the y design done

8/14/2019 The Y Design Done

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The Y DesignSOLIDWORKS FINAL DESIGN PROJECT

Meng Mary Liu

December 2, 2009

EML2023


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I. INTRODUCTION

The purpose of the project is to design a mechanical device that will

sort a series of three different parts into their respective containers

placed at the end of a conveyor belt. Information on the location and

identity of each part will be provided by a computer vision system

connected to the device. Using a closed-loop motor control circuit to

control the system between the optical encoder, switches, and DC motor

along with a control computer to calculate the device positioning, the

device must successfully sort each part at a sufficient rate contingent on

the speed of the conveyor belt.

The conveyor belt and boxes appear as they would in Figure 1.

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II. DESIGN SPECIFICATIONS

Various requirements and restraints were placed on the device design

by the set-up of the conveyor belt. Each part on the belt will be separated

by at least 18 inches, and the speed of the belt was given at 2.5 inches per

second. As a result, the device must be able to sort at least one part every

7 seconds. The parts will be made of ABS plastic, and the coefficient of

friction between the part and conveyor belt is nominal.

The size and durability of the conveyor also places several restraints

on the sorting device. The designed device may be either free-standing or

attached to the side plates of the conveyor. Excluding the computer

technology and vision system, the entire device must weight no more than

40 pounds. Lastly, any part of the design can extend no more than 12

inches in any direction from the side of the conveyor table due to space

constraints.

The device will be used with a computer vision system that will locate

and identify each part, a close-loop motor control circuit, and a control

computer that will calculate the position of the motor based on the type and

location of the part traveling down the conveyor belt.

No height specifications were given. However, the height of the device

will be such that

the devices efficiency will not be compromised. The cost of materials andwires connecting the computer vision system and control computers to the

device is sought to be minimized.


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III. DESIGN CONCEPTS

Design Concept 1

The first design concept, shown in Figure 2.3, features a device

attached to one side of the conveyor belt via three aluminum rods. The rods

one short, and two longer of equal length, will raise the motor ten inches

above the conveyor belt. A fourth rod of length 6 inches, connected to a

motor attached to the end of the erected horizontal rod, will hang down to

the conveyor belt. This hanging rod will be melded to the revolving slider

(top view in Figure 2.4). The motor acts to revolve the arm, and will revolve

at most 180-degrees from center. The motor will also serve to lift up the rod

when a part initiallyplaced at center needs to

travel down the center

pathway.

When the part,

location and identity

registered by the

computer visual system

approaches the revolving

slider, the motor will spin

the slider, which acts like

a revolving door to push

the part onto the correct

side of the table. The change of angle from center will be pre-determined to

I love my mom! This computer is also the best Ive everseen!


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three options in accordance with the three desired trajectories to each box

at the end of the conveyor belt. Because the design contains for spinning

blades, the optical encoder will not need a switch to signal a change of

direction, as either the counterclockwise or clockwise direction of angular

motion will be chosen. The optical encoder will be pre-programmed

according to the time it takes to revolve to each of the three changes of

angle options, and the computer visual system provides the corresponding

information on location and part type to be sorted. The maximum diameter

of the cross-shaped revolving door was taken to be less than 18 inches, at a

preferred 14 inches, to ensure that the motion of the subsequent part

traveling down the belt would not be interfered with indirectly by the

revolving motion of the blades.

Design Concept 2

The second design concept features two lever arms, each attached

directly to the edges of the conveyor belt stand (Figure 2.5). Two motors

are used at the pivot point of each arm, and each motor corresponds to a

switch placed on the same edge of the belt stand. The distance between

the motor and the switch relates to the length of the lever arm, allowing the

tip of the lever arm to flick the switch when the arm is fully extended

downwards along the table (Figure 2.6). Collision with the switch sends a

signal to the motor to reverse its direction of motion. In addition, an opticalencoder attached on the other side of the each lever arms pivot point will

be preprogrammed to facilitate four angle changes, allowing the lever arm

to be at 90 degrees East of South (taking the origin to be the pivot point in

the plane of the conveyor belt and positive Y-axis along the edge of the

conveyor belt away from the part baskets), 60 degrees East of South, 30

degrees East of South, and 90 degrees South of East (Figure 2.7). If both

arms have this range of motion, then coordination between the computer

visual systems, optical encoder, and switch successfully sorts any

combination of initial part location and desired final part location.

