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