Wyman Gordon Forging Locator Johnathan Knight – Team Manager

Min Han Zhao – Team Facilitator

Shimona Gorelick – Lead Electrical Engineer

Nick Perrotte – Lead Mechanical Engineer 1

Overview

• Project Background

• Detailed Design Output

• Bill of Materials

• Drawings

• Schematics

• Risk Assessment

• Customer Needs and Test Plans

• Feasibility Analysis

• MSDII Schedule

2

Background Info - Customer

3

A Precision Castparts Corporation Company, is a global leader in the manufacturing of titanium, steel and nickel-based forgings primarily for the aerospace, energy, and military markets.

50,000 ton press National Historic Mechanical Landmark

Background – Customer Process & Justification

4

Current Process

• Mult heated until “red hot,” 1700-2100°F

• Oil soaked carbon paper is applied to the die to prevent the mult from sticking

• About 60 seconds of operating time to position forging

• Operator controls the piece with a fork truck and other simple tools until it is aligned properly

• Final alignment is based on operator judgment

Project Justification

• Current alignment process is conducted visually

• Experienced workers are approaching their retirement years

• Cost approximately $1M annually to rework

• Proper alignment in the die could reduce this figure by 30% ($300,000).

Engineering Metrics

5

Previously Designed System

6

Senior Design P12556 • Bought 6 lasers from Micro Epsilon (OPTONCDT ILR1181) • Built a track for adjustable positioning • Built cases for the lasers to be able to withstand the conditions.

• The cases are made of aluminum and have been drop tested to check for durability

• Thermal insulation inside the cases allows the lasers to be as close to the process as possible

• A mirror has been set up so that no lasers will be in the direct path of the fork truck

• A user interface has been set up and coded in Visual Basic

System Layout

7

How the System Works

8

How the System Works

• Distances “A” and “C” are known from the mechanical locating bars placed against the machine edges of the die

• Distances “B” and “D” are measured between lasers on Tracks 1 and 3 and Tracks 2 and 4, respectively, during calibration

• Distances “G1/2” and “H1/2” are then calculated when the mult is placed into the die

• Because the distances between the true edges of the die and the centerline of die on Tracks 1 and 2 are known, the size of the mult, and therefore the centerline of the mult can be calculated and compared to the centerline of the die

• Rotation is known by distances “G1/2”: When 1 and 2 equal each other, the part is parallel to the edge of the die 9

How the System Works

10

Ideal

Upgrades • Overview of the following slides

• Laser aperture enclosure

• Protect the laser from any outside debris during the forging process

• Replace manual shutter system that would involve added steps to the forging process

• Die locating bars

• Give a known distance from the laser to the die to replace the need for two calibrating lasers; in turn, one of the lasers can be used for rotational measurements

• Display box

• Add rotational indicators, input connectors, and a mounting mechanism

• Microcontroller interface

• Replace pure hardware logic with microcontroller processing to allow flexibility for different parts and to optimize the speed of the system

• Magnet mounting

• Improve the strength of the magnets with the capability to be turned on and off when needed

11

Bill of Materials - Electrical

12

System Sub System Part Description Vendor Unit PriceQty.

OrderedTotal Cost

Input Power DC Power Adapter - 9V or 12V Digi-Key $18.60 1 $18.60

Connector on board Digi-Key $1.67 1 $1.67

Voltage Regulation Voltage Linear Regulator LDO Digi-Key $0.66 7 $4.62

Laser Inputs RS232 input Digi-Key $3.90 6 $23.40

Mux Digi-Key $0.26 4 $1.04

Demux Digi-Key $0.26 4 $1.04

Output to LED Power transistor Digi-Key $0.88 7 $6.16

LED Lightbulb Home Depot $10.97 7 $76.79

Red Film Ebay $23.00 1 $23.00

Green Film Ebay $23.00 1 $23.00

Directional Cover - Black stock paper Paper and More $18.99 1 $18.99

Microcontroller TI MSP430 TI $26.00 1 $26.00

Oscillator Clock Digi-Key $3.90 2 $7.80

Op-Amp Digi-Key $0.51 4 $2.04

JTAG Cable Digi-Key $63.75 1 $63.75

Board 2-layer PCB ExpressPCB $335.00 1 $335.00

General Resistors Digi-Key $0.10 50 $5.00

Capacitors Digi-Key $0.10 50 $5.00

Diodes Digi-Key $0.46 50 $23.00

Cabling/Connectors 20 ft DB9 M/F Black Box $17.99 1 $17.99

DB9 to USB US Converters $34.95 1 $34.95

DB9 Bulkhead mount Digi-Key $4.23 8 $33.84

$752.69

Ele

ctri

cal

Electrical Total

Bill of Materials - Mechanical

13

Laser Glass Windows CAD name 'GlassEnclosure1' 3/8" x 3" DIA. McMaster $55.45 1 $55.45

