Team 5 Andrew Sloggy, Andrew Denbow, Evan Thurman, John Strudel, - PowerPoint PPT Presentation

Team 5 Andrew Sloggy, Andrew Denbow, Evan Thurman, John Strudel, Elan Weinberg, Joey Suprick

Project Introduction Design, build, program, and demonstrate a computer controlled welding torch adapter. ● Must hold a MillerMatic 212 welding torch and accommodate strain relief ● Must terminate in a 12.7mm shaft to be mounted in a CAT40 collet holder ● Provide 2 rotary degrees of freedom ● Presses, holds, and releases the switch on the welding torch ● Performs a predermined homing and positioning sequence

Project Introduction The project will be evaluated based on the following equation: 230 33 16500    Score t m c Where: ● t is time in seconds ● m is mass in kilograms ● c is cost in dollars

Project Introduction 230 33 16500    Score t m c Based on this equation ● The time to complete the sequence should be 6.9 seconds ● The mass should be 1 kg ● The cost should be $495

Isometric View 1 Isometric View 2

Mechanism Introduction An automated welding device that is mounted in a CNC milling machine, capable of actuating a welding torch. The device is programmed to carry out a sequence of movements as required by the operator.

Mechanism Introduction Our Robot is composed of 5 subsystems: 1. The Base 2. Rotary Axis 1 3. Rotary Axis 2 4. Trigger Actuator 5. Control

Isometric View 1 Isometric View 2

Base ● The Base supports all other subsystems. ● It freely rotates around the collet adapter ○ It rests on a thrust bearing to support the load in the z-axis

Base Failure Analysis – Rotation 1 Max: 5.04MPa Deflection Von Mises 0.008 mm 5.04 MPa 2.53 MPa 0.004mm 5.88 Pa 0 mm Yield Strength: 41.36 MPa Max: 0.008 mm

Base Failure Analysis – Rotation 2 Max: 5.76 MPa Deflection Von Mises 0.017 mm 5.76 MPa 0.009 mm 2.88 MPa 0 MPa 0 mm Yield Strength: 41.36 MPa Max: 0.017 mm

Rotary Axis 1 ● Rotary axis 1 is attached to the base and provides 180° horizontal rotary motion ● A stepper motor and a micro switch will control the movement. ○ The microswitch is located on top of the base and a flag that is attached to the collet adapter will trigger it as shown.

Rotary Axis 1 Collet Adapter Thrust Bearing Thrust Washer Stepper Motor 1 with Planetary Gearbox

Rotary Axis 1 – Switch Actuation

Calculations for Stepper Motor 1

Stepper Motor 1 Sizing Tool

Rotary Axis 2 ● Rotary axis 2 controls the 45° vertical motion ○ Movement is controlled by a stepper motor and a microswitch ○ The switch is located on the outside of the base and is triggered by a flag that is attached to the shaft on the handle holder as shown ● This also carries the trigger actuator which is controlled by a servo motor

Rotary Axis 2 – Overview & Switch Actuation

Calculations for Stepper Motor 2

Stepper Motor 2 Sizing Tool

Trigger Actuator ● This gives the ability to press, hold, and release the trigger on the welding torch. ● The servo motor will attach directly to the RP handle holder ○ A cable will be used to depress the trigger ○ A force of 8.5N is needed to adequately depress the trigger

Trigger Actuator

Trigger Actuator - Servo Calculations

Control ● Microswitch (x2) ● Arduino UNO ○ Power Supply ● Arduino v2.3 Motor Shield ○ Power Supply

Control The Arduino hardware and software will be used for controlling the electrical ● components of the robot. The programming language is C++ or C. ● The Arduino Uno Rev3 will have a v2.3 Motor Shield stacked on top. ○ The v2.3 is optimal because of its h bridge circuit design that allows current load to flow in 2 directions for the stepper motors. ○ Allows 1.2 amps per bridge with 3 amps max for 20ms ● The microswitches will be used for home position calibration. ● Both stepper motors will be controlled independently of one another but will share the same power source ● A 9 volt battery will supply 500mA of current to the servo. A 26-30 ohm resistor will restrict current to 340mA.

Circuit Construction Switches Switches Servo Servo Power Supply to Motor Shield Stepper 1 Stepper 1 Stepper 2 Stepper 2 Power Supply Power Supply from USB port from USB port into Barrel Jack into Barrel Jack

Code

Bill of Materials

Summary Isometric View 1 Isometric View 2

Questions?