ECE 480 Senior Capstone Design Accessible Manufacturing Equipment

ECE 480 Senior Capstone Design Accessible Manufacturing Equipment Phase 2 Team 2 Nicholas Neumann Ralph Prewett Jonathan Brouker Felix Adisaputra Li Tian December 10 th, 2010

Contents § § § § Background Design Specifications Final Design Results and Evaluations Conclusion Future Improvements Demonstration

Background § Basic Purpose of the Project § Former 2008 Machine

Background § Former 2008 Machine (Continued) § PIC Programming • C Code • Timing Loop § Stepper Motors • Parallel Operation (Belt) § Cam Motors § Rotary Cutter § Stationary and Movable Clamps

Background § Major Problems § Programming Interface • No C programmers on staff at location • Difficult Maintenance § Stepper Motors • Inaccuracy • Slow Operation § Motor Drivers • Overheat Issue

Design Specifications § Critical Customer Requirements § Simple Programming Language • Easy Maintenance § High Level of Accuracy • Different Types of Motor § Variable Speed Control • Higher Maximum Speed of Operation

Design Specifications § Secondary Objectives § Visual and Audio Feedback § Reliability and Robustness • Reduce Occurrence of Jamming § Safety • Better Design of Safety Guards § Reduce Noise During Operation § Compact Machine § Aesthetics

Final Design § Mechanical Systems § Pneumatic Guillotine Cutter § Valves Assembly

Final Design § Mechanical Systems (Continued) § Two Capstans Design • Increases the Speed of Operation

Final Design § Mechanical Systems (Continued) § Adjustable Frame

Final Design § Mechanical Systems (Continued) § Tracking Guard

Final Design § Hardware § LEGO NXT Brick as Microcontroller • LCD Screen for Speed Display • Limited I/O Ports § LEGO Servo Motors • High Accuracy • Compatibility § I 2 C Serial Communication Bus • I/O Expander PCF 8574

Final Design § Hardware (Continued) § Input (Buttons) § 8 -Segment LED Display • Length Output

Final Design § Hardware (Continued) § Cutter Relay Control • Power Transistor § LEGO NXT Brick Power Supply • Step-Down Converter Circuit – LM 7809 Voltage Regulator

Final Design § Software § LEGO Mindstorms NXT-G Time

Final Design Accepts User Input. Executes Commands Starts or Stops Cutting Process Contains Cutting Process Drives 8 Segment Displays Length and Speed on NXT Display

Results and Evaluations § Improved Accuracy § 2008: 13. 24% defects § 2010: 1. 46% defects § Reduced Percentage Error § 2008: -12. 99% § 2010: 2. 7%

Results and Evaluations § Enhanced Speed of Operation § For 100 Cycle Run: • 2008: 7 min 49. 7 sec • 2010: 2 min 27 sec § 3. 19 Times Faster

Results and Evaluations § Capstan Feed Design § Removed Drift Factor § Smaller Size of the Machine § 4. 7 Times Smaller in Area § LEGO Servo Motors § Eliminated Overheating Issue § Sources of Error § Susceptible to Ribbon Feed Method • Ribbon at Similar Elevation Improves Accuracy Significantly

Conclusion § Accomplishments § Maintain Simplicity of the Programming • LEGO Mindstorms NXT-G § Better Accuracy and Consistency • LEGO Servo Motors § Variable Speed Controller Implementation • Higher Maximum Speed of Operation

Conclusion § Accomplishments (Continued) § LED Display and Speaker § Reliable and Robust • Tracking Guards Prevent Jamming § Better Safety • Safety Guards § Less Noise § Smaller Size § Aesthetics

Cost Part Guillotine Knife IC LED Driver LED Display 4 digit LED Driver with I 2 C Bus interface Number 1 1 Cost $358. 16 $2. 80 $1. 67 $3. 20 LED driver w/I 2 C 0. 33 u. F Capacitor A Voltage Regulator I 2 C interface 8 bit I/O Expander 1 1 1 2 $1. 54 $0. 83 $0. 70 $3. 32 IC I/O Expander Tubing Valve Filter Regulator Pneumatic Lubricator Male Straight 1/4 NPT*1/4 inch 5 1 1 1 $9. 30 $18. 75 $19. 75 $11. 25 $17. 00 $12. 25 $4. 50 Male Straight 1/8 NPT*1/4 inch 2 $5. 00 Male Elbow 1/8 NPT*1/4 inch Shipping *Lego Mindstorms NXT 2. 0 2 $12. 00 $32. 64 $299. 99 1 *Sponsored by Sponsor Total Cost: $814. 65

Future Improvements Warning Message • Detects Jam Number Pad • Length • Speed • Faster • More Range

Future Improvements § Audio (ISD 1400) § Louder § Adjustable Volume Control A 4 A 5 A 6 A 7 0 0 0 1 1 0 0 1 1 0 0

Demonstration

Questions