CAD name 'Glassenclosureback' 5/8" x 1' x 3' McMaster $120.12 1 $120.12

O-Rings 3/32" thick OD 2" SAE 133 QTY. 50 McMaster $9.03 50 $9.03

Actual Glass 1/8" x 2" DIA Heat Resistant Silica Glass McMaster $34.08 6 $204.48

18-8 SS Blind Rivet with 18-8 SS Mandrel Domed, 3/16" Dia, .251"-.375" Material Thickness McMaster $13.00 50 $13.00

Alignment Feature Mechanical Locating Bars 3/8" x 1' x 3' 6061 McMaster $72.41 1 $72.41

Magnet Mounts: Multipurpose Aluminum (Alloy 6061) .125" Thick, 24" X 24" McMaster $76.28 1 $76.28

18-8 SS Button Head Socket Cap Screw 5-40 Thread, 1/2" Length McMaster $3.19 50 $3.19

Easy on-Off Encased Neodymium Magnet 95 lbs Breakaway Force McMaster $37.14 9 $334.26

Adjustable Laser Mount Aluminum Metric T-Slotted Framing System Four-Slot Single, 45 mm Hollow Extrusion (4 ft.) McMaster $25.80 1 $25.80

Aluminum Metric T-Slotted Framing System 90 Degree Brace, Single, 2-Hole, for 45 mm ExtrusionMcMaster $8.28 4 $33.12

Type 304 SS End-Feed Fastener, for 45 mm Aluminum Metric T-Slotted Framing System McMaster $5.25 6 $31.50

Minitek Slide LWN 32 X 45 - 45 McMaster $115.00 2 $230.00

3" x 3" rectangle, 1/4" thick Clear Glass with Satin Pencil Polished edgesHooker Glass,

Mirror & Beveling $4.29 3 $12.87

Display AmazonBasics 60-Inch Lightweight Tripod with Bag Amazon $20.75 1 $20.75

18-8 SS Button Head Socket Cap Screw 10-32 Thread, 1" Length McMaster $6.41 50 $6.41

Back Bracket: Multipurpose Oversize Aluminum (Alloy 6061) 1/4" Thick, 18" X 18" McMaster $86.57 1 $86.57

Tripod Mount: Multipurpose Aluminum (Alloy 6061) 5/8" Thick, 2" Width, 1' Length McMaster $14.34 1 $14.34

Display Light Baffles: Multipurpose Aluminum (Alloy 6061) .032" Thick, 12" X 24" McMaster $17.98 1 $17.98

3M Adhesive Duo-Pak Cartridge DP-100, 1.7 Ounce (50 Milliliter), Clear McMaster $17.11 1 $17.11

Water jet cutting for Display Front and Back Bracket (per hour) RIT $95.00 - $285.00

$1,669.67

Me

chan

ical

Mechanical Total

Bill of Materials - Total

14

Site Visits 2 Site Visits $500.00 2 $1,000.00

$2,422.36

$1,000.00

$100.00

$199.84

$121.12

$3,843.32

Overal Total For Parts

Shipping (est.)

Tax (8.025%) (Minus Site Visits)

Tota

ls

5% Contingency

Final Total

Site Visits

Specific details for each upgrade will be addressed in upcoming slides

Mechanical Calibration

• Currently, two lasers are used to locate the forging die and create a datum to compare to the position of the mult

• By using mechanical calibration, we can eliminate the need for 2 of the lasers, and use them in other applications (proposed layout shown below).

15

Mechanical Calibration

• Mechanical Calibration will be done with Locating bars that attach to the rails being used with bolts.