Design Concept 3

The third and final design concept features a Y-shaped funnel device

that is attached to a table via a cross-shaped rod (Figure 2.8). The


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table is fastened to the side plates of the conveyor belt stand and acts to

stabilize the contraption. The cross-shaped rod is connected to the motor

on top and the optical encoder from below. The dimensions of the arms of

the Y funnel are pre-calculated to ensure no interference with the legs of

the table. The motor secured to the top of the table provides angularmotion to the rod, which pivots the funnel clock-wise or counter-clockwise

to aim at the desired part box at the end of the belt. The three desired

angular shifts are shown in Figure 2.9. Two switches are attached on the

side of the table legs tangent to the edge of the conveyor belt. When an

arm of the funnel collides with the switch, it sends a signal to the motor to

reverse direction. The motor will pause once the switch is hit to allow the

part to travel out of the funnel. After the allotted three seconds, the motor

will revolve the funnel back to its original center. A pause of three seconds

takes place between every rotation to allow for the part to travel down the

belt before it is funneled into the desired third of the belt. The placement

of the two switches on the legs of the table demonstrates the efficiency of

the table to provide a grounding apparatus for more than one device.

For all designs, the bottom face of the device is raised at most 0.25

inches away from the conveyor belt to eliminate any opposing forces of

friction.


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IV. SELECTION OF DESIGN APPROACH

Although each of the three design concepts accomplished the endgoal, multiple factors contributed to the final design selection. The third

design concept was ultimately chosen for its relatively superior usability,

simplicity, and performance.

Usability

The third design offered the greatest ease of use and construction to

the supervisor of the task. The design of each part minimized the need for

additional manufactured parts to be used as stands for the motor, the

switches, etc. The primary deflection from the first design concept was

caused by the complexity of the part sorter itselfthe manufacturing of the

cross-shaped revolving door and its sloping blades added unnecessary

intricacy to the design process.

Although the second design concept used merely long shafts of

aluminum as the lever arms, complications surrounding the mounting of the


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nine different combinations of positions of the two lever arms,

notwithstanding its motor-to-motor communication system requires far

more advanced computer technology. The first design also demands a far

more complex motor, causing the success of the performance to be based

upon the sophistication and timeliness of the designs motor rather than theoriginality and cleverness of the design itself.

Table 1 on the next page summarizes the information detailed above.

Table 1: Comparison Matrix of Design Concepts


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Description

Assembly/Manuf.

Range ofmotion

Specialmaterialsneeded

Add.Comments

Four-blade

revolvingdoor sorter

Requiresvertical androtationalmotion

Complex

assembly ofblades torevolving rod

Sophisticatemotor needed

Success basedupon technologyof motor

180 degrees

Only onespecifieddirectionnecessary

Sophisticated

motor*

Stronger metal(larger shearmodulus value)needed forsupporting rods

*Standard

Gearhead/Window DC Motor isinsufficient formulti-planarmotion.

Twooverlapping

lever arms Two pivotcenters

Stand requiredfor levers,

attached directlyto conveyor belttop plate.

Easy lever armmanufacturingprocess (two longAlum T6063-T6shafts)

Two motors

90 degrees

optical

encoderneeded forreversemotion

Four pre-setconfigurations (change ofangles)

Advancedcomputer

technology to synctwo motors

Increasedcomplexity ofwiring from centralcomputer visualsystem to bothpivot arms

*Given computervisual system and

optical encoderinsufficient forlevel ofcomplexityrequired of part-to-partcommunication.

Y-shapedfunnel

w/tableapparatus

All parts arebasic and simple

to manufacture

Cross-shaped rodrequired fortorque (transfer ofmotion)

60 degrees

Reversemotionsignaled byoptimallyplacedswitches

Multipleassemblies

six+ originalparts, all in T6063-T6 Aluminum

*Placement ofoptical encoder

and switchesmaximizes designconcept andingenuity.

DESIGN

CONCE

PT

#1

DESIGN

CONCEPT

#2

DESIGN

CONCEPT

#3


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V. DESIGN DESCRIPTION

The third design concept may be built and assembled in the order

prescribed below. From here onwards, this design concept will be referred

to as the Y Design. All units are in inches, degrees, or seconds. All parts are

to be made from T6063-T6 Aluminum, and all screws except for the set of

screws for the threaded inserts are zinc-plated steel, pan-head Phillips

screws, with McMaster Part Number 90272A151. Reasons for selection

details are given below.

