intelligent tooling
DESCRIPTION
INTELLIGENT TOOLING. Team 99.08 Joseph StaleyJeffrey Roushey Glenn GardnerAndrew Graybill. Design Concept Review. Background - Mission - Approach Customers - Wants - Constraints Benchmarking Quality Metrics - Target Values Concept Generation Concept Selection - PowerPoint PPT PresentationTRANSCRIPT
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INTELLIGENT TOOLINGTeam 99.08
Joseph StaleyJeffrey RousheyGlenn GardnerAndrew Graybill
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Design Concept ReviewBackground - Mission - ApproachCustomers - Wants - ConstraintsBenchmarkingQuality Metrics - Target ValuesConcept GenerationConcept Selection Schedule - Budget
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BackgroundWhat is Metal Foam?
How is it Produced?
Why Use Metal Foam?
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Project Summary MissionTo develop a sensor system that will signal the completion of the metal foaming process inside a mold.ApproachBy working together as a team, making use of the customers resources, and performing extensive research we will provide the best possible sensor system design for our problem.
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Customers - Wants - Constraints
Customers
Wants
Constraints
Metrics
Chin-Jye Yu, Fraunhofer USA
High % of Successful Foams, System Simplicity / Reliability,
Low Cost
Cost, Operating Temperature,
LabVIEW, Furnace
Dimensions, Surface Defects, Max. temp, Signal Alts., Set-up time, Mold Alts., Life, Cost, Program time
Harald Eifert, Fraunhofer USA
High % of Sucessful Foams, Low Cost
Dimensions, Surface Defects, Cost
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Customers - Wants - Constraints
Customers
Wants
Constraints
Metrics
Bernard McGuiness, Lab RA, FRC-DE
Jim Adkins, Lab Coordinator, FRC-DE
High % of Successful Foams, System Simplicity / Reliability
Operating Temperature,
Furnace
Dimensions, Surface Defects, Max. temp, Signal Alts., Set-up time, Mold Alts., Life
Automotive, Aerospace, Building /Construction Industries
High % of Successful Foams, System Simplicity / Reliability, Low Cost
Operating Temperature
Dimensions, Surface Defects, Max. temp, Signal Alts., Set-up time, Mold Alts., Life
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System BenchmarkingDie Casting / Injection Moldinggeneral process, sensorsHigh Temperature Monitoringhigh temperature materials (Macor)data acquisitionMaterials Level Monitoringsensors
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Functional BenchmarkingElectrical Properties SensorsPiezo-electric TransducerThermocoupleOptical FiberEddy Current Detector
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Target Values
Metric
Target Value
Dimensions
3.5 X 3.5 X 0.5
# Surface Defects
0
Sensor System Life
5 years
Maximum Operating Temp.
700 C
# Signal Alterations
0
Programming Time
20 hours
Set-up Time
30 minutes
# Mold Alterations
0
Cost
$2,000
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Critical FunctionsSense metal foaming process completionAttenuate/Amplify the sensor output signalChannel signal(s) into data acquisition cardUse LabVIEW software to interpret signals and alert user that the process is complete
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Concept GenerationElectrical Circuit CompletionPiezo-Electric Force SensorThermocouple ArrayOptical FiberEddy Current Position Sensor
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Concept Selection Method
Metric
Raw Score
SSD Correlation
Weighted Score
Estimated Target Value
Dimensions
4
9.89
39.56
?
# Surface Defects
3
9.89
9.67
No (1)
Sensor Sys. Life
5
13.187
65.935
Yes
Max. Op. Temp.
5
14.286
71.43
Yes
# Signal Alts.
5
9.89
49.45
Yes
Progrmg. Time
5
9.89
49.45
Yes
Set-up Time
4
9.89
39.56
Yes
# Mold Alts.
2
9.89
19.78
No (2)
Cost
5
13.187
65.935
Yes
Total Score
430.77
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Concept Selection
Concept
Total Weighted Score
Electrical Circuit Completion
431
Piezo-Electric Force Plate
325
Thermocouple Array
312
Eddy Current Position Sensor
235
Optical Fiber
196
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Conductivity Testing at Room Temperature
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Conductivity Testing at 700 C
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Schedule - Fall 98
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Schedule - Spring 99
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Estimated Budget
Part
Material Cost
Machining Cost
Approximate Cost
Copper Mold
$5
$495
$500
Ceramic Insulator
$150
$450
$600
Copper Electrode Large
$2
$128
$130
Copper Electrode Small
$2
$128
$130
Copper Wire
$4
$0
$4
Terminal Board
$0
$0
$0
Battery 9V
$0
$0
$0
Computer (CPU)
$0
$0
$0
Total Cost
$1,364
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Future DirectionWinter Break - Build ConceptFebruary - Testing and Design IterationsMarch - Cushion PeriodApril - Final Report Preparation