16

Mechanical Calibration

• Mounting Bracket

17

Mechanical Calibration

• Locating Bar

18

Programming Choice

Programmable Logic Controllers

• After consulting the PLC expert on campus, it was determined that the PLC was no longer the best approach functionally or fiscally

19

Part Description Manufacturer Price

8-channel analog input module for DL05/06 PLCs, range: 4-20 mA current output at 16-bit resolution Koyo $134.00

8-channel analog output module for DL05/06 PLCs, range: 0-10V voltage output at 16-bit resolution Koyo $186.00

DL06 PLC Units Koyo $251.00

DirectSOFT5 PLC Programming Software Koyo $395.00

6 IN. TOUCH PANEL GRAYSCALE, STN, ETHERNET & USB, SUPPORTS COMPACT FLASH Koyo $540.00

C-MORE TOUCH PANEL PROGRAMMING SOFTWARE Koyo $129.00

Sub Total $1,635.00

Tax 8.25%

Shipping $0.00

Total $1,769.89

Programming Choice

Microcontrollers

• System Requirements:

• Serial input capabilities (USART)

• 7 outputs for LEDs (N, S, E, W, CW, CCW, and Go Ahead)

• 3 outputs for multiplexer control signals

• 5 laser serial inputs & computer serial input is multiplexed to the microcontroller

20

Coding Logic

• Initialize Micro-Controller (MSP430)

• Initialize Setup

• Send laser configuration from computer to laser

• Continuous measurement

• Calibration Routine

• Get distance between lasers

• Laser distance from machined edge

• Ideal part dimensions at measured locations

• Tolerance acceptability for each axis

• Distance Tracking

• Increment mux control signals to poll distance values

• If part is misaligned, turn appropriate LED on (N, S, E, W, CW, CCW)

21

Schematic

22

Printed Circuit Board

• 3x3.5 inches

23

MSP430F123

• Low-power, 16-bit RISC mixed signal processor.

• 11 General Purpose Input/Outputs (GPIO)

• 1 USART input

• Bigger package to allow for cheaper PCB

• However, bigger package calls for bigger PCB.

24

Display Lighting

• The front of the display will have additional water-jet cut outs to display rotation feedback to the operator

25

Display Mounting

• Back mount screws into existing #10-32 holes in the back of the display box

26

Display Mounting

• Back mount then screws into and adaptor block that’s has a ¼-20 tapped hole to mount it to a standard tripod.

27

Display Mounting

28

Laser Protection

• The previous design had no way of protecting the laser from the conditions during the process, this could pose a big problem to the expensive system so we are going to incorporate high temperature glass to protect the laser

29

Aperture Enclosure

Glass Enclosure

Laser Protection

• Aperture Cover

30

Laser Protection

• Glass Enclosure

31

Magnet Attachment/Strength

• Magnets are there only to prevent accidental movement of the rails

• Magnet bracket screws to on/off magnet from McMaster-Carr

• #5 screws have a 70,000 psi tensile strength

• 𝜎 =𝐹

𝜋∗𝑟2 → 70,000𝑝𝑠𝑖 =𝐹

𝜋∗(0.0952

2)2

• 𝐹 = 498.27 𝑙𝑏𝑓 which is well below any expected load

• L-shape then attaches to rail

32

Magnet Attachment/Strength

33

Risk Assessment

34

ID Risk Item Effect Cause Importance Action to Minimize Risk

1 Fai lure due to temperature System Fai lure High Temp Bi l lets 4 Enclose sensors/cool ing

2 Fai lure due to interference Distorted/no reading Smoke/Workers/Dirt 6 Location/Fi l ter/Screen

3 Fai lure due to human Interaction Cut Cords/Plugs removed/knocked outsensors Forkl i fts/Human error 4 Isolation/ hide cords

4 Programming Errors System Errors/Incorrect data Human Error 2 Reviewing/Testing code

5 Mechanica l Fa i lure of mounting Distorted/no reading Poor Des ign/Analys is 2 Good Des ign/Operation Manual

6 Team Cooperation Delay of Progress Disagreement/Laziness 2 Show Cons ideration/ Address Issues Immediately

7 Exposure to Water Damage to Electrica l Equipment Poor Seal ing of Hous ing 6 Des ign Hous ing to be Water Res is tant

8 Going over budget Project to expens ive to construct/test Expens ive components 2 Price components/Find cheaper a l ternatives

9 Not meeting customer needs Customer dissatis faction Poor communication 4 Site vis i ts/customer contact

10 Time Management Delay of Progress/Lead to incomplete Porject Not Arrange the tasks properly 6 Always look out degree of completion of tasks

11 Miscommunication with group Confus ion and des igns do not mesh Poor communication 1 Double check that a l l portions are understood

12 Interface to di fficul t for user User never uses Adding unneccessary compl ications 1 Keep des ign s imple and understandable

13 Miscommunication with customer Incorrectly des ign system Poor communication 4 Double check when communicating

14 Incomplete Information from customer Incorrectly des ign system Not foreseeing use of information 3 Keep in constant contact with customer

