AML I Team A: FlashDriver Fall 2007

cypriotcamelUrban and Civil

Nov 29, 2013 (3 years and 6 months ago)

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AML I Team A: FlashDriver

Fall 2007

Updated Product Renders

Manufacturing Operations


Plastic Injection Molding


Metalworking and Broaching


Electrical Contact Punching

Top Case

Top Case Mold

Case Bearing Insert

Bottom Case

Bottom Case Mold

Button and Bit Cap

Button and Bit Cap Mold

MasterCAM Picture of Mold

Bottom Casing Male Mold

Bottom Casing Female Mold

Injection Molding Specifications

Preliminary Specifications


Material:


Polycarbonate


Injection Temp:


550
°
F


Mold Temperature:

220
°
F



Injection Pressure:

800 Bar


Shot Size:


~0.75 in
3


Mold Creation Specifications

Preliminary Mold Machining Specifications


Machined on HAAS 4x mill


6061 aluminum stock


20+ hours machining time per part


Using ¼” to 1/32” end mills


High quality finishing required


Integrated core and ejector pins



Through Pin


Metalworking Steps


Feed square bar stock
into CNC lathe.


Turn stock down to
desired diameter at
appropriate locations.


Slit saw stock with CNC
mill to obtain end slit on
the pin for torsion
spring.

Cold Finished 1018 Steel
Square Bar Stock

Hex Shaft


Metalworking steps


-
Load bar into CNC Lathe


-
Rotary Broach in CNC Lathe


-
Mount in mill fixture for
Square broaching





Cold Finished 1018 Steel

Round Stock

Broaching Operation

Square Broach

Rotary Hex Broach

Source: http://www.slatertools.com/

Critical Tolerances and Quality Control


Critical Tolerances:


The 4 screw pins on the top
and bottom casings


Broaching hole on hex shaft for
through pin


Bit cap interface with casing
halves


QC:


Go/no go gauges for top and
bottom casings, broach for
through pin will be applied to
all manufactured parts.


Measuring 1
st

manufactured
component on CMM and then
every 3
rd

for the first 50 on
calipers

Adjustability of Mechanism

Since the system will most likely
need tuning, parts are easily
adjustable


-
Removable mold insert can be
changed to adjust bearing
tolerances


-
Adjustable rig to change cut
length of compression springs


-
Slit saw cut angle can be
adjusted to change torsion
spring pretension

Battery Contacts


Rapid Prototype Dies and Water Jet Pattern to get
perfect contact shape


Use Existing 1/4” copper material in AML

Battery Contacts


Proposed Plan: Use hydraulic press to make
contacts


Modify female and male press parts on press

Battery Contact Press

Battery Contact Pallet

Assembly Operations


Electronics Subassembly


Spring Subassembly


Overall Construction

Electronics Subassembly

Final Electronics Subassembly

Soldering Jig

Electronics Subassembly continued

Heat Staking Fixture

Torsion Spring Placement


The Torsion spring
requires one arm to
be pre
-
tensioned one
-
half turn.


It would be loaded
onto a slotted static
shaft, and then bent,
and slid into position
by a simple collar.


Assembly Overall Flow


Utilize Adept


3 End Effectors

Shaft Placement/Rotation


Gripper/Flipper


Screwdriver






Pallets/Feeders


Bottom, Button, Shaft Subassembly


Top, Bits, Bit Cap


Assembly Fixtures



Top Fixture


Clamping/Screwdriving



Final Assembly

Assembly Plan View

1

2

3

4

5

Screw Feeding

6

7

8

AML Budget


Broken down into Component, Manufacturing & Assembly


Component has 15% overhead for shipping costs.


Manufacturing & Assembly has 30% overhead for additional
purchases.


Best Case


The best case AML budget was created taking into account the items
that may already be in stock in the AML or available at no charge.


Worst Case


The worst case AML budget was created by using the suggested AML
budget values as found in the course syllabus.

Component Budget

Manufacturing and Assembly Budget Part I

Manufacturing and Assembly Budget Part II

30% overhead added for
purchase of some materials

Summary


Sum of Best Case AML Component, and
Manufacturing & Assembly Budget


$4,346


Sum of Worst Case AML Component, and
Manufacturing & Assembly Budget


$10,759


Proposed AML II Schedule

Sunday

Monday

Tuesday

Wednesday

Thursday

Friday

Saturday

Jan 13
th

Project familiarization. Design and process optimization. Mold review.

19

20

Cost reduction. Acquire tooling. Start machining molds.

26

27

Procurement of material and tooling for all processes.

Feb 1
st

2

3

Procurement of material and tooling for all processes.

9

10

Component manufacturing and assembly fixture creation.

16

17

Component manufacturing. Assembly setup.

23

24

Component manufacturing. Assembly setup.

Mar 1
st

2

Component finalization and finishing touches.

8

9

Spring Break

15

16

Sys integration

22

23

Sys integration

29

30

Sys integration

Apr 1
st

System integration/Assembly

5

6

Assembly

12

13

Assembly

19

20

Packaging

26

27

Final TDP and Presentation preparation

May 1
st

2

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