Assembly A

Preliminary analysis of measurements

The main body of the part sorter is shown in Figure 3.1. (Drawing

sheets with full dimensions for all parts are attached in the appendix.) The

distance between the inner faces of the blades making up the funnel is 6

inches. The distance lengthwise of the funnels channel is 12 inches, and

the total vertical distance is 12 + 12cos(30), which is approximately 22.4

inches. Although this

distance surpasses the

minimum distance (18

inches) between parts, the

computer visual system is

set up to trigger the first

oscillation of the motor

when the first part

surpasses the 6-inch mark

measured down from the

beginning of the parallelblades of the funnel. In this

way, the pause of 2.5 seconds pre-programmed into the optical encoder

prior to every range of motion allows the part to move 6.25 inches down the

belt and hence out of the funnel onto the desired pathway of motion. See

Figure 3.2 on the next page for clarification of the first few scenarios of parts

Figure 3.1: The Y funnel primary body of part sorter


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Construction of Assembly A/Construction Analysis

The exploded view of Assembly A is shown in Figure 4.1 to provide a

summary of the first assembly of the two-part assembly series.

The roughly Y-shaped cover of the funnel, along with the funnel itself,

Figure 4.1: Exploded assembly view of Assembly A isometric summary


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is an original manufactured part. With dimensions provided in the drawing

sheets, this cover has a cross-shaped hole with the midpoint of the line

between the inner vertices of the arms as the center. This exploded view

summary will be the basis of the upcoming discussion of Assembly As

components.

Figure 4.2 shows a close-up of the cross-shaped hole and its

corresponding rod and stabilizer. Four screws reflecting the screw

specifications included in the introduction to

this section were used to attach the square

stabilizer to the bottom of the cover.

Evidently, the hole is cross-shaped to provide

resistance and transfer rotational torque ofthe rod to rotational movement of the funnel.

Aluminum T6063-T6 was chosen for its

exceptional strength, high shear modulus

value, and relatively accessible nature as a

building material.

In addition, the optical encoder is

attached also to the underside of the cover

into a threaded hole made on the bottom of

the cross-shaped

rod. Figure 4.3

provides a bottom-

up perspective of the cross-shaped rod, the

cover, the square stabilizer, and the optical

encoder. The

figure reveals a key

hole made on the bottom face of the rod toaccommodate for the discreetly placed optical

encoder. Note that the optical encoder has

approximately a height of 0.45 inches. As a

result, the height of the arms of the funnel was

made to be 1.5 inches to compensate for the

Figure 4.2: Close-up of cross-


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intrusion of the optical encoder piece onto the pathway of the parts.

The cross-shaped hole was dimensioned with a

maximum diameter of 1.50 inches because of aluminums

relatively tensile nature (re: high value of shear modulus).Consequently, a length of 0.5 inches for each arm of the cross was

considered sufficient to supply the torque for the movement of the weight of

the funnel. The height of Assembly A was chosen for its maximum durability

at a minimum cost of material and assembly. Once secured to Assembly B,

the Y funnel is suspended approximately 0.10 inches off of the conveyor belt

to eliminate opposing frictional forces.

Lastly, the motor is attached to the

cross shaped rod directly via a flexible

coupling and a motor output shaft adapter.

Figure 4.4 shows how the motor was

attached to the cross-shaped rod. The

flexible coupling (with two specified

screws) couples the dimensioned rod

protrusion from the cross-shaped body

with the motor output shaft adapter. The

motor is secured to a table-like apparatus,

a.k.a. Assembly B.

ure 4.3: Close-up of optical

coder, screws.

Figure 4.4: Exploded view of

DC Motor to output shaft to

flexible coupling in Assembly


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Assembly B

The Y Design incorporates a table-like apparatus that a) secures the

motor, b) supports the funnel, c) provides an optimum location for two

switches, and d) is attached to the side plates of the conveyor belt stand via

two McMaster screws that are compatible with the McMaster threaded

insert, Part Number 94615A113. Figure 5.1 shows this table apparatus

along with the rest of the components of Assembly B.


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Preliminary analysis of measurements

The height of the table, shown in Figure 5.2 on the next page along

with the motor securing mechanism, was chosen to allow for a 0.1 inch

suspension of the belt by the funnel. The height also took into account the

belt placement inside of the conveyor belt stand, allowing flexibility for the

user to choose where to bolt the device according to their model of the

conveyor belt stand. The width of the table is 1.5 inches because when

attached to the belt stand, the edges of the legs in relation to the arms of

the funnel provide the perfect location for the placement of a switch. The

table is bolted with two threaded inserts (specified McMaster Part No.) on

each table leg on either side of the belt stand approximately 16 inches

Figure 5.1: Table apparatus et al of Assembly B


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away from the back end of the conveyor belt table. The

first bolt is placed one-inch on center from the edge of

the table, and the second one-inch on center from the

end of the leg. Figure 5.3 depicts the locations of the

holes on the table part that corresponds to the threaded

inserts.