15 Teamate does not complete tasks Des ign fa l l s behind schedule Lack of effort/Busy Schedule 2 Constant updates given on s tatus of tasks

16 Equipment not deployable at location System cannot function Poor research at faci l i ty 4 Site vis i ts/customer contact

17 Feedback is not perceivable Operators do not know i f part placed right Bad location/display type 3 Ensure operators can see/understand

18 Tolerances not met System does not give des irable results Poor technology choice 4 Research measurement tolerances

20 Teamates do not arrive prepared Des ign fa l l s behind schedule Too much work/ busy/laziness 3 Ass ign correct amounts of work/work around schedules

21 Componenets do not interface System wi l l fa i l Poor component selection 6 Research correctly the requirements to interface

22 loss of team member Tasks left to individual do not get completed Injury/Emergency 3 Prepare to spl i t extra work amoungst group

23 Purchased sensor does not function Delay of Progress Inaccurate data sheet 1 Cal l dis tributor/test sensors

24 Parts arrive late Delay of Project Late orders/long lead time 2 Plan ahead and set and meet deadl ines

25 Nature Disaster (Hurrican, earthquake, etc.) Delay the meeting Nature 3 Can't s top i t/ Change to skype meeting

26 Software expire Can't access software and des ign Expire Time Approched 1 Re-download

27 Sickness Depends on how bad i t i s (Cough? Ignore) Virus 3 Go see a doctor

Scale: l ikel ihood x severi ty = importance

See Handout

Safety and Usage

35

• ILR-1181-30 Time of Flight Sensor manufactured by Mirco-Epsilon

• Class II Laser: described as a low-power visible laser that emits

above Class I levels but at a radiant power not above 1 mW.

• Human aversion reaction to bright light will protect a person

• Accident data on laser usage have shown that Class II lasers are

normally not considered hazardous from a radiation standpoint

unless illogically used.

• Direct exposure on the eye by a beam of laser light should always

be avoided with any laser, no matter how low the power.

• Sensor will be enclosed, so no protection will be needed.

Engineering Metrics

36

Test Plan 1 – System Operation Metrics Tested : EM1, EM2, EM3, EM10, EM11

• System will be set up once all components are built, including coding

• Lasers will be set up on the rails and aimed at different sized and shaped boxes

• Dimensions will be hand measured, as well as calibration

• The system will take readings and be compared to the known dimensions

• Actual operational and feedback time will be recorded using a timer

• Sensor range will be verified by moving the lasers away from the object being measured to determine a max distance where accuracy is within the acceptable tolerance

37

Test Plan 2 – Ruggedness Test Metrics Tested : EM4 - Temperature inside enclosure

• Objective: Must remain below the sensor’s maximum operating temperature of 50°C

• Steps:

• Place thermocouple inside enclosure

• Place enclosure near forge during 1st site visit

• Requirement

• Internal temperature must remain below 50°C

• Ideally it will remain below 20°C

38

Test Plan 2 – Ruggedness Test Metrics Tested : EM5 – No openings for water ingress

• Objective: Enclosure should be sealed

• Steps:

• Add glass aperture covers to enclosure

• Requirement

• Verify no water has entered enclosure during normal useage

39

Test Plan 2 – Ruggedness Test Metrics Tested : EM6 – Housing remains intact after drop test

• Objective: Housing integrity remains intact after a drop of 0.5 meters

• Steps:

• Housing was tested by the previous group, dropped on all three axes from 1.2 meters (48 inches)

• Requirement

• Housing suffered no significant damage

40

Test Plan 3 – Usability Test Metrics Tested : EM7 - Able to position display relative to press

• Objective:

Test each button: North, South, East, west, and Rotate

• Steps:

1.Move billet away from the center of the die

2.Then correct arrow will light up and tell operator where to move to the center

• Requirement

Should light up the arrow which will lead the billet to the center of the die (North, South, East, and West)

41

Test Plan 3 – Usability Test Metrics Tested : EM8 - Visible Distance

• Objective:

Clearly visible at variety distance

• Steps:

1. Tester stands away from assign distance

2. Tester with good sight and short sight

• Requirement: Minimum: 5 meter

Ideal: 10 meter

42

Test Plan 3 – Usability Test Metrics Tested : EM9 - Brightness

• Objective:

Able to see in following condition:

1. Bright environment

2. Dark environment

3. Smoggy environment

• Steps:

