Damian AshmeadDamian Ashmead

Adam BinkleyAdam Binkley

Angela HuenerfauthAngela Huenerfauth

Beth MillerBeth Miller

Jonathan RashidiJonathan Rashidi

Ion Selective Paste DispenserIon Selective Paste DispenserCurrent Dispense Process

- Laser Scan to Measure Electrode Elevation

- Dispense Paste using Stitch Pattern Onto Electrode

- Move to Next Laser Read Location

Apparent Design Flaws• Stitch Pattern• Excess Movement• Human Interaction• Outdated Control Device ········

Sponsor GoalSponsor Goal

Dispense Machine is the bottle-neck in the Dispense Machine is the bottle-neck in the electrolyte test cartridge production line.electrolyte test cartridge production line.

Increase productivity of paste dispense Increase productivity of paste dispense process. process.

Project FocusProject Focus

Developed Top 5 Wants->MetricsDeveloped Top 5 Wants->Metrics Productivity – Manufacture RateProductivity – Manufacture Rate Simplicity – Minimal Hardware ChangesSimplicity – Minimal Hardware Changes Paste Quality – Stay Within Existing TolerancesPaste Quality – Stay Within Existing Tolerances Low Cost - $Low Cost - $ Accuracy – Number of Paste Lines Within TolerancesAccuracy – Number of Paste Lines Within Tolerances

InvestigationInvestigation Record Video Footage of Existing ProcessRecord Video Footage of Existing Process Analyze Time BreakdownAnalyze Time Breakdown

Process Time BreakdownProcess Time Breakdown

Time Percentage of Actions During Paste-Dispense Process

13%

13%

5%

67%

2%

Arm Moves to Sensor

Sensor Read

Arm Moves to Thread Loci

Stitching

Other

Process Time BreakdownProcess Time Breakdown

Concept SelectionConcept Selection

Based Upon the Time BreakdownBased Upon the Time Breakdown Total Time ~ 218 secondsTotal Time ~ 218 seconds

Areas of Focus:Areas of Focus: Paste Stitch Time ~ 146 seconds (67%)Paste Stitch Time ~ 146 seconds (67%) Laser Reads ~ 38 seconds (18%)Laser Reads ~ 38 seconds (18%)

Initial ConceptsInitial Concepts More dispense apparatusesMore dispense apparatuses Use dispense manifoldUse dispense manifold Alter dispense methodAlter dispense method Altering laser read processAltering laser read process Buy new dispense machine Buy new dispense machine

Concept Selection - BenchmarksConcept Selection - Benchmarks

• Both Show Potential for Faster Dispense Methods

• Both Show Minimal or More Advanced Laser Scans

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Project ComponentsProject Components

Project Scope Broken Down Into 2 Parts.

Maximize Speed and Accuracy For Both Parts

Increase Process Capacity

Part #1Alter Dispense

Method

Part #2Decrease Number

Of Laser Reads

Part #1 - Dispense MethodPart #1 - Dispense Method

Reduce Dispense Time - 16 lines of pasteReduce Dispense Time - 16 lines of paste 5 seconds per line currently5 seconds per line currently Increase speed while maintaining accuracyIncrease speed while maintaining accuracy

How Will We Accomplish This?How Will We Accomplish This? Develop new paste dispense methods using offline Develop new paste dispense methods using offline

test device.test device.““Toothpaste” methodToothpaste” method

ValidationValidation Time – Video FootageTime – Video Footage Accuracy – Light MicroscopeAccuracy – Light Microscope

•••••••••

Offline Test DeviceOffline Test Device

Time ResultsTime Results

““Toothpaste” Method – 1.4s per electrodeToothpaste” Method – 1.4s per electrode

Accuracy ResultsAccuracy ResultsTolerances: 0.024” to 0.036”Tolerances: 0.024” to 0.036”

Paste Lines Examined with Light MicroscopePaste Lines Examined with Light Microscope Max Width – 0.029” Min Width – 0.026”Max Width – 0.029” Min Width – 0.026”

Part #2 – Decrease Laser ReadsPart #2 – Decrease Laser Reads

Decrease Laser Read TimeDecrease Laser Read Time Reduce Number of Laser ReadsReduce Number of Laser Reads

How will we accomplish this?How will we accomplish this? Prove electrodes are at same heightProve electrodes are at same height

Hold ceramic plates flat under vacuumHold ceramic plates flat under vacuum

Scan electrodes using CCM laser scannerScan electrodes using CCM laser scanner

Analyze data to show electrodes are at consistent Analyze data to show electrodes are at consistent elevationelevation

Vacuum Plate DesignVacuum Plate Design

Current Design•Square Design

• Vacuum Area ~ 4in2

• 0.25” Thick Vacuum Channel

Experimental Design• Circular Design

•Vacuum Area ~ 6.75in2

• 0.03125” Thick Vacuum Channel

CCM Laser Scan Test CCM Laser Scan Test

.

.

• Collect Plates from Variety of Batches• Good Test-bed

• Hold Plates in Same Position• Assures Accurate Repeatable Data Collection

• Scan Individual Rows of Electrodes • Compare Electrode Elevation

Variables

1. Vacuum Plate2. Batch Numbers

Data from multiple scans of single line were averaged. Data from multiple scans of single line were averaged.

Electrodes located from graph of data.Electrodes located from graph of data.

Heights averaged over each Heights averaged over each

electrode in line (Six per line).electrode in line (Six per line).

Difference was calculated Difference was calculated

between maximum and between maximum and

minimum electrode height on minimum electrode height on

plate. plate.

Laser Scan Data AnalysisLaser Scan Data Analysis

-3.085

-3.080

-3.075

-3.070

20 40 60 80

Laser Scan ResultsLaser Scan ResultsElectrode Elevation Data Electrode Elevation Data

Variation using current vacuum plate: 0.0015”Variation using current vacuum plate: 0.0015”

Variation using experimental vacuum plate: 0.0010”Variation using experimental vacuum plate: 0.0010”

0.1238

0.124

0.1242

0.1244

0.1246

0.1248

0.125

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Electrode Elevations Over Single Plate

0.001 in

Electrodes

Ele

va

tio

n (

in)

Time Reduction AnalysisTime Reduction Analysis

218s

170s

124s

Prototype / Experiment CostPrototype / Experiment Cost

Offline Test DeviceOffline Test Device $110$110Hardware $60Hardware $60

Aluminum MIC-6 $50Aluminum MIC-6 $50

Aluminum Vacuum PlatesAluminum Vacuum Plates $100$100Vacuum PlatesVacuum Plates

Total CostTotal Cost $210 $210

Process SummaryProcess Summary

Dispense MethodDispense Method Decrease Dispense TimeDecrease Dispense Time Maintain AccuracyMaintain Accuracy

Laser ReadsLaser Reads Decrease Laser ReadsDecrease Laser Reads ACCOMPLISHEDACCOMPLISHED

ACCOMPLISHEDACCOMPLISHEDACCOMPLISHEDACCOMPLISHED

ImplementationImplementation

“ “Toothpaste” Dispense MethodToothpaste” Dispense Method Software Engineer – alter control code Software Engineer – alter control code

Replace vacuum plate with new plate Replace vacuum plate with new plate designdesign Decrease laser reads to 1 per plateDecrease laser reads to 1 per plate Software Engineer - alter control codeSoftware Engineer - alter control code

Conduct further calibrations and on-line Conduct further calibrations and on-line teststests2-3 months, $20,000 – $30,000 2-3 months, $20,000 – $30,000

Questions?Questions?