Figure 5.2: Height of table off of conveyor belt allows for 0.10 in. suspension of Assembly A


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Further Analysis

Combining Assembly A and Assembly B, the Y Design is complete.

Figure 6 shows an exploded view of the amalgamation. It is important to

remember that the securing part is to be fastened on last, after the

construction of Assembly A and the stabilizing of Assembly B.

Figure 6: Exploded view of Assembly A plus Assembly B, combined to make the Y Design for


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in order to fully capture the entire surface area of the belt, the diverging

arms had to be long enough to reach the edges of the table. The angle

between a diverging arm and its corresponding component that form the

actual funnel of the part would affect how long the arm extends. In the YDesign, the angle is shown to be 150 degrees, which allows measurements

to be made based off of the 30,60,90 right triangle. Accordingly, these

angles signify the angular range of motion for the motor, although it is

unnecessary for the motor to revolve a full 90 degrees.

Item

no.

Part no./name

CAD-MP-****

Description Source Material Qty. X

cost

ea. $

=

Cost

total

1 0001 Y-shaped funnel, part

sorter

Solidworks,

originalmanufacturing

Aluminum

T6063-T6

1 ~35 $35

2 0002 Y funnel cover Solidworks,originalmanufacturing

Aluminum

T6063-T6

1 ~23 $23

3 0003 Cross-shaped rod Solidworks,originalmanufacturing

Aluminum

T6063-T6

1 ~28 $28

4 0004 Square-shaped

stabilizer

Solidworks,

originalmanufacturing

Aluminum

T6063-T6

1 ~10 $10

5 Machine screws

90272A151

Phillips pan-head 3/4"screw

McMaster-Carr Steel, Zinc-plated 14 2.38

/100

$2

6 Motor outputshaft adaptor

Hexagonal shaftadaptor, Hex Shank

Insty-Bit, USA Steel 1 ~5 $5

7 Optical Encoder

600-128-C24

Optical encoder with0.160 vertical mount.

Honeywell Stainless steel,brass, gold-platedterminals

1 38.16 $38

8 Shaft Coupling

2463K401

3/8, 3/8 black set-screw, helical beamshaft coupling

McMaster-Carr Anodizedaluminum

1 25.46 $26

9 DC Motor Right side, 3 Volts, 35RPM

DC Gear Motors 1 19.95 $20

Subtotal: $187


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For Item No. 2, the funnel cover was made at a thickness of 0.25

inches to minimize the material needed without compromising the resistance

needed from the material. The funnel cover,

shown isolated in Figure 7.1, contains the cross-

shaped hole in anticipation of the cross-shapedrod whose rotational torque supplied by the

motor will transfer to the cover and therefore to

the Y-shaped funnel. In

comparison, the cross-

shaped rod, Figure 7.2, is

much thicker. The

cylindrical protrusion from

the top face of the rod is

attached to the flexible

coupling, on which other end is the motor output shaft

adaptor and motor. As such, the materials needed for

the design have been starkly minimized by the

conservative nature of the Y Design. Lastly, the square

stabilizer was dimensioned at a minute 1.5 by 1.5 inch

to correspond with the maximum diameter (1.5 in.) of

the cross-shaped hole. In order to support the weight

of the design, the square-shaped stabilizer and its four screws adds another

level of safety, control, and stability to the design.

Design Y needed only one optical encoder, one flexible coupling, and

one hexagonal shaft adaptor. The optical encoder chosen has a mount of

length 0.160 which is sufficient for the purposes of the cross-shaped rod.

With the standard 128 pulses per channel per revolution, the encoder and its

rotary action is competent to capture the information regarding the total 60

degrees range of motion. Lastly, the DC motor chosen for Assembly A has a

specified 35 revolutions per minute with 4 Volts. Relating the RPM to

approximately 0.58 revolutions per second, the Gearhead DC Motor is

sufficient for the merely 0.167 revolutions per second required of the Y

Design.

Figure 7.2: Cross-

shaped rod part,

Figure 7.1: Funnel cover part,

showing cross-shaped hole.


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Cost of Assembly B

The decisions for Assembly B were made in the same manner. The

following table, Table 3, details the bill of materials for Assembly B.

As stated in the design specifications, the supporting tables

dimensions were crafted to ensure flexibility of placement along the edge of

the conveyor belt stand. At a suggested distance of 16 inches, the

placement of the threaded inserts and corresponding machine screws are

contingent on the belt location inside of the conveyor belt stand. As a result,

the table has a height of 14.75 inches to accommodate for the 7.25 inches

above the perpendicular tangent line to the conveyor belt, and the range of

flexibility allowed by the 7.5 inches below.

