edge.rit.eduedge.rit.edu/edge/P16603/public/P16603.docx · Web viewSome examples of necessary documentation include a timing diagram for each of the possible use scenarios; this might

Multidisciplinary Senior DesignProject Readiness Package

Project Title: Glass Cutting Machine: Work Piece Movement

Project Number:(assigned by MSD) 16603

Primary Customer:(provide name, phone number, and email)

Glass Fab-Wayne Leon ([email protected]), Tom Kirk ([email protected])

Sponsor(s):(provide name, phone number, email, and amount of support)

Glass Fab-Wayne Leon ([email protected]), Tom Kirk ([email protected])

Preferred Start Term: e.g., Spring 2015

Faculty Champion:(provide name and email)

John Wellin [email protected]

Other Support: As applicable

Project Guide:(assigned by MSD) Edward Hanzlik [email protected] 475-7428 17-2527

PRP created Alec Ragnetti DPL student; modified by E Hanzlik Aug 2015Prepared By Date

Received By Date

Items marked with a * are required, and items marked with a † are preferred if available, but we can work with the proposer on these.

RIT – Kate Gleason College of EngineeringMultidisciplinary Senior Design

Project Readiness PackageTemplate Revised Jan 2015

mailto:[email protected]




Project Information

* Overview:Glass cutting is a process that can be done on both large and small scales with many different cutting tools. Some examples include using a saw blade, a diamond coated wire, or a brass coated wire in the presence of an abrasive slurry. Each of these methods will differently impact the way the glass is cut. The saw blade will cause a significant amount of movement and vibration of the glass. The diamond coated wire does not need any other tools to assist in cutting, but the wire can create chips in the surface of the glass during cutting. The brass coated wire with the slurry will give a finer cut than the diamond; however, temperature needs to be monitored.

Glass Fab Inc. currently uses a brass coated wire utilizing abrasive slurry for both large and small volume glass blanks. It is a Meyer Burger DS 264 glass cutting system that uses a wire wrapped around two guide rollers. These guides have grooves that the wire will sit in and can be adjusted to create various thickness cuts in the glass to get a range of different blanks. There is a control panel on the front as well to monitor the sensors and adjust the feed rate of the wire.

This machine works very well for Glass Fab, especially for high volume parts. However, the current Meyer Burger machine draws more power than every other machine Glass Fab owns put together. It takes a while to start up and because of the amount of power used, does not make sense to use for low volume parts. Glass Fab would like to look into creating a smaller machine, similar to the one that they currently have, that can be utilized only for low volume parts. There are existing smaller machines, but can only cut one blank at a time. The goal is to take elements of the bigger machine, essentially shrink it, and make a more energy efficient wire glass cutter.

This MSD project is part of a tightly coupled group of three projects that will run in the fall of 2015. The three projects are 16601, 16602 and 16603. Each of these project teams will develop, design and build a test fixture for their functional part of the overall system. In addition, members of this project team will actively participate on a “system engineering team”. The System engineering will define, develop and conceptually design a complete wire saw machine. The system engineering team will utilize CAD to convey the design. The system engineering team will work with the three project teams to array and manage all relevant project metrics at the system level. Some examples of these system metrics are weight, volume, power consumption, noise, heat emission. In addition, the system engineering team will be responsible for develop the necessary documentation to describe machine behavior and operation. Some examples of necessary documentation include a timing diagram for each of the possible use scenarios; this might include, cycle up, cycle down, and some diagnostic routines.

The P 16603 project team will focus on the definition, design and implementation of work piece movement for the glass cutting saw system. At this point, the project is asking for linear motion with a range from 0.1mm/min to 2mm/min. Movement of the workpiece in a controlled manner is one of the key factors in determining the quality of the finished cut. The team will be asked to consider and evaluate more complex kinematic motions that may enable better cut



quality outcomes. The team will develop, design and build a standalone fixture that will be properly sized to move workpieces in the final saw system. Below are some images of the workpiece movement for glass cutting wire saws.

* Preliminary Customer Requirements (CR):What attributes does the customer seek in the final project? Each CR should map to one or more ER (see below).



† Functional Decomposition What functionality will be delivered in order to satisfy the customer requirements? This may be in the form of a list of functions, a function tree or a FAST diagram.

* Preliminary Engineering Requirements (ER):Include both metrics and specifications. Each ER should map to one or more CRs (see above).Metrics: what quantities will be measured in order to verify success?Specifications: what is the target value of the metric that the team should design to?



