Team 4

Automate Sample Measurement for Leco GDS 900

Design Proposal Presentation

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By: David DeHaro, Eric Montejo Francisco, Louis King, Micah Cerros

Problem/Objectives Overview

2

Problem Overview: Hardware

Spoke

Cooling Puck

Wagon-wheel samples (8 and 16 sample)

Pusher/Cleaner

• Objective: Automate Movement/Alignment of both types of wagon wheel against O-ring for GDS900 analysis process, 0.5mm precision required

O-Ring/Lamp

Wagon Wheel

Spoke

Louis

3

Wagon Wheel

z

y

x

Problem Overview: Software

• Objective: Facilitate Communication between GDS900 Machine (Through CornerStone Application) and PLC

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• API user input requirements:
• Start/Stop Analysis from PC
• Calibration for Zero Position
• Vacuum seal error response:
• Skip specific spoke
• Try again
• Abort

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Micah

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Motors

4

PLC

GDS900

API

GDS900

PLC

CornerStone

API

Windows PC

Completed Risk Reductions

5

Completed Risk Reduction 1

Application/Device Communication Tests Completed:

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1. Successfully networked devices via Ethernet (PLC, PC, GDS900)

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• Established Python Client/Server Sockets Communication

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• Successfully sent test XML commands to GDS900

Micah

6

Motors

GDS900

PLC

CornerStone

API

Windows PC

Client Socket Script

Server Socket Script

Data

Completed Risk Reduction 2

Stepper Motor Control:

1. Successfully “jogged” motor to desired location
2. Return “home” when prompted
3. Change “home” location as needed
4. Resolved GPIO problems with the PLC

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7

Eric

Proposed Designs

8

Overall Wagon Wheel Movement Mechanism

9

Finalized Design Decisions:

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• Two Axis (y,z axis) Gantry for spoke alignment
• Precise movement
• Accounts for wagon-wheel tolerances

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In-Progress Design Decisions:

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• X-axis movement actuation
• Mounting to GDS

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z-axis

y-axis

x-axis

Spring-loaded gripper

Louis

GDS Lamp

y-axis

z-axis

x-axis

Vertical (z-axis) Mechanism

10

Finalized Design Decisions:

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• FUYU FSK40E Ball Screw ($150)
• +/-0.03mm precision
• Max Load: 20kg
• Max speed: 100mm/s

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In-Progress Design Decisions:

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• Mounting y-axis to mounting block

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NEMA 23 Stepper Motor

Rigid Extruded Aluminum Support

Ball-screw drive system

Mounting block with threaded holes

Louis

Horizontal (y-axis) Mechanism

11

Finalized Design Decisions:

• NEMA 8 Stepper Motor with Lead Screw
• Max horizontal force: 15lb
• 0.003048mm nut linear movement per 1.8° motor step (High precision)

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• McMaster Low-Profile Cartridge/Rack Roller Ball Sliders
• Precise movement
• Rate Max load 600 lbs
• Load Mass 3 lbs
• Max moment 5.7 ft-lbs
• Calculated moment 0.25 ft- lbs

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In-Progress Design Decisions:

• Lead Screw/Motor Position on 10mm Extrusion (Left or Right Side)

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David

Wagon Wheel Gripper

12

Finalized Design Decisions:

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• Spring Loaded Clamp Arm with V-Base
• Ease of loading/unloading
• Easy to Manufacture (2D Cuts)

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In-Progress Design Decisions:

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• Extension Spring v.s Torsion Spring
• Additional Grip
• Indented Clamp Arm v.s Flat
• Attachment to Slider Cartridge

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Micah

Motor Control System

13

Finalized Design Decisions:

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• PIAM-200 Programmable Logic Controller (PLC) to control motors
• Arduino IDE for Programming PLC
• User will need set zero position spoke for accurate spoke alignments

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In-Progress Design Decisions:

• Length of wiring harnesses
• Control box choices and placement

Eric

API (Software) Design

14

Flowchart of automation process

Eric

GUI’s

Logistics

15

Design Decision Timeline

16

Determine how to mount Y-axis to Z-axis

Determine how to mount mechanism to GDS Plate

Week 2

Gripper design finalization:

• Extension Spring v.s Torsion Spring
• Additional Grip
• Spoke Alignment Design
• Attachment to Slider Cartridge

Week 3

Week 4

Week 5

Determine gripper X-axis actuation

Determine Y-axis lead screw positioning

Determine control box and harness placement

David

Component Purchasing and Machining

17

Purchasing:

• FUYU FSK40E: Purchased today from Amazon
• Anaheim Automation Stepper linear actuator: Purchased, arriving tomorrow
• Low profile rails and carriages: Purchased from McMaster-Carr, arriving week 3

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Machining:

• Gripper Parts 2D Laser Cut (Aluminum): week 3
• Drill press/Taps Gripper Parts: week 3-4

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3D Printing:

• Horizontal axis lead screw mounting parts: week 3-4

David

Questions and Challenges

Questions for LECO (Maker of GDS900 Machine):

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• What specific remote control XML commands we will need?
• Need more documentation with specifics for each remote control commands

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• Can we have machine built in puck clamp push wagon wheel against O-ring?

18

David

Updated Gantt Chart

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Thank you!

Questions?

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Extra Slides

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Completed Risk Reduction 1

Rotating Gripper Prototype:

Issues:

• Side of wagon-wheel tapered
• Tends to shift and fall out

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• Friction Drive imprecise

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• Large Manufacturing tolerance of wagon-wheel diameter

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• Measured Tolerance OD Wagon Wheel: +/-1.5mm

⇒ One full rotation: 360^o+/-7.2^o (unacceptable)

Micah

22

Conclusion: Rotating Gripper is NOT feasible!

Wagon Wheel Gripper

23

Finalized Design Decisions:

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• Spring Loaded Clamp Arm with V-Base
• Ease of loading/unloading
• Easy to Manufacture (2D Cuts)
• Room for Spoke Alignment Design

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In-Progress Design Decisions:

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• Extension Spring v.s Torsion Spring
• Additional Grip
• Spoke Alignment Design
• Indented Clamp Arm v.s Flat
• Attachment to Slider Cartridge

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Micah

API (Software) Design

24

Finalized Design Decisions:

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• Source code: Python
• Tkinker Library for Graphic User Interface (GUI)

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• Executable Application on PC Desktop

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In-Progress Design Decisions:

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• Specific Functions to be created

Eric