1. Conceptual Design Review Senior Design 2004-2005 University of Idaho College of Engineering

2. Overview 1.Functional requirements and constraints 2.Material Flow –Remove cartridges from tray –Presentation of cartridges in front of camera –Gage wheel –Put cartridges into 50ct tray 3.Cartridge Inspection –Lighting –Inspection Software 4.Future focus 5.Budget 6.Schedule

3. 1. Functional Requirements and Constraints

4. Minimal change in height desired from 500ct to 50ct tray Minimize risk of incurring incidental and other defects while processing product Cost of x-y positioning systems 2. Material flow considerations

5. 2.1 Remove cartridges from tray Gravity feed from 500ct tray –Freefall acceleration velocities are sufficient for 600parts/min requirement –How do we get them back up higher in elevation? Vertical ascent out of 500ct tray –Vacuum and air blast alternatives considered –Air is readily available –Experimental results

6. Vertical ascent: Air jet and tube array Remove cartridges from 500ct tray –20 tube array, 1-D positioning system –500ct tray gets positioned, tubes are stationary –Varied length tubes, cartridges arrive at different times –Ten cartridges pulsed every 1 second with an air jet array below the tubes

7. Where the tubes end Cartridge queue –Accepts cartridges from feed tube –Advances cartridges to inspection area –Provides better advancement control than gravity feed tube

8. 2.2 Presentation of cartridges in front of camera Dropping Contact Rolling –Single Roller –Multiple Roller

9. Dropping Image: 3 images within one picture Pros –Gravity is consistent and does work for us –Gravity produces proper orientation Cons –Scaling issues, consistency in falling distance –Mirrors in place to give 360 degree view

10. Image: 3 images taken 120 o apart Pros –Consistent image in front of camera –Multiple parts within picture window Cons –3 images taken 120 o apart cause long process time –High transfer rates, rotational and linear Single Roller

12. Multiple Roller Image: 1 unrolled image of entire cartridge Pros –Consistent image in front of camera –Multiple parts within picture window Cons –High transfer rates, rotational and linear –Complex apparatus

13. Multiple Roller

14. 2.3 Gage Wheel Pros –Gages parts for proper diameter –Outputs bad parts to separate bin –Produces timing interval between parts Cons –Limited to one type of defect –Allows minor defective parts to pass

15. 2.4 50-ct Tray Package Machine Existing Prototype to be utilized for project Electromechanical device that can be controlled by camera processor Built for existing tray configuration

16. 3. Cartridge Inspection 3.1 Lighting 1.Front lighting 2.Back lighting 3.Structured lighting

17. Things to Consider Metallic reflective surface Curved shape of case Surface defects on case Measurements of dimensions of entire bullet

18. Applications

19. Front lighting Brightfield illumination Darkfield illumination

20. Front lighting Diffused Front light Omni-directional illumination Shiny Object Reflective surface

21. Back lighting Optical Diffuser

22. Structured lighting

23. Lighting options for material flow

24. 3.2 Inspection Software Three ways to use software to inspect bullets –Intensity –Edges –Shapes

25. Inspection Software Intensity - Use multiple polygons to look for dark areas (flaws) on the cartridge surface. This sensor is looking for the amount of “white space” inside the red box

26. Inspection Software Intensity –Pros Easily detect major defects Checks areas Easily manipulate intensity values –Cons Smaller sensors are better, but more work to make them Hairline fractures can cause problems if intensity settings aren’t sensitive enough

27. Inspection Software Intensity Pass

28. Inspection Software Intensity Fail

29. Inspection Software Edges - Use multiple sensors to look for edges (flaws) inside areas that are white on the cartridge surface. These sensors are looking for edges on the red lines

30. Inspection Software Edges –Pros Easily detect major defects Checks for all edges Easy to make multiple sensors in different places –Cons Smaller sensors are better, but more work to make them Hairline fractures can cause problems if edges are too far apart

31. Inspection Software Edge Pass

32. Inspection Software Edge Fail

33. Inspection Software Shapes - Use a single or multiple sensors to look for “perfect” cartridges or parts of the cartridge. This sensor is looking for the “white” shapes on the cartridge

34. Inspection Software Shapes –Pros Easily detect major defects Checks for all white “blobs” larger than a specified size. –Cons Smaller sensors are better, but more work and more processing time Smaller defects including hairline fractures and small dents are difficult to see

35. Inspection Software Shape Pass

36. Inspection Software Shape Fail

37. 4. Future Focus Based on recent discussion with ATK, focus will be on the inspection process Further testing –Material handling –Lighting Combination of front and back lighting –Software inspection Combination of intensity and edge sensors

38. 4.2 Lighting Combination of front lighting and back lighting –Pro Cheaper Works well with dropping –Cons Hard to adjust Reflection

39. 4.3 Software Combination of intensity and edge sensors –Pros Both sensors work well on different sections of the cartridge Inspects entire cartridge –Cons Multiple sensors Increased processing time

40. 5. Phase 1 Budget Expected expenses –Materials –Controls Motors Microcontroller –Lighting Expected date for budget approximation –December 6, 2004

41. 6. Short Term Schedule Experiment (to be completed by December 3 rd ) –Take pictures Different lighting Different transfer methods –Detect defects Implement different sensors Minimize processing time Deliverables (December 17 th ) –Preliminary design of phase 1

42. Questions