1. Guitar Neck Duplicator By Eric Hall

2. Background  Difficult to Replicate  Time Consuming  Generally done by hand

3. What’s Available Expensive ($2,000 – $4,000) Manually Operated

4. Problem The customer wants a more time efficient way to duplicate guitar necks.

5. Requirements  The process must perform high enough quality work so that only sanding is required to finish the product.  It must be able to duplicate a variety of different length necks (about 10"- 18" long).  Wear items must be easy to replace.  It must be autonomous.

6. Solution The device is based on the key maker concept. (The cutting tool follows a path that is dictated by a previously fabricated pattern part.) The key maker is explicitly two dimensional, while the Guitar Neck Duplicator will be three axis (The third being rotational).

7. System Overview PLC

8. Mechanical Concept

9. Traverse Motor Force Calculation F T D Torque =.2 x Diameter(Thread) x Force(axial) 45 LB*Inches =.2(.25 inches) x F F = (45 LB*Inches) / (.2 x.25 inches) F = 900 LB

10. Electrical Concept Overview Programmable Logic Controller Traverse Motor Rotation Motor Router Front Limit Switch Rear Limit Switch Inductive Current Sensor

11. Electrical Failsafe Concept Overview Traverse Motor Front Safety Limit Switch Rear Safety Limit Switch Programmable Logic Controller

12. Software Concept Overview Turned On 0 0 0 Setting 0 2 0 Set 0 0 0 Ready 0 0 0 Start 0 0 1 Traverse Direction 1 X 1 1 Stop Direction 2 +1 0 1 Traverse Direction 2 X 0 1 Stop Direction 1 +1 0 1 Stop 100 0 0 Button == PressedSwitch 1 == PressedButton == ReleasedButton == Pressed Wait == 2 Seconds Button == Pressed Switch 2 == Pressed State 0 0 0 Wait == 1 Sec Switch 1 == Pressed Wait == 1 Sec Stepper == 100% Stepper (0 – 100%) Traverse Motor (0,1,2; stop,fwd,rev) Router (0,1; off,on)

13. Budget DC Gearhead Motor$30.00 Stepper Motor$80.00 Aluminum$50.00 Spring$3.00 Limit Switches (4)Donated from ELT Dept. Programmable Logic Controller$130.00 Relay Module (2)$88.00 Microcontroller$2.00 RouterSupplied by Customer Router Bit$25.00 Misc. Hardware$40.00 Total Cost$423.00

14. Work Breakdown

15. Timeline

16. Resource Management  Have a working agreement with another group  I am gaining machining assistance in return for software and electrical help.

17. Questions