Final Presentation Procter & Gamble: Gillette, South Boston

Summer 2014 Internship

Hannah Neitzke Automation & Packaging Equipment Engineering

Manager: Keith Swenson

2

Personal Background Hometown: Sugarland, TX

Education: Louisiana State University:

BSME, May 2015

Interests: Soccer, College Football,

Engineering, Mountain Biking, The

Outdoors, Good Country Music

Sugarland

LSU

“Goal Diggers”

Summer Projects •Set-up Gauges

•ASAM/JSAM

•Blade Break & Transfer Station

•Jump-start for next project

•Automated Carrier Reference Station

•FCAM Chassis

•What is it?

•Measures variation in the location

of dowel pins on Precision Link

Carrier

•Purpose: ensures accurate assembly of

product takes place

•Digital Value Chain

•Will allow for instant update of

information throughout the company

ASAM Gauge

20%

Carrier

Reference

Station

70%

DVC

10%

Project Breakdown

Project #1:

Set-up Gauges Blade Break & Transfer Station

ASAM/JSAM

Blade Break & Transfer Process

Nest Indexes under tooling

Vacuum Head clamps the blade

Nest tooling pivots and snaps blade

Vacuum Head transfers blade and places in housing on

nest

Nest indexes to next station

Nest for Blade Break & Transfer Station Blade Break & Transfer Station

on ASAM/JSAM

Main Objective: Snaps the blade and transfer to housing

Purpose of Set-up Gauge

•Locates vacuum head to correct

location of blade

•Ensures breaking of blade

will take place

•Ensures accurate placement

of blade in housing

Gauge Requirements

Reference surface

Nest

Vacuum

Head .05 mm

Current Gauge Set-Up

Remove Nest from station

Remove pivoting components from nest

Attach gauge to nest

Return nest to station force suction piece flush against gauge. Ensure stopper block is flush with tooling

1 • Remove Nest from station

2 • Remove pivoting components from nest

3 • Attach gauge to nest

4 • Return nest to station. Move vacuum head

attached to tooling flush against gauge

5

• Measure distance between indexing piece and stopper block with gauge blocks. Add spacer block to fill the gap

1

2 3

4

5

Opportunity Area:

•Increase set-up Accuracy

Gauge Concepts

DESIGN 1 •Attaches to top of nest

•Suction piece fits in slot

•Minus-minus tolerance of

suction piece

DESIGN 2 •“Mock Nest” Design

•Easier Set-up

•Minus-minus tolerance of

suction piece

DESIGN 3 •Replaces suction piece

•H7 fit slot fits over

accurately machined

carbide

•Least tolerance stack-up

Additional Concepts Sketched

Final Gauge Design

Set-up Procedure

Carbide

1 • Replace vacuum head

with gauge

2 • Locate slot of gauge

over carbide on nest

3

• Measure gap between indexing piece and stopper block with gauge blocks. Fill with spacer block

Finished Product

Multiple Design Reviews

Familiarity with NX Package

Tolerance stack ups

GD&T

Manufacturing Exposure

CNC Machining

Metrology

New working gauge for value stream

Results

Prototype gauge- Al 6061

Final Gauge- Hardened A2 Steel

Project #2:

Automated Carrier

Reference Station

Automated Carrier Reference

Station

•Goal: Design automated carrier reference station for FCAM

chassis

•Manual process already in place

•Measures vertical and horizontal variation in dowel pins before

nests are set up

•Location is important to ensure accurate assembly of product

Current Process

Current Carrier Reference Station Design

1 • Set up Carrier Reference Station

2 • Apply pre-load to sensor

3 • Manually push indicating tooling forward until

locating pin

4 • Record Measurement

5 • Manually hand wheel chassis to next pin

6 • Repeat process for 101 carriers

Concept Development

Laser

Camera

Mechanically Driven

Servo or Camshaft Driven

Concept Development for Driving

Mechanism Concept 1 Cam

Concept 2 Linear Servo

Concept 3 Curved Rail

driven by

Cam or

Linear Servo

Concept 4 Crank

Mechanism

DESIGN #4

Final Design

Sequence of Operation

1 • Register servo motor with

gage pin and reference block

2 • Chassis indexes, stops at

carrier reference station

3 • Indicator actuates forward

and cams over the pin

4 • Crank and Chassis are both in

dwell

5 • Plunger is actuated back,

reading is transferred to PLC

6 • Indicating piece is actuated

back by crank

7 • Indicator dwells as chassis

moves to next position

Measurements

Horizontal Measurement Vertical Measurement

Custom

Components

Commercial

Components

Selecting an Indicator

Requirements:

•Data Output

• ≥.001 mm resolution

•Digital

•Plunger Design

Final Design: Simulation

Timing Diagram

0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0.8

0.9

1

0 20 40 60 80 100 120 140 160 180 200 220 240 260 280 300 320 340 360

s

θ deg

Position vs. Time Diagram (1 cycle)

