston relative to that. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

11. Fine-Tuning the Heating Process Our team is still conducting experiments to find the source of the insert temperature inconsistencies. Depending on the results, we will choose a refinement. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

12. Fine-Tuning the Heating Process OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging Solutions we are still considering: Forced Convection in the tube Better insulation of the tube Extending heated section of the tube Monitoring insert temperature

13. Purging When Necessary Design of other components comes first, a system for evacuating the inserts out of the column can be worked around everything else. The rest of the system comes first. OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

14. Purging When Necessary Methods currently in consideration: Better hook and rod device Pez dispenser action Clearing a fall path OverviewAnalogyMeet InsertMaterials IDDepthHeatingPurging

15. Summation Our internal and external research have been tightly meshed. Discoveries of existing technologies have introduced new design concepts. Some phases of the design rely on decisions from previous phases.