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SHIM ONA GORELICK J OHN K NIGHT NIC K PEROT T E M IN HA N ZHA O
Forging Position Feedback System SHIM ONA GORELICK J OHN K NIGHT - - PowerPoint PPT Presentation
Forging Position Feedback System SHIM ONA GORELICK J OHN K NIGHT - - PowerPoint PPT Presentation
Forging Position Feedback System SHIM ONA GORELICK J OHN K NIGHT NIC K PEROT T E M IN HA N ZHA O Contents Background Customer Needs House of Quality Concept Description and Summary System Architecture Current State of
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Background – Customer Process & Justification
Current Process
Mult heated until “red hot,” 1700-2100°F Oil soaked carbon paper is applied to the die to prevent the mult from
sticking
About 60 seconds of operating time to position forging Operator controls the piece with a fork truck and other simple tools until
it is aligned properly
Final alignment is based on operator judgment
Project Justification
Current alignment process is conducted visually Experienced workers are approaching their retirement years Cost approximately $1M annually to rework Proper alignment in the die could reduce this figure by 30% ($300,000).
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Customer Needs
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House of Quality
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Concept Description & Rationale (MSDI)
Mechanically calibrate the lasers Use easy on-off magnets to allow for setup variation Program and run the system using a microcontroller Use the microcontroller to activate LED’s in the
display
Protect the lasers from foreign debris using glass
aperture enclosures
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Concept Summary (MSD II)
Switch from microcontroller processing back to
Visual Basic
Lasers are able to be calibrated mechanically via
locating bars
Magnets are mounted and workable Aperture enclosures have been attached and
successfully protect the lasers
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Glass aperture covers attached Model of magnet mount
Concept Summary (MSD II)
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Locating bar as attached to rail Screenshot of laser program
Concept Summary (MSD II)
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System Architecture
- 1. Lasers receive command from VB
to track the distance of the billet
- 2. Lasers output serial data of
distance back to VB (inches)
- 1. VB turns on lasers, and sends the command
to begin distance measurement. 2.VB receives serial data from lasers.
- 3. Data from all 5 lasers are assigned variables
- 4. VB begins calculations; outputs distances to
a GUI.
- 5. Netbook is connected to a remote monitor
to display which direction the mult needs to move
- 1. Monitor displays real-time
values, and positional feedback.
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System Architecture
5 1 4 2 6 Laser and display position relative to die and mult
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System Architecture
Laser rails set up on shoe (3rd Site Visit)
Shoe Bottom Die
East West North South
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Current State of Design
Performance
Visual basic program reads information from all lasers,
calculates distances, and outputs positional feedback via a NSEW display
Updates near instantaneously Some calculations need to be revisited to ensure proper
feedback
Schedule
Behind schedule by two weeks do to unforeseen circumstances
by us and the customer
Budget
Currently under budget by ~$1000
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System Testing Results – 2/11/13
2nd Site Visit
Mechanical calibration successful System is easy to use (per WG personnel) Programming is buggy, and minor calculation changes must be
done
Feedback is provided via a computer monitor All mechanical concepts have been implemented Glass apertures Standardization of laser mounts Locating bars Magnet mounts
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System Testing Results – 2/15/13
Test Plan 1, “System Operation”
Coding changes were made from the 2nd site visit and tested at RIT using
boxes to represent die and shoe
System was run in a cold environment at WG facility to test changes in more
accurate conditions where it was able to locate a mult correctly and in real time
Test Plan 2, “Ruggedness”
Enclosure durability was drop tested from a height of 48” on an empty
- enclosure. No mechanical failure of the housing was noted
Water intrusion was tested by running an empty enclosure under a faucet
with glass aperture covers attached. No water intrusion was found
Laser temperature was monitored over the course of the test setup done at
WG as the lasers sat next to a hot die. The highest temperature recorded
- ver the 5 hour test period was 34°C using the internal temperature display
- command. This is below the maximum operating temperature of the lasers
(50°C)
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System Testing Results – 2/15/13
Test Plan 3, “Usability”
The display was easily visible at the ranges the forge operators
normally worked at (~10ft – 20ft) as verified by operators during hot testing
The feedback indicators were aligned relative to the die and
- perators had little trouble interpreting the feedback after a
few cold runs
The program itself was run by two different WG engineers and
they were able to use it successfully after minimal training
Test Plan 4, “Cost”
Was just a track of the money spent against money available The group managed to stay under budget for the duration of
the project
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System Implementation
East West North South
Feedback display with green “Press” indicator lit Lasers tracking mult position
Successful cold positioning test (3rd Site Visit)
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System Implementation
Successful cold positioning display screenshot (3rd Site Visit)
Only the “Press” indicator is lit Mult size is measured accurately Rotation error is within 0.125” tolerance
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Successes Failures
Able to calibrate system
without buying a 7th laser
Coding provides
instantaneous feedback
Mechanical concepts have
been implemented
Locating bars Magnet mounts Aperture covers Relocation of die tracking laser
Microcontroller
implementation was unsuccessful
LED display unsuccessful
Internal circuitry on
purchased LEDs caused issues
Mechanical concepts were not
- ptimal
Calibration off centerline of
die was not a rigorous as hoped
System accuracy limited to
user accuracy, on top of other error sources
Objective Project Evaluation
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