Chassis

Tooling

Low Dwell

High Dwell

Kinematics & Dynamics of System

1 • Motion Profile of

Servo

2 • Sizing the Servo

Motion Profile of Servo

1. Select Motion Profile for End

of Arm Tooling

2. Calculate SVAJ curves for

End of Arm Tooling

3. Calculate relationship between

crank angle and machine

angle (servo map)

1

Motion Profile of Servo

STEP 1: Select Motion Profile of End

Piece

•Motion profile for end piece is more logical

solution

1

0

5

10

15

20

25

0 0.5 1 1.5 2 2.5

Po

siti

on

(m

m)

CamShaft Angle, θ

Position vs. Angle

S

β1

0

5

10

15

20

0 0.5 1 1.5 2 2.5

Ve

loci

ty (

mm

/rad

)

CamShaft Angle, θ

Velocity vs. Angle

Velocity vs.Time

β1

-30

-20

-10

0

10

20

30

0 1 2 3

Acc

ele

rati

on

(m

m/r

ad^2

)

CamShaft Angle, θ

Acceleration vs. Angle

Acceleration vs.Angle

β1

Motion Profile of Servo

STEP 2: Calculate SVAJ curves of end piece

1

1

-5

0

5

10

15

20

25

0 50 100 150 200 250 300 350 400

Stro

ke

Machine Angle

Motion of End Piece

Motion Profile of Servo

STEP 2 (continued): Calculate SVAJ curves of end piece

1

Motion Profile of Servo

STEP 3: Solve for position of crank with respect to machine angle

How does θ2 change

with respect to θ?

Need θ2(θ)

1

Motion Profile of Servo

STEP 3 (continued): Solve for position of crank with respect to machine angle

1

Motion Profile of Servo (Analytical

Method)

Implicit Equation

STEP 3 (continued): Solve for position of crank with respect to machine angle

1

Motion Profile of Servo (Analytical

Method)

Solution of Implicit Equation:

STEP 3 (continued): Solve for position of crank with respect to machine angle

1

Motion Profile of Servo (Geometric

Method)

STEP 3 (continued): Solve for position of crank with respect to machine angle

1

Motion Profile of Servo (Geometric

Method)

-50

0

50

100

150

200

250

300

350

400

0 50 100 150 200 250 300 350 400

Cra

nk

An

gle

, θ

2 (

de

gre

es)

Machine Angle, θ (degrees)

Crank Angle vs. Machine Angle (Motion Profile)

STEP 3 (continued): Solve for position of crank with respect to machine angle

1

Sizing Servo Motor 2

1. Solve for angular velocities

using instantaneous center

method

2. Solve for angular

acceleration using

acceleration diagram

3. Solve for torque: (T=Iα)

Sizing Servo Motor STEP 1: Solve for ω’s using instaneous centers of system

2

•(12-23) is know:

crank radius

•Distance (13-34)

and (13-23) are

changing with time

Sizing Servo Motor STEP 1 (continued): Solve for ω’s using instaneous centers of system

0

100

200

300

400

500

600

700

800

900

1000

1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.1

Y (

mm

)

θ2 (radiians)

Y vs. Crank Angle (rise)

2

13

34`

Y

z θ2

Sizing Servo Motor STEP 1 (continued): Solve for ω’s using instaneous centers of system

0

100

200

300

400

500

600

700

800

900

1000

0.5 1 1.5 2 2.5 3 3.5

h (

mm

)

θ2 (radians)

h vs. theta2

23

13

12

2

13

23 θ2

z

Sizing Servo Motor

0

1

2

3

4

5

6

7

8

9

1 1.2 1.4 1.6 1.8 2 2.2

om

ega

3 (

rad

/se

c)

theta (machine angle)

Omega3 vs. Theta

0

20

40

60

80

100

120

1 1.5 2 2.5

om

ega

2 (

rad

/se

c)

theta(machine angle)

Omega2 vs. Theta

Results for ω2 and ω3 using instaneous centers of system

2

STEP 1 (continued): Solve for ω’s using instaneous centers of system

Sizing Servo Motor STEP 2: Solve for angular acceleration using acceleration diagram.

Repeat for multiple iterations. Draw to scale

2

Sizing Servo Motor

STEP 3: Solve for torque

T=Iα •Inertia calculated from lumped parameter method

•Check following: •Peak Torque ˂ Max Torque

•RMS Torque ˂ Continuous Running Torque

•Driven Inertia ˂ 10*(Driver Inertia)

2

Overall Results of Carrier Reference

Project

Automated system

Quicker Process

Data output

First servo-driven carrier reference station

Wealth of Knowledge

Key Summer Takeaways Collaborative Relationships

Machine Design Experience

Learned from Talented Engineers

Exposure to NX (Modeling, Drawing, Simulations)

Practical application of Kinematics, Dynamics & Machine Design subjects from

school

Welding Lesson

CNC Machining Experience

A&M Machine Shop Tour (Increased Machining Knowledge)

GD&T

Tolerance stack-ups

Opportunities to travel New England

Metrology

New network of friends in Boston

Key Partners

•Keith Swenson

•Chris Zannella

•Loren Gjata

•Dave Morris

•Tim Sweet

•Ken Belliveau

•Arthur Borgeson

THANK YOU!

Questions?