P16601: Guide Rollers. Multi-Wire Glass Cutting Machine

Transcription

1 P16601: Guide Rollers Multi-Wire Glass Cutting Machine

2 P16601 Ryan Cavanaugh EE Lead Engineer (EE) Samantha Degerick ME Purchasing/EDGE Evan Ney ME Facilitator Noah Stransky ME Project Lead Quincey Stuck ISE Collaborator/Scribe Viniamin Tokarchuk EE Researcher Kenneth Wilkinson ME Lead Engineer (ME)

3 Agenda Project Background Problem Statement Use Scenarios Customer Requirements Engineering Requirements Design Constraints Concerns Risk Assessment Project Plan

4 Project Background Glass Fab, Inc. currently uses a Meyer Burger DS264 to make their larger order cuts of glass at sizes of 2.5mm, 6mm, and 9mm. They use a steel wire with a brass coating with a slurry made of silicon carbide to cut through ingots. This wire is wrapped around 2 large guide rollers that have specific grooves for the wire for the cuts. To improve the efficiency of the machine a smaller version should be made in order to handle the volume of the orders at an appropriate magnitude.

5 Problem Statement Glass Fab Inc. cuts glass ingots for various purposes. They are currently using a Meyer Burger DS264 for both high volume and low volume parts. Unfortunately, this machine uses excessive amounts of energy and requires a long startup time which makes it inefficient for low volume production. Ultimately, Glass Fab Inc. is looking for a downsized wire saw suitable for low volume parts, with increased product flexibility, lower power consumption and designed from a minimalist approach. The creation of this wire saw will be done with a multiple team approach. Our team will primarily focus on the wire saw s guide rollers. Our team will determine the arrangement, size and materials of the rollers based on customer requirements. The expected end result is a guide roller developmental fixture with proper diagnostic instrumentation. The resulting design must be compatible with the coupling projects.

6 Problem Statement Highlights Glass Fab Inc s current multi-wire glass saw is oversized The new multi-wire saw needs to consume less power and take up less space Reduce the boot-up time of the saw After a wire break, resetting the wire takes one worker a whole day Our team, P16601, will focus on the design of the guide rollers Goal: Create sized down, energy efficient guide rollers to be used in a modified glass cutting machine for Glass Fab, Inc.

7 Stakeholders USERS: Glass Fab, Inc. Machine Operator Glass Fab s Customers DESIGNERS RIT Senior Design Team MSD Team P16601 Coupling and Future Teams

8 General Use Scenario

9 Additional Use Scenarios

10 Customer Requirements

11 Engineering Requirements

12 House of Quality

13 Constraints Constraints were defined as limitations or restrictions that work as a bottleneck, requiring the use of one design option over others. Cost Constraints: Construction and implementation cost falls within the prescribed budget: Guide Rollers (2): $5,000 - $50,000 Guide Roller Drive Motors: $3,000 - $10,000 Sensors/Controllers: $0 (Must be included with COTS drive motor) Fixture Frame: $5,000 - $10,000 Fixture Control: $2,000 - $5,000 Experimental Hardware: $0 - $5,000

14 Other Constraints

15 Concerns/Challenges Process Type Glass Fab is unsure whether they want the Wet Slurry Cutting Process or the Dry Diamond-Wire Cutting Process. Currently the team has been told to design for the Wet Slurry Process. The type of process will certainly affect the design of the guide rollers as well as eventually every aspect of the project from guide roller controller construction, to safety, to controls. Is it possible to design for both? Project Coupling Projects P16601 (Guide Rollers), P16602 (Wire Supply, Movement and Takeup), and P16603 (work piece movement) are heavily interdependent on each other. If one of the projects does not meet the required design criteria, the other two teams most likely will suffer. Even if each team develops great designs on their own, they may not be able to integrate the designs together and perform the required task. Each of the three projects need to cooperate if the project is to be successful. Glass Fab Inc. A correct or incorrect/ faulty design will cost the Glass Gab company and its employers/employees capital. An incorrect design will obviously be the most costly. However, there are many possible correct designs with different costs. What trade-offs will need to be made between design and cost? The correct or incorrect design of this project will have long-term effects on the Glass Fab company.

16 Risk Assessment

17 Project Plan Key Questions for Next 3 Weeks: 1. Will the guide rollers be modeled off of the DS264 or will a unique design be created? 2. How many guide rollers are going to be used? 3. Where in the cutting process is the most power being used? 4. How powerful do we need the motors to be? 5. What materials will the guide rollers be made of?

18 Questions?