Glass Fab Inc.Design Project Leadership: R15601

OverviewProblem Statement: Develop a low cost glass cutting machine with the capability to process small lot sizes without consuming much energy.

• Glass Fab’s current machine is overkill• Glass cutting can be achieved using various techniques• Project will focus on safety, cost, and cut quality• Several MSD iterations

Cut Glass Blank

Feed Glass

Maintain proper

feed rate

Apply z-axis

force

Move Wire

Maintain wire path

Tension wire

Maintain proper

wire speed

Index wire

Store wire

Monitor wire

Engineering Requirements• Metrics and Specification:

• In theory, it’s a simple operation, so few requirements.• In practice, it’s the little things.• The amount of Y/N questions needed.• All functions accounted for.

rqmt. # Function Engr. Requirement (metric)Unit of

MeasureMarginal

ValueIdeal Value

S1 Adhere blank to top guide Force adhesive needs to sustain N 250 350S2 Apply z-axis force Vertical force required to guide blank through wire N 150 200S3 Maintain proper feed rate Velocity required ensure blank will be cut mm/min 0.3-2.5 0.35-2S4 Store wire Length of wire that can be stored before each job km 0.8 5S5 Index wire Stroke length m 300 400S6 Maintain proper wire speed Velocity of wire m/min 10 15S7 Provide tension Force required to tension wire around guides N 20-30 N ~ 25 N

S8 Convert electrical to mechanical power(Y/N) when glass cutter is connected to power supply, all mechanical

components operate (Y/N) Y YS9 Accept standard voltage input Voltage required to power glass cutter V 440 220

S10 Controls interface accepts user inputs (Y/N) control panel prompts user to input values (Y/N) Y Y

S11 Machine runs off inputs (Y/N) machine changes initial conditions based on different user inputs (Y/N) Y Y

S12 Controls monitor safety sensorsNotifications (red light?) appear on control panel and machine shuts

off when machine operates outside safe conditions (Y/N) Y YS13 Keep building safe (fire code) OSHA/Fire/Electrical safety standards are met (Y/N) Y Y

S14 Keep machine components safeOSHA/Fire/Electrical safety standards are met, internal components

are housed while machine is in use (Y/N) Y YS15 keep operator safe OSHA safety standards are met and proper PPE is worn (Y/N) Y YS16 Machine consumes minimum power Amperage draw is minimum Amps 150 50S17 Monitor components temperature Temperature of bearing, coolant, etc. °F 200 150S18 Wire break detection detects wire breaks (Y/N) Y YS19 Wire break detection time to detect wire breaks ms 400 0.1S20 Housing allows for max blank size (Y/N) Housing allows for blank (L x W x H : 10in x 8in x 8in) (Y/N) Y Y

Engineering Requirements• House of Quality mapping

• Illustrated further critical Engineering requirements• Helped further establish specific areas for MSDs.• Solid ability to meet the needs of the customer.

Potential Concepts & Feasibility• Focused primarily on the functions of moving the wire and

moving the work piece.Two Grooved Roller                

Means Wire Path Tension Wire Wire Speed Index Wire Control Store Wire Wire Break Length on Spool Proper Feed Rate Z-axis Force1 2 grooved rollers tensor pulley take up motors guide roller rotation angle on spool current through spool weight tension feed back loop actuator2 4 grooved rollers take up reel speeds guide roller motors pay off spool rotation angle pile tension track rotation/index set constant rate gravity fed3 spool roller speeds 3rd party roller motor timed control loop motor current draw visual (spool color indicator) based on position pneumatic4 multiple pulleys hang weight   footage counter   operator visual footage counter set rate recipe hydraulic5 eyelets apply initial tension   speed * time = distance          6 clothes line apply brake/drag              7 guide rods tension arm              8 3 grooved rollers                   

Four Grooved Roller

Means Wire Path Tension Wire Wire Speed Index Wire Control Store Wire Wire Break Length on Spool Proper Feed Rate Z-axis Force1 2 grooved rollers tensor pulley take up motors guide roller rotation angle on spool current through spool weight tension feed back loop actuator2 4 grooved rollers take up reel speeds guide roller motors pay off spool rotation angle pile tension track rotation/index set constant rate gravity fed3 spool roller speeds 3rd party roller motor timed control loop motor current draw visual (spool color indicator) based on position pneumatic4 multiple pulleys hang weight   footage counter   operator visual footage counter set rate recipe hydraulic5 eyelets apply initial tension   speed * time = distance          6 clothes line apply brake/drag              7 guide rods tension arm              8 3 grooved rollers                

Potential Concepts & Feasibility• Have to balance creating a commercial grade machine

while remaining in the scope of a MSD project. Cascading effect if one MSD team is behind schedule.

• Ambiguous budget and uncertainty of component costs.

• From benchmarking and evidence from Glass Fab’s current equipment, the technology has already been proven to work.

Next Steps• Continuously benchmark as more information comes

• Become more knowledgeable on diamond wire cutting

• Scheduled Meeting with Glass Fab. - April 15th

• Discuss budget concerns• Ask about suppliers, costs, and lead times• Initiate discussion on content of 5 PRPs

• Clarify Engineering Metrics and Specification Values