Bring the system to the environments list above

• Requirement:

Minimum: 15 lumens

Ideal: 30 lumens

43

Test Plan 3 – Usability Test Metrics Tested : EM12- Easy to use

• Objective: Can an untrained operator use system after minimal instruction* • Minimal instruction includes: System setup • Steps: Find numbers of groups to use the system 1.Different ages: 20-55 years old 2.Different education: High school diploma or lower and College. • Environment: Heavy industry: Hot, Dirty, and Smoky • Requirement:

• 1.Should not have any main problem by using the system • 2.Should understand what means of arrows on the display box • 3.Should understand numbers in software interface

44

Test Plan 4 – Cost Test Metrics Tested – EM13, EM14

• For Sensor and Software cost to pass the test, a budget will be submitted to the customer, and if approved, the cost of either of these components must stay under the acceptable limit agreed upon

45

Test Plan 5 – Programming Test Metrics Tested : EM15 – Is coding needed to adjust for part shape?

• Objective: No additional coding should be required to adjust for different part shapes

• Steps:

• Add interface to GUI to allow for user defined values

• Requirement

• Part shape updated should be able to be performed by someone with no programming knowledge

46

Test Plan 5 – Programming Test Metrics Tested : EM16 – Number of part shapes the system can measure

• Objective: System should be able to measure a variety of different parts

• Steps:

• Add interface to GUI to allow for user defined values

• Requirement

• Because this is a prototype system, at the moment it is only configured for one part, which meets the customer requirement

• The addition of user defined values will allow system to be configured for other part geometries

47

Manufacturing Plan

• Locating bars, aperture covers, display case, and display mount will all be water jetted at RIT, quoted at $95/hr for 3 hrs of work

• Additional machining will be done by John and Nick for their respective mechanical parts which will include milling and using a lathe.

• Tolerances, unless otherwise stated:

• Electrical hardware will be put together by Shimona and Min.

48

# of Decimal Digits

Tolerance

x.xx ± 0.10

x.xxx ± 0.005

x.xx° ± 0.5°

Feasibility

• Locating Bars – A simple machined design with minimal cost and high precision from the use of water-jetting. The locating bars will properly align the lasers to the die each time and eliminate the need for extra lasers to account for rotational misalignment.

• Laser Aperture Cover – The lasers need to be protected from the elements during all parts of the forging process and therefore some kind of seal and transparent material would need to be used to do this. The simple design outlined previously should be easy to build, use very little material, and eliminate the need for a shutter system which would add another step to the process.

49

Looking Ahead to MSDII

• Order long lead parts and finalize any open spots in our design

• Begin manufacturing of all components (Electrical and Mechanical)

• Assemble the system

• Troubleshoot the system

• Bring the system to Wyman Gordon for preliminary testing

• Make any changes suggested by the customer

• Deliver the finished product to Wyman Gordon Week 9 of Winter Quarter

50

MSDII Schedule

51

1 11/25 - 12/1

2 12/2 - 12/8

3 12/9 - 12/15

4 12/16 - 12/22

5 1/6 - 1/12

6 1/13 - 1/19

7 1/20 - 1/26

8 1/27 - 2/2

9 2/3 - 2/9

10 2/10 - 2/16 Contingency Time

Finals/End of MSD

Christmas Break

MSDII

Finish Mechanical and Electrical Hardware

Test Program

Site Visit 1 (Tentative)

Incorporate Knowledge from Site Visit

Final RIT Review

Site Visit 2

Order remaining parts and begin coding/assembly

Continue building and debug

Continue building and debug

Questions & Comments

52

MicroEpsilon Lasers

53

• Time of flight sensor

• Data acquisition and interface software available

• RS232 or RS422 serial interfaces

• Has been utilized on measuring red hot materials.

• Class 2 laser (No eye protection) Red 650 nm

output

• Alarm function to supply up to half an amp

• Can reference measurement from any point

• Measuring Range Black Material .4m - 17m

• Resolution .1mm

• Repeatability less than .5 mm

• Linearity ±2mm (+15°C … +30°C), ±5mm (+30°C …

+50°C)

Laser Enclosures

54

• Protective housing for Micro-Epsilon Sensors

• Thermal insulation is primary function • Die Temp 700-900 °F • High temperature insulation for use in fire

protection

• Aluminum Housing • 1/8” thick sheet top • ¼” Al Block bottom support • Weight: 9.5 lbs.

• External Port for Sensor Harness

• View hole for Sensor Optics