C L I E N T: S P E C I A L I Z E D T R A I N I N G F O R A D U LT R E H A B I L I TAT I O N, I N C. ( S . T. A . R . T. )

C O N TA C T:KAT H Y B A U M A N, E X E C U T I V E D I R E C T O R

T E A M M E M B E R S :B E N B L A I R

L I N D E N E A SO NJ O H N H U G H E Y

J O R D A N JO H N ( P M )FA C U LT Y T E C H N I C A L A DV I S E R S :

D R . FA R H A N G

Cardboard Bumper Assembly Jig

Ref: SEC F11-75-NISH

Outline

Executive Summary – Jordan Subsystem Description

Racking System – Jordan Clamping System – Ben Mechanical Analysis – Ben Sensors – John Logic Control Circuit – John Containment and Ventilation – John Light Emitting Diodes (LED) – Linden Power Supply – Linden

Overview of Device Operation – Ben Responsibilities – Jordan Costs – John and Jordan Time to Build – Ben Potential Improvements – John and Jordan Summary – Linden

Executive Summary

Background Current System Client’s new production needs

Design Challenge History Rules

Project Description

Create a jig to increase production of cardboard bumpers, while also allowing for a wider range of employees to use the device

Features: Low cost to build and maintain Provides mechanical advantage to operator Simple notification system

Diagram of Systems

Carboard Banding System

Electrical System

AC to DC Power Supply

LogicCircuit

Overflow LED

Fill LED

Underfill LED

Fill Sensor

Overflow Sensor

Ventilation

Mechanical System Racking Jig Clamping

Mechanism Taping

Subsystems

Mechanical Racking System Clamping System

Electrical Sensors Indicators Sensor control logic Power Supply Ventilation

Racking System

Clamping System

Two Part SystemoU-Bolt LockoConnective Pin

Mechanical Analysis

User Run 1 (sec) Run 2 (sec)

1 51 44

2 63 55

3 49 58

4 46 53

5 62 50

1 2 30

5

10

15

20

25

30

Series1Series2Series3

Trial

Forc

e A

ppli

ed (

lbs)

Force Analysis Speed Analysis

Max: 25, Min: 11, Avg: 17.22 Max: 63, Min: 44, Avg: 53.1

Sensors

Single unit with LED and phototransistor

Sensor Control Logic Circuit

Gate Level Logic

Containment and Ventilation

Clear acrylic box cut to size Cheap Effective

Running temperature nearly indistinguishable from room temperature while outside the box

Positioned small vent holes on sides and top to allow for moderate airflow

Indicator LEDs

Indicators are RGB LEDs Low cost and long life

Indicators use a well-known pattern

Power

Need the jig to be able to use standard 120 volt alternating current

Components require a 5 volt direct current

Overview of Device Operation

Responsibilities

Ben – Construct and integrate clamping system

Jordan – Construct and integrate racking system

John – Construct sensor controller, calibrate sensors, mount components in the case, attach the case to the jig

Linden – Solder the power supply, attach power supply to the control logic circuit

Cost (Mechanical Subsystems)

Mechanical Subsystems Costs

Part Number Material Unit Price Quantity Total Price

1 Leg $6.81 2 $13.62

2 Leg Separator $1.64 1 $1.64

3 Base Plate Arm Long $3.50 1 $3.50

4 Base Plate Arm Short $1.75 1 $1.75

5 End Plate Arm $2.38 2 $4.76

6 End Plate $1.68 1 $1.68

7 Fall Arm $2.13 1 $2.13

8 Electrical Housing Under Plate $0.60 1 $0.60

9 Electrical Housing $4.29 1 $4.29

10 Hinge Assembly $2.49 1 $2.49

11 Hinge Plates   2  

12 Hinge Pin   1  

13 Base Plate $1.68 1 $1.68

14 Moving Plate $1.68 1 $1.68

15 Connective Pin $0.79 1 $0.79

16 U-Bolt $1.12 1 $1.12

17 U-Bolt Attachments $0.83 2 $1.66

18 ANSI B18.6.3-NO 6-32-1 1/4 Bolt $0.43 2 $0.86

19 ANSI B18.6.3-5/16-18-1 3/4 Bolt $0.52 1 $0.52

Total $44.77

Cost (Electrical Subsytems)

Part Number Material Unit Price Quantity Total Price

1 Optical Detector/Phototransistor $1.13 2 $2.26

2 Breadboard Power Supply 5V/3.3V $9.95 1 $9.95

6 Multicolor RGB LED w/ White Diffused Lens $1.75 3 $5.25

8 LM311N High Performance Voltage Comparator $7.46 2 $14.92

12 Rosin Core Solder $7.49 1 $7.49

13 AC Adapter 9V 1.5A $29.99 1 $29.99

14 L Adaptaplug $6.99 1 $6.99

15 Solder Iron $5.47 1 $5.47

16 PCB Standoff $1.99 1 $1.99

17 Universal PC Board $3.19 1 $3.19

18 De-soldering Braid $4.19 1 $4.19

Total $91.69

Time Required to Build Prototype

Step of Construction Hrs.

Machining base components 0.5

Welding base components 0.75

Machining jig components 2

Welding Jig components 2

Welding base to jig 0.5

Installing Latch system 0.5

Installing pin system 0.25

Mounting electrical components to circuit board 2

Soldering Components to Circuit Board 5

Preparing Container for Electrical Components 2

Mounting and Aligning Sensors 0.5

Mounting and Aligning LEDs 0.5

Total Time to Construct 16.5

Potential Improvements

Mechanical Improvements Adjustable Base Machined Parts Width Adjustment for Feed Slot

Electrical Improvements Adjustable sensor mounting Better Case

Summary

Electronic jig

Clamping system

User friendly

Cheap to build and maintain

Small improvements can be made

Contest Video

http://www.youtube.com/watch?v=Firs8vAgFOw