Lockheed Martin Design Project #2: FOD Identification and Retrieval

EDSGN100: Introduction to Engineering Design Section 7 Team #3

The FOD Snake

Submitted by: Albert Zuba

Caitlyn Martin Matt Chapla Steph Voitek

Robert Khayat Submitted to:

Xinli Wu Date of Submission: Spring 2018

Abstract: Through six weeks of design through the engineering process, Group 3 finalized an ideal

FOD identification and retrieval prototype through careful consideration of various conceptual parameters as well as the need for efficiency and practicality for potential users.

Table of Contents Abstract…………………………………………………………………………… iii (Caitlyn)

Introduction…………………………………………………………………………1 (Steph)

Design Task………………………………………………………………………. 2 (Matt)

Design Approach…………………………………………………………………. 3 (Albert)

Final Design………………………………………………………………………. 5 (Matt)

Engineering Analysis…………………………………………………………….. 6 (Albert)

Summary and Conclusions……………………………………………………… 7 ( Caitlyn, Steph)

References………………………………………………………………………… 8 (Robert)

Introduction: FOD is defined as foreign object debris that could potentially cause damage to an

aircraft. In Lockheed Martin’s case, FOD can be any unwanted material within a subassembly of an aircraft that must be removed to avoid damaging or compromising the function of the aircraft. Such material includes metal shavings, broken screws or bolts, wires, plastic washers, and many other forms of debris. If FOD is not retrieved, it could possibly tear holes in the aircraft or destroy wires necessary for its functions. However, the issue with retrieving the FOD is that it might take a long time (and therefore, money) to determine where the material is and how to get it out.

Design Task: Problem Statement:

Lockheed Martin performs frequent FOD inspections for unwanted debris during production of portions of aircraft or subassemblies. The problem is these inspections are very time consuming and it can take hours to disassemble, retrieve the FOD, and reassemble the part. Mission Statement:

The mission is to design a device to expedite the process of identifying and retrieving FOD of many different sizes and materials in various locations throughout aircraft subassemblies.

Design Approach: Gantt Chart: Table. 1.

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6

Brainstorm

Design Matrix

Final Design Decision

Improvement of Design

Build Prototype

Make Report/Presentation

Design Matrix: Choosing a Design Table. 2.

Criteria Drone/ RC Car Snake with Wheel

Snake Manual X-Ray/ Claw

Identification - + 0 +

Retrieval - + 0 -

Cost 0 - + -

Size + 0 0 0

Retrieval Versatility

- + 0 0

Sum +’s Sum 0’s Sum -’s

1 1 3

3 1 1

1 4 0

1 2 2

Net score Rank Continue?

-2 4 no

2 1

Yes/ improve

1 2 no

-1 3 no

Design Matrix: Improving the Snake with Wheel Design Table. 3.

Type of FOD: Retrieval

Vacuum Magnet Disposable Adhesive

“Pincer”

Shavings (Metal, Plastic, etc)

YES Not ideally NO NO

Fasteners (Loose screws, bolts, etc)

Very small fasteners (limitations)

YES YES “Larger” fasteners

Tools (And other large FOD)

NO Very limited NO YES

Miscellaneous (Plastic washers, etc)

Very small items (limitations)

Must be of magnetic material

YES YES

Customer Needs:

Lockheed Martin is in need of a tool or device that can detect, identify, and retrieve FOD of various sizes from various sized hard-to-reach spaces. The system needed to remove the FOD with as little disassembly as possible in a timely manner. Concept Generation:

From the start, the team’s snake-like design for identification and removal of FOD seemed most versatile, practical, and cost efficient. This was ultimately decided to be true through design matrices, Gantt charts and careful consideration of Lockheed Martin’s needs. The team realized many old ideas were simply not as maneuverable within tight spaces in an aircraft. While balancing cost efficiency, ease of use, and effectiveness in completing the job task, it was clear the best option for the team was to improve and mold the Robotic Snake idea precisely to fit Lockheed Martin’s needs.

Final Design: Figure. 1. Box and motor assembly

Figure. 2 Full assembly

Figure. 2. Reel

Figure. 4. Joint assembly

Figure. 5. Prototype

Operation Instructions: The team decided it was most useful to implement a robotic snake-like device to ‘tunnel’ into tight or otherwise unreachable areas, identify the location of the FOD via a small camera, and remove it with its vacuum or claw features. A user friendly phone or computer application would serve as the FOD snake’s primary method of control and is designed to be used by 1 engineer.

1. A worker deploys the FOD Snake in the general area of the FOD. 2. Using computer controls and the camera feature identify exact location of FOD. 3. User determines and implements best removal tool (vacuum/claw) to match type and

size of FOD present Design Features:

This device is meant to be used in conjunction with machinery already present in Lockheed Martin workshops. For example, a monitor can be plugged in via USB port to display feedback from the camera, and a common shop-vac can be inserted into the side of the device (similar to an attachment) when removing small material such as metal shavings. This helped save the team a substantial amount of money in its design, and would provide great practicality in real-life application.

Engineering Analysis

Working Mechanisms: The main working mechanism used in the FOD snake is the alternating hinges that make up the snake portion of the system (Shown in figure. 4.). These joints are bent to any angle to allow the snake to move through the tight spaces of subassemblies. The snake is deployed from a reel to provide sufficient length to access the FOD. A vacuum and a claw are used to retrieve FOD depending on the size and type. The reel, the joints, vacuum and claw are all controlled by the user with computer software. Cost Analysis: Aluminum Sheets and Rods for Snake and Box (12” by 24” sheets, .012” thickness) X 1 https://www.mcmaster.com/#standard-aluminum-sheets/=1ckhu58 Stainless Steel Sheets for Rollers and Reels (6” by 10’ .012 thickness) X 1 https://www.mcmaster.com/#standard-stainless-steel-sheets/=1ckhx2t Motor to Support Whole Machine (3.5” diameter, 120 V AC Motor) X 1 https://www.mcmaster.com/#fan-motors//=1bo3noy 18-8 Stainless Steel Phillips Flat Head Screws, one pack X 1 https://www.mcmaster.com/#stainless-steel-tapping-screws/=1cki0qx

Total: 1 120 V A/C Motor X $19.98 1 Stainless Steel Sheets for Roller and Reels X $28.89

1 Aluminum Sheets and Rods for Snake and Box X $8.89 1 pack of Phillips Flat Head Screws X $4.71

+_______________________________________________ $62.47

Summary and Conclusions:

Conclusion: Lockheed Martin performs frequent FOD inspections for unwanted debris during

production of various projects. These inspections are very time consuming and it can take hours to disassemble, retrieve the FOD, and reassemble the part. Overall, group 3 has successfully created a design that fits all of the customer needs set by Lockheed Martin. The FOD Snake’s user friendliness, versatility, and cost efficiency allows this model to be beneficial to aircraft FOD removal in the company’s future. Suggestions for Future Improvements:

More time to develop the best placement for the vacuum attachment. In addition, more time to develop an iOS app to make design more user-friendly and efficient.

References

Video: https://www.youtube.com/watch?v=cJuNe50uuzk Supplies: https://www.mcmaster.com