1. CLIENT: SPECIALIZED TRAINING FOR ADULT REHABILITATION, INC. (S.T.A.R.T.) CONTACT: KATHY BAUMAN, EXECUTIVE DIRECTOR TEAM MEMBERS: BEN BLAIR LINDEN EASON JOHN HUGHEY JORDAN JOHN (PM) FACULTY TECHNICAL ADVISERS: DR. FARHANG Cardboard Bumper Assembly Jig Ref: SEC F11-75-NISH

2. Outline Executive Summary – Jordan Subsystem Description  Racking System – Jordan  Clamping System – Ben  Mechanical Analysis – Ben  Sensors – John  Logic Control Circuit – John  Containment and Ventilation – John  Light Emitting Diodes (LED) – Linden  Power Supply – Linden Overview of Device Operation – Ben Responsibilities – Jordan Costs – John and Jordan Time to Build – Ben Potential Improvements – John and Jordan Summary – Linden

3. Executive Summary Background  Current System  Client’s new production needs Design Challenge  History  Rules

4. Project Description Create a jig to increase production of cardboard bumpers, while also allowing for a wider range of employees to use the device Features:  Low cost to build and maintain  Provides mechanical advantage to operator  Simple notification system

5. Diagram of Systems Carboard Banding System Electrical System AC to DC Power Supply LogicCircuitOverflow LEDFill LEDUnderfill LEDFill Sensor Overflow Sensor Ventilation Mechanical System Racking Jig Clamping Mechanism Taping

6. Subsystems Mechanical  Racking System  Clamping System Electrical  Sensors  Indicators  Sensor control logic  Power Supply  Ventilation

7. Racking System

8. Clamping System Two Part System o U-Bolt Lock o Connective Pin

9. Mechanical Analysis UserRun 1 (sec)Run 2 (sec) 15144 26355 34958 44653 56250 Force Analysis Speed Analysis Max: 25, Min: 11, Avg: 17.22 Max: 63, Min: 44, Avg: 53.1

10. Sensors Single unit with LED and phototransistor

11. Sensor Control Logic Circuit

12. Gate Level Logic

13. Containment and Ventilation Clear acrylic box cut to size  Cheap  Effective Running temperature nearly indistinguishable from room temperature while outside the box Positioned small vent holes on sides and top to allow for moderate airflow

14. Indicator LEDs Indicators are RGB LEDs  Low cost and long life Indicators use a well-known pattern

15. Power Need the jig to be able to use standard 120 volt alternating current Components require a 5 volt direct current

16. Overview of Device Operation

17. Responsibilities Ben – Construct and integrate clamping system Jordan – Construct and integrate racking system John – Construct sensor controller, calibrate sensors, mount components in the case, attach the case to the jig Linden – Solder the power supply, attach power supply to the control logic circuit

18. Cost (Mechanical Subsystems) Mechanical Subsystems Costs Part NumberMaterialUnit PriceQuantityTotal Price 1Leg$6.812$13.62 2Leg Separator$1.641 3Base Plate Arm Long$3.501 4Base Plate Arm Short$1.751 5End Plate Arm$2.382$4.76 6End Plate$1.681 7Fall Arm$2.131 8Electrical Housing Under Plate$0.601 9Electrical Housing$4.291 10Hinge Assembly$2.491 11 Hinge Plates 2 12 Hinge Pin 1 13Base Plate$1.681 14Moving Plate$1.681 15Connective Pin$0.791 16U-Bolt$1.121 17U-Bolt Attachments$0.832$1.66 18ANSI B18.6.3-NO 6-32-1 1/4 Bolt$0.432$0.86 19ANSI B18.6.3-5/16-18-1 3/4 Bolt$0.521 Total$44.77

19. Cost (Electrical Subsytems) Part NumberMaterialUnit PriceQuantityTotal Price 1Optical Detector/Phototransistor$1.132$2.26 2Breadboard Power Supply 5V/3.3V$9.951 6Multicolor RGB LED w/ White Diffused Lens$1.753$5.25 8LM311N High Performance Voltage Comparator$7.462$14.92 12Rosin Core Solder$7.491 13AC Adapter 9V 1.5A$29.991 14L Adaptaplug$6.991 15Solder Iron$5.471 16PCB Standoff$1.991 17Universal PC Board$3.191 18De-soldering Braid$4.191 Total$91.69

20. Time Required to Build Prototype Step of ConstructionHrs. Machining base components0.5 Welding base components0.75 Machining jig components2 Welding Jig components2 Welding base to jig0.5 Installing Latch system0.5 Installing pin system0.25 Mounting electrical components to circuit board2 Soldering Components to Circuit Board5 Preparing Container for Electrical Components2 Mounting and Aligning Sensors0.5 Mounting and Aligning LEDs0.5 Total Time to Construct16.5

21. Potential Improvements Mechanical Improvements  Adjustable Base  Machined Parts  Width Adjustment for Feed Slot Electrical Improvements  Adjustable sensor mounting  Better Case

22. Summary Electronic jig Clamping system User friendly Cheap to build and maintain Small improvements can be made

23. Contest Video http://www.youtube.com/watch?v=Firs8vAgFOw