Final Advisor Mr. Harker Presentation May15-03 Agenda System - PowerPoint PPT Presentation

Team (May 15-03) Shawn LaGrotta lagrotta@iastate.edu Matt Eckes mweckes@iastate.edu Jacob Mayer jdmayer@iastate.edu Trevor Boone tdboone@iastate.edu Jacob Schulz jschulz@iastate.edu Client HGST Final Advisor Mr. Harker Presentation May15-03

Agenda System Technical Project Problem Test Results Overview Challenges Management Statement • Concept • Motor Issues • Functional • Cost • Background Sketch Testing • Calibration • Summary • Use Case • Block Diagram • Hypothesis • File Parsing • Requirements May15-03

PROBLEM STATEMENT May15-03

Background Malfunctioning HDD • Shipping costs Send HDD to engineer • High turn around time • Time consuming Find via using • Easy to make chart mistakes Manually probe via May15-03

Use Case May15-03

Requirements Functional Non-Functional • Hold and move LeCroy • Move to any point within Probe 60 seconds • Make a good electrical • LEDs and LCD that indicate contact state • Calibration method that • Take up less than 4ft ³ ensures accurate • Support a manual performance operation mode May15-03

SYSTEM OVERVIEW May15-03

Concept Sketch Concept Sketch May15-03

Block Diagram May15-03

Software Overview May15-03

PROGRESS May15-03

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Video May15-03

TECHNICAL CHALLENGES May15-03

Calibration: Probe/HDD Coordinate System 𝑦 𝑦 𝑧 𝑜𝑓𝑥 = cos⁡ (𝜄) −sin⁡ (𝜄) Coordinate 𝑧 𝑝𝑚𝑒 sin⁡ (𝜄) cos⁡ (𝜄) θ Translation May15-03

Z-Axis Motors ~30 hours to debug Continuity? Transients? Signals? High Load? Bad Motor? May15-03

File Parsing Binary File Plain text • No preparation needed • Preparation needed • Information rich • Only contains via coordinates • Proprietary parser • Easy to parse • Windows only • Platform independent May15-03

PRODUCT VERIFICATION May15-03

Hardware Testing Probe Locating Motor X, Y, and Transition Electrical Test Controls Z Motion Time Contact Points May15-03

Hardware Test • Test 80 randomly generated vias • 3 Trials Plan • Time: 21 min 20 seconds (16 seconds between points) • Accuracy: 69/80 vias made electrical contact (86% Results accuracy) May15-03

Test Results Analysis Goal Actual Transition time 60 sec 16 sec Accuracy 80% 86% May15-03

Missed Points Note: Missed vias by ~5 μ m Calibration Point May15-03

Possible Issue May15-03

Cost Description $619.37 RepRap Prusa i2 3D Printer Kit $50.00 Raspberry Pi B+ w/ 8GB NOOBS microSD card $162.14 Enclosure + Switches + Hardware + Connectors $32.00 SainSmart LCD Control Panel $5.05 Locked Spring Loaded Metal Security Barrel Bolt Latch 5.5cm $15.00 Probe Holder (3D Printed) at $5/in 3 $0.00 HDD Jig ~$883 / $1500 Total / Budget May15-03

Summary Problem Hardware Solution Software Solution Cost Delivery Remote HDD Testing Modified 3D Printer Web + Python + Printer ~$883 / $1500 May 2015 May15-03

QUESTIONS? May15-03

Software Testing Operational Tests Unit Tests of GUI • Navigation to Points • Via Selection Module • File Management • File Selector Module • Embedded Communication Module May15-03

Calibration Procedure May15-03

HDD May15-03

HDD ∆𝑦 𝜄 𝐼𝐸𝐸 𝜄 𝐼𝐸𝐸 = tan −1 ∆𝑧 ∆𝑦 ∆𝑧 May15-03

Probe May15-03

Probe ∆𝑦 𝜄 𝑄𝑠𝑝𝑐𝑓 𝜄 𝑄𝑠𝑝𝑐𝑓 = tan −1 ∆𝑧 ∆𝑦 ∆𝑧 May15-03

Rotation Angle • 𝜄 𝑠𝑝𝑢𝑏𝑢𝑗𝑝𝑜 = 𝜄 𝐼𝐸𝐸 − 𝜄 𝑞𝑠𝑝𝑐𝑓 𝑦 𝑦 = cos⁡ (𝜄) −sin⁡ (𝜄) • 𝑧 𝑜𝑓𝑥 𝑧 𝑝𝑚𝑒 sin⁡ (𝜄) cos⁡ (𝜄) May15-03

2-Probe Math May15-03

Market Survey Bed of Nails Flying Probe Pros Cons May15-03

Schedule – Fall May15-03

Schedule – Spring May15-03