Pro

ject

: R

1560

1

rqm

t. #

Sou

rce

Func

tion

Eng

r. R

equi

rem

ent (

met

ric)

Uni

t of

Mea

sure

Mar

gina

l V

alue

Idea

l V

alue

Com

men

ts/S

tatu

sTe

st (h

ow a

re y

ou g

oing

to v

erify

sat

isfa

ctio

n)

S1

Gla

ss F

ab. R

equi

rem

ents

Adh

ere

blan

k to

top

guid

eFo

rce

adhe

sive

nee

ds to

sus

tain

N25

035

0E

stim

ated

val

ues

furth

er in

vest

igat

ion

need

ed

mea

sure

forc

e to

see

if m

argi

nal v

alue

is m

etS

2G

lass

Fab

. Req

uire

men

tsA

pply

z-a

xis

forc

eV

ertic

al fo

rce

requ

ired

to g

uide

bla

nk th

roug

h w

ireN

150

200

Est

imat

ed v

alue

s fu

rther

inve

stig

atio

n ne

eded

m

easu

re fo

rce

to s

ee if

mar

gina

l val

ue is

met

S3

Gla

ss F

ab. R

equi

rem

ents

Mai

ntai

n pr

oper

feed

rate

Vel

ocity

requ

ired

ensu

re b

lank

will

be

cut

mm

/min

0.3-

2.5

0.35

-2V

alue

s fro

m C

usto

mer

mea

sure

vel

ocity

to s

ee if

mar

gina

l val

ue is

met

S4

Gla

ss F

ab. R

equi

rem

ents

Sto

re w

ire

Leng

th o

f wire

that

can

be

stor

ed b

efor

e ea

ch jo

bkm

0.8

5E

stim

ated

val

ues

furth

er in

vest

igat

ion

need

ed

mea

sure

leng

th to

see

if m

argi

nal v

alue

is m

etS

5G

lass

Fab

. Req

uire

men

tsIn

dex

wire

Stro

ke le

ngth

m

300

400

Est

imat

ed v

alue

s fu

rther

inve

stig

atio

n ne

eded

m

easu

re le

ngth

to s

ee if

mar

gina

l val

ue is

met

S6

Gla

ss F

ab. R

equi

rem

ents

Mai

ntai

n pr

oper

wire

spe

edV

eloc

ity o

f wire

m/m

in10

15E

stim

ated

val

ues

furth

er in

vest

igat

ion

need

ed

mea

sure

vel

ocity

to s

ee if

mar

gina

l val

ue is

met

S7

Gla

ss F

ab. R

equi

rem

ents

Pro

vide

tens

ion

Forc

e re

quire

d to

tens

ion

wire

aro

und

guid

esN

20-3

0 N

~ 25

NV

alue

s fro

m C

usto

mer

mea

sure

forc

e to

see

if m

argi

nal v

alue

is m

et

S8

Gla

ss F

ab. R

equi

rem

ents

Con

vert

elec

trica

l to

mec

hani

cal p

ower

(Y/N

) whe

n gl

ass

cutte

r is

conn

ecte

d to

pow

er s

uppl

y, a

ll m

echa

nica

l co

mpo

nent

s op

erat

e(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

esvis

ual c

heck

to s

ee if

gui

de ro

llers

and

spo

ols

mov

e w

hen

mac

hine

is in

use

S9

Gla

ss F

ab. R

equi

rem

ents

Acc

ept s

tand

ard

volta

ge in

put

Vol

tage

requ

ired

to p

ower

gla

ss c

utte

rV

440

220

Val

ues

from

Cus

tom

erm

easu

re v

olta

ge to

see

if m

argi

nal v

alue

is m

et

S10

Gla

ss F

ab. R

equi

rem

ents

Con

trols

inte

rface

acc

epts

use

r inp

uts

(Y/N

) con

trol p

anel

pro

mpt

s us

er to

inpu

t val

ues

(Y/N

)Y

YFu

nctio

n ne

eded

for m

argi

nal a

nd id

eal c

ases

oper

ator

s ca

n ea

sily

inpu

t val

ues

on c

ontro

l pan

el

S11

Gla

ss F

ab. R

equi

rem

ents

Mac

hine

runs

off

inpu

ts(Y

/N) m

achi

ne c

hang

es in

itial

con

ditio

ns b

ased

on

diffe

rent

use

r inp

uts

(Y/N

)Y

YFu

nctio

n ne

eded

for m

argi

nal a

nd id

eal c

ases

mea

sure

inpu

t ope

ratio

ns to

ens

ure

corre

ct

valu

es

S12

Gla

ss F

ab. R

equi

rem

ents

Con

trols

mon

itor s

afet

y se

nsor

sN

otifi

catio

ns (

red

light

?) a

ppea

r on

cont

rol p

anel

and

mac

hine

shu

ts

off w

hen

mac

hine

ope

rate

s ou

tsid

e sa

fe c

ondi

tions

(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

este

st to

see

is m

achi

ne s

