Automated Adhesion System

ugliestmysticΤεχνίτη Νοημοσύνη και Ρομποτική

14 Νοε 2013 (πριν από 3 χρόνια και 6 μήνες)

55 εμφανίσεις

Automated Adhesion System

Sponsor:


Team members:

Phil Jaquish

Kevin Lakowski

Cliff Lewis





Joel Oostdyk

Chris Spikes

Jeff Willner

Project Objectives

Automate an adhesive application
process at American Seating.

Minimize the amount of adhesive used
during operation.

Support an increase in production from
325 to 500 parts per 8 hr. shift.

Functional Requirements
(1 of 2)

Design, build, and install an engineering
solution to gain part capacity, maintain
adhesive application consistency and
reduce material waste.

The system will be capable of producing
a minimum of 500
parts per 8 hr. shift.

Functional Requirements
(2 of 2)

The fabric loading and unloading
processes must be ergonomic.


Use “off the shelf” equipment, parts
and materials where possible for ease
of service and availability.

Project Risks

Supplier miscommunication


Failure of parts during testing and
assembly

Restrictions on necessary resources

Incorrect, damaged, or late parts


Proposed Solution

Two
-
axis motion controlled linear
actuators

Manual nozzle height adjustment

GE Programmable Logic Controller
(PLC) for motion control

Vertical adjustable workstation

Operator interface for ease of
changeovers and troubleshooting

System Schematic


Adjustable base


Aluminum extrusion frame


2 axis linear actuators

Step 1: Load Fabric
onto Board. Load
Board onto Fixture.
Step 2: Cycle Machine.
Step 3: Unload
Board/Fabric from
Fixture. Pass Fabric
to next operation.
Process Flow Diagram

User Interface

Lighted “start” button

Selector switches for fabric dimensions
and automatic or manual operation

Indicator lights for incorrect fabric,
home position and in
-
cycle

Two zero
-
force palm buttons

E
-
stops


Sub
-
system Schematic

Start
Power up
Palm button
pushed?
System check
no
yes
Fabric select
(1 of 2)

Sub
-
system Schematics

Linear Actuators

(2 of 2)

Calculations and Studies
(1 of 2)

Time Study


Cycle time to load part, 10.77 sec


Cycle time to apply adhesive, 20.46 sec

Study of applied adhesive spray width


Desired, 3 inches


Measured, 2.16 inches

Calculations and Studies
(2 of 2)

Cycle Times (CT)


Overall Maximum Cycle Time, 46.8 sec


For 500 part per shift (shift = 6.5 hours)



CT of adhesive application for Seat, 30.03 sec


Not including Load CT or a 6 second safety factor



CT of adhesive application for Back, 21.47 sec


Not including Load CT or a 6 second safety factor

Velocity Analysis


Minimum velocity to achieve CT, 9.074 in/sec


Maximum velocity, 29.835 in/sec

Environmental Impact

Reduction of over
-
spray from current 12
lbs per shift.

Electrical components compatible with
current ASC standards.

Work cell has capacity to be
reconfigured for future expansion.


Cost Savings

Pounds of
waste per
day

Total cost
per year

% Reduction

Cost
savings per
year

12


$38,095.20





10


$31,746.00

17%


$ 6,349.20

8


$25,396.80

33%


$ 12,698.40

6


$19,047.60

50%


$ 19,047.60

4


$12,698.40

67%


$ 25,396.80

2


$ 6,349.20

83%


$ 31,746.00

0


$
-


100%


$ 38,095.20

*Adhesive cost = $12.21/lb

* Year based on 40 hr. weeks


Adhesive Testing

Supplies


SC
-
5 Pail Unloader


Adhesive


Seat backs and seat bottoms

Variables


Nozzle height


Air pressure


Adhesive temp.


Nozzle flow settings


Project Milestones

Proposal presentation:


4/10/01

Final approval:


4/20/01

Components ordered:




4/27/01

Programming complete:


5/30/01

Assembly/Debug:



7/03/01


System test & review:


7/15/01

Product presentation:


8/03/01

Budget

Electrical

Cost

Supplies

$234.66

PLC Components

$2,529.90

Sensors and Cables

$1,698.98

Light Curtain System

$4,926.00

Power and Terminators

$965.30

Interface / Switches

$888.42

Enclosures / Misc.

$1,136.24

Subtotal

$12,379.50

Mechanical

Motion System

$12,093.30

Framing / Structure

$1,838.19

Miscellaneous

$1,757.67

Subtotal

$15,689.16

Total

$28,068.66

Personnel Assignments

Project Component

Responsibility

Electrical, Programming, Electrical
Drawings

Phil Jaquish and Kevin
Lakowski

Linear Motion

Cliff Lewis

Cell Layout, CAD drawings,

Web page

Joel Oostdyk

Adhesive Application, Project
Management

Christopher Spikes

Material Handling, Budget Tracking

Jeff Willner

Deliverables

Product


Automated adhesive spray system


Locating boards to support the fabric during
operation

Documentation


Training manuals for engineering, maintenance,
and operator personnel


Preventative Maintenance manual


Drawing files


Bill of Materials


Hardcopies and electronic files of electrical
schematics, layouts and flowcharts

Questions and Answers