1. Airbag Automaton John Bailey Hattie Hiatt Chun Hau Low Jason Harwood Wayne Gallup Jason Canaday

2. Presentation Outline  Problem Definition  Customer Needs Summary  Project Breakdown  ME Subteam Designs  ECE Subteam Designs  How They Fit Together  Deliverables  Budget  Work Plan

3. Problem Definition Problem Statement  Autoliv uses a variety of machines to fold and package their airbag. These machines take up space, capital, and require a new machine design for each new folding process.

4. Project Breakdown Customer Needs Customer Needs Plug and play machine that supports airbag folding processes 1) SMED tool interface 2) Move interface and tooling 3) Central Hub that supports all operations of folding process

5. Tool Interface Concepts  Decision Criteria  Ease of use  In-house manufacturability  Cheaper alternative to existing robotic interfaces  Important Design Aspects  Auto connect/disconnect pneumatic connection  Rocking docking  Lock down mechanism Design Inspiration Top to Bottom: Switch Step in Snowboard Bindings Walther Tool Master Robotic Tool Changer Techno-Sommer Robotic Tool Changer Robotic Accessories Robotic Tool Changer Applied Robotics in Use at Autoliv

6. Tool Interface Concepts  Functional Requirements Docks tool to machine  User Locks/Unlocks tool manually  Hands-free connection of utilities  Senses secure connection  Design Criteria  Usability  Cost  SMED  Two Step Connection Procedure  Put on  Lock in

7. Slider Support Concept  Alternatives for Slider Support  Roller/Ball Bearings  Dovetail ways  Triangular ways  Closed cylindrical bushings Slider support using open cylindrical bushings on precision ground shafts

8. Hub Concept Conceptual Design -Actuator attached to 12 O’clock arm -Pivot connection depends on arm design -Tilt connection mounted to Bobcat (base)

9. ME Budget ItemCost Linear Guides Linear Bushings 200 Precision Shafts 500 Aluminum for brackets 50 Tool Interface Manufacturing Materials 150 Power/Data/Pneumatic Connections (Male/Female) 500 Stainless Steel Rods 50 Hub Pivot bushings 150 Steel for Pivot Axles 50 Various Fasteners 150 TOTAL COST $1800

10. Tool Positioning System Requirements: Control position of tool within 1/8 th inch resolution Move tool to minimize cycle time but stay within hardware specifications

11. Drive Position Sensor Controllers Hardware Components

12. Drive StepperDC servoAC servo CompanyOriental Motors Mavilor Kollmorgen Model #AS911AA MSS-6MT306B1 Continuous stall Torque N/A 1.83 Nm 3.32 Nm Max Holding torque 4.0 Nm N/A Peak TorqueN/A11 Nm 11.3 Nm Max speed3000 RPM 6000 RPM 4000 RPM Rated current6.5 A10.7 A5.35 A Rated voltage100-115 VAC single phase 67.8 VDC 230 VAC single phase Rotor inertia0.000271 kg- m 2.00040 kg- m 2.000111 kg- m 2 Motor weight6.6 lb12.79 lb8.4 lb Frame size3.35 in 3.54 in Cost$1,180.00 $1,116.00$930.00

13. Position Sensor Requirements: Minimum velocity of 15 in/s (0.4 m/s) Maximum 1/8 th inch (3 mm) resolution Measurement range of 600mm Sensor Options

14. Controller Currently researching: -Programmable Logic Controller -Microcontrollers

15. Tool Controller Controls tool movements Tool identification Computer requests tool ID or Tool sends ID at interface connect

16. ECE Budget Drive$1200 Motor$1000 Controllers$150 Position Sensor$500 Cables$300 Other Discrete Electronics$100___ Total$3250

17. Putting it all Together

18. Team Design Deliverables  SMED tool interface  Single arm assembly  Hub System  Accommodates 3 arms, Linak tilt system and routes utility cables  Tool identification system  Proof Of Concept tool recognition and automatic program download  Tool positioning control

19. Team Documentation Deliverables  Complete set of engineering drawings of custom parts and product information for manufactured parts  Repeatability testing  Failure and Fatigue analysis with predicted machine lifetime  Electrical circuit diagrams control models

20. AIRBAG AUTOMATON Design Schedule

21. AIRBAG AUTOMATON Overall Budget ME Budget $1800 ECE Budget $3250 Miscellaneous Costs $400 Total Cost $5450