Item

no.

Part no./name

CAD-MP-****

Description Source Material Qty. X cost

ea. $

=

Cost

total

10 0005 Supporting tableapparatus

Solidworks,originalmanufacturing

Aluminum

T6063-T6

1 ~25 $25

11 0006 Motor securing part Solidworks,original

manufacturing

Aluminum

T6063-T6

1 ~15 $15

12 Machine screws

90272A151

Phillips pan-head 3/4"screw

McMaster-Carr Steel, Zinc-plated 6 ~2.38

/100

$0

13 Switches

7779K140

Miniature snap-actingswitches, 10 amps, hp @250 VAC, Rollerlever, Force 4.2 oz.,Actuator Height 0.3

McMaster-Carr Plastic 2 6.12 $12

14 Threaded

Inserts

94615A113

Press-Fit knurled,

3/16, length , Plainfinish

McMaster-Carr Brass Alloy 360 4 $10.5

2

/50

$10

15 Machine screws

91772A092

Phillips pan, , 3-48inch thread size, forthreaded inserts

McMaster-Carr 18-8 StainlessSteel

4 $8.13

/100

$8

Subtotal: $70

Table 3: Bill of materials for


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The motor securing part, item no. 11, has an inner height of 1.38

inches, analogous with the height of the motor. For this part, the material

composition was chosen to remain as Aluminum T6063-T6 because of its

relatively high shears modulus value and thus tensile strength. The motor is

fastened between the table and the securing device to prevent sliding alongthe top of the table.

Conclusively, the approximated cost for Assembly A and Assembly B,

which combined forms the Y Design, totals to $257. This price includes both

Solidworks generated parts and McMaster-Carr, Honeywell, and Insty-Bit

manufactured parts.

VII. APPENDICES


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b. Cost of AssemblyB---------------------------------------------------------------------- 21 -22

VII.Appendices------------------------------------------------------------------------------------------- 23 - 33

a. Table ofContents------------------------------------------------------------------------- 23

b. Lists of Tables &Figures----------------------------------------------------------------- 24- 25

c. Solidworks Part DrawingSheets------------------------------------------------------ 26 - 31

d. Solidworks Assembly DrawingSheets----------------------------------------------- 32-33

List of Tables & Figures

TablesPage #

1. Table 1: Comparison matrix of designconcepts--------------------------------------------------- 9

2. Table 2: Bill of Materials for AssemblyA------------------------------------------------------------ 19

3. Table 3: Bill of Materials for AssemblyB------------------------------------------------------------ 21

Figures


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1. Figure 1: Scenario of conveyor belt, parts, andboxes-------------------------------------------- 2

2. Figure 2.1: Design Concept#2-------------------------------------------------------------------------- 5

3. Figure 2.2: Design Concept#3-------------------------------------------------------------------------- 6

4. Figure 2.3: Design Concept #1 Revolving Door, frontview------------------------------------ 4

5. Figure 2.4: Design Concept #1 Revolving Door, topview-------------------------------------- 4

6. Figure 3.1:The Y funnel primary body of partsorter-------------------------------------------10

7. Figure 3.2: Scenario of parts with distance approximationthrough isolated Y

funnel.------------------------------------------------------------------------------- 11

8. Figure 4.1: Exploded assembly view of Assembly A isometric

summary---------------------------------------------------------------------------------------- 12

9. Figure 4.2: Close-up of cross-shapedhole.---------------------------------------------------------- 13

10. Figure 4.3: Close-up of optical encoder,screws.---------------------------------------------------13

11. Figure 4.4: Exploded view of DC Motor to outputshaft to flexible coupling in Assembly

A.------------------------------------------------------------ 14

12. Figure 5.1:Table apparatus et al of AssemblyB----------------------------------------------------15

13. Figure 5.2: Height of table off of conveyor belt

allows for 0.10 in. suspension of AssemblyA--------------------------------------------------------16

14. Figure 5.3: Location of holes corresponding with threadedinserts in stand of conveyor

belt.----------------------------------------------------------------------16


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List of Tables & Figures cont.

15. Figure 5.4: Exploded view of motor securing device ontop of table of Assembly

B.------------------------------------------------------------------------------1716. Figure 5.5: Collision with switch by funnel

arm.----------------------------------------------------17

17. Figure 6: Exploded view of Assembly A plus Assembly B,combined to make the Y Design for sorting

parts.-------------------------------------------------18

18. Figure 7.1: Funnel cover part, showing cross-shapedhole.-------------------------------------20

19. Figure 7.2: Cross-shaped rod part, showing topface.--------------------------------------------20

the y design done

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