huts

off

base

d on

sen

sor

valu

esS

13G

lass

Fab

. Req

uire

men

tsK

eep

build

ing

safe

(fire

cod

e)O

SH

A/F

ire/E

lect

rical

saf

ety

stan

dard

s ar

e m

et(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

esO

SH

A a

nd G

lass

Fab

. sta

ndar

ds a

re m

et

S14

Gla

ss F

ab. R

equi

rem

ents

Kee

p m

achi

ne c

ompo

nent

s sa

feO

SH

A/F

ire/E

lect

rical

saf

ety

stan

dard

s ar

e m

et, i

nter

nal c

ompo

nent

s ar

e ho

used

whi

le m

achi

ne is

in u

se(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

esO

SH

A a

nd G

lass

Fab

. sta

ndar

ds a

re m

etS

15G

lass

Fab

. Req

uire

men

tske

ep o

pera

tor s

afe

OS

HA

saf

ety

stan

dard

s ar

e m

et a

nd p

rope

r PP

E is

wor

n(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

esO

SH

A a

nd G

lass

Fab

. sta

ndar

ds a

re m

etS

16G

lass

Fab

. Req

uire

men

tsM

achi

ne c

onsu

mes

min

imum

pow

erA

mpe

rage

dra

w is

min

imum

Am

ps15

050

Est

imat

ed v

alue

s fu

rther

inve

stig

atio

n ne

eded

m

easu

re to

tal a

mpe

rage

dra

wS

17G

lass

Fab

. Req

uire

men

tsM

onito

r com

pone

nts

tem

pera

ture

Tem

pera

ture

of b

earin

g, c

oola

nt, e

tc.

° F20

015

0E

stim

ated

val

ues

furth

er in

vest

igat

ion

need

ed

mea

sure

tem

pera

ture

of i

tem

sS

18G

lass

Fab

. Req

uire

men

tsW

ire b

reak

det

ectio

nde

tect

s w

ire b

reak

s(Y

/N)

YY

Func

tion

need

ed fo

r mar

gina

l and

idea

l cas

esvis

ual c

heck

to s

ee if

wire

sto

ps a

fter w

ire b

reak

S19

Gla

ss F

ab. R

equi

rem

ents

Wire

bre

ak d

etec

tion

time

to d

etec

t wire

bre

aks

ms

400

0.1

Val

ue s

houl

d ap

proa

ch 0

m

easu

re ti

me

to s

hut d

own

S20

Gla

ss F

ab. R

equi

rem

ents

Hou

sing

allo

ws

for m

ax b

lank

siz

e(Y

/N) H

ousi

ng a

llow

s fo

r bla

nk (L

x W

x H

: 10

in x

8in

x 8

in)

(Y/N

)Y

YFu

nctio

n ne

eded

for m

argi

nal a

nd id

eal c

ases

Bla

nk h

as c

lear

ance

to b

e fu

lly c

ut

Not

e: C

ells

hig

htlig

hted

as

this

one

per

tain

to th

is p

roje

ct.

* Constraints:List any external factors that limit the selection of alternatives, e.g., allowable footprint, budget, required use of legacy hardware/software.

To be determined.

† Potential Concepts: Generate a short list of potential solutions, along with the disciplines that may be required to realize each. This helps to ensure that projects are feasible.

* Project Deliverables:Minimum requirements: Work piece movement and control development fixture with the properly sized workpiece

holders, mechanical hardware and drive motor. Fixture is completely operational; Fixture is properly instrumented to evaluate workpiece movement stability as a function of drag loading, and other parameters.

Team has actively participated in the development and delivery of a final wire cutting saw. Design that incorporates all of the key functional elements for P16601, 16602, and 16603. The design will be captured in CAD as a proposed wire saw system. Additionally, appropriate system level documentation such as timing diagrams, operational details and use cases will be created. A comprehensive rollup of key parameters such as cost, weight, power consumption etc.. will be created and managed to minimize running costs/ cut.

All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)

Technical paper per course standards. Presentation poster per course standards.



Team will demonstrate working prototype at ImagineRIT.

Additional required deliverables: List here, if applicable

† Budget Information:List major cost items anticipated, and any special purchasing requirements from the sponsor(s).Budget is being finalized by client at this time.

* Intellectual Property:Describe any IP concerns or limitations. Is there patent potential? Will confidentiality of any data or information be required? IP is possible.



Project Resources

† Required Resources (besides student staffing):Describe the resources necessary for successful project completion. When the resource is secured, the responsible person should initial and date to acknowledge that they have agreed to provide this support. We assume that all teams with ME/ISE students will have access to the ME Machine Shop and all teams with EE students will have access to the EE Senior Design Lab, so it is not necessary to list these! Limit this list to specialized expertise, space, equipment, and materials.

Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for more than a basic technical question during office hours)

Initial/date

Professor Wellin; technical consultant on projects 16601 16602 and 16603Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or hazardous gases, specific electrical requirements such as 3-phase power)

Initial/date

Will need significant floor space for fixtures for 16601 16602 16603Equipment (specific computing, test, measurement, or construction equipment that the team will need to borrow, e.g., CMM, SEM, )

Initial/date

Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must be purchased and stored)

Initial/date

OtherInitial/date

† Anticipated Staffing By Discipline:Indicate the requested staffing for each discipline, along with a brief explanation of the associated activities. “Other” includes students from any department on campus besides those explicitly listed. For example, we have done projects with students from Industrial Design, Business, Software Engineering, Civil Engineering Technology, and Information Technology. If you have recruited students to work on this project (including student-initiated projects), include their names here, as well!

Dept. # Req. Expected ActivitiesBMECEEE 1.Work piece motor selection and implementation, 2. Sensors for operation

and test activitiesISE Very Active participation on systems engineering team; define and

implement work processes where necessary for system integration



ME 4 1. Active participation on systems engineering team includes CAD; DME , 2. Lead design activities on workpiece motion and kinematics, DME 3. CAD design for test fixture; extensive DME,

Other

* Skills Checklist:Indicate the sills or knowledge that will be needed by students working on this project. Please use the following scale of importance:1=must have2=helpful, but not essential3=either a very small part of the project, or relates to a “bonus” featureblank = not applicable to this project

Mechanical EngineeringME Core Knowledge ME Elective Knowledge

1 3D CAD 1 Finite element analysisMatlab programming Heat transfer

1 Basic machining Modeling of electromechanical & fluid systems1 2D stress analysis 1 Fatigue and static failure criteria1 2D static/dynamic analysis 1 Machine elements

Thermodynamics AerodynamicsFluid dynamics (CV) Computational fluid dynamicsLabView BiomaterialsStatistics Vibrations

1 Materials selection IC Engines1 GD&T1 Linear Controls

CompositesRoboticsOther (specify)

Electrical EngineeringEE Core Knowledge EE Elective KnowledgeCircuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, sensor bias/support circuitry)

Digital filter design and implementation

1 Power systems: selection, analysis, power budget Digital signal processing1 System analysis: frequency analysis (Fourier,

Laplace), stability, PID controllers, modulation schemes, VCO’s & mixers, ADC selection

Microcontroller selection/application

Circuit build, test, debug (scope, DMM, function generator

Wireless: communication protocol, component selection

Board layout Antenna selection (simple design)Matlab Communication system front end designPSpice 1 Algorithm design/simulationProgramming: C, Assembly Embedded software design/implementationElectromagnetics: shielding, interference Other (specify)



Industrial & Systems EngineeringISE Core Knowledge ISE Elective KnowledgeStatistical analysis of data: regression 2 Design of ExperimentMaterials science 1 Systems design – product/process designMaterials processing, machining lab Data analysis, data miningFacilities planning: layout, mat’l handling 1 Manufacturing engineering

1 Production systems design: cycle time, throughput, assembly line design, manufacturing process design

1 DFx: manufacturing, assembly, environment, sustainability

Ergonomics: interface of people and equipment (procedures, training, maintenance) 1 Rapid prototyping

Math modeling: OR (linear programming, simulation) Safety engineering

Project management Other (specify)Engineering economy: Return on InvestmentQuality tools: SPCProduction control: schedulingShop floor IE: methods, time studiesComputer tools: Excel, Access, AutoCADProgramming (C++)



Documents

edge.rit.eduedge.rit.edu/edge/P16603/public/P16603.docx · Web viewSome examples of necessary documentation include a timing diagram for each of the possible use scenarios; this might