Accessible Manufacturing Equipment Phase 2 Team 2 Nicholas Neumann Ralph Prewett Jonathan Brouker Felix Adisaputra Li Tian December 10 th, 2010 ECE 480 Senior Capstone Design

Contents  Background  Design Specifications  Final Design  Results and Evaluations  Conclusion  Future Improvements  Demonstration

Background  Basic Purpose of the Project  Former 2008 Machine

Background  Former 2008 Machine (Continued)  PIC Programming C Code Timing Loop  Stepper Motors Parallel Operation (Belt)  Cam Motors  Rotary Cutter  Stationary and Movable Clamps

Background  Major Problems  Programming Interface No C programmers on staff at location Difficult Maintenance  Stepper Motors Inaccuracy Slow Operation  Motor Drivers Overheat Issue

Design Specifications  Critical Customer Requirements  Simple Programming Language Easy Maintenance  High Level of Accuracy Different Types of Motor  Variable Speed Control Higher Maximum Speed of Operation

Design Specifications  Secondary Objectives  Visual and Audio Feedback  Reliability and Robustness Reduce Occurrence of Jamming  Safety Better Design of Safety Guards  Reduce Noise During Operation  Compact Machine  Aesthetics

Final Design  Mechanical Systems  Pneumatic Guillotine Cutter  Valves Assembly

Final Design  Mechanical Systems (Continued)  Two Capstans Design Increases the Speed of Operation

Final Design  Mechanical Systems (Continued)  Adjustable Frame

Final Design  Mechanical Systems (Continued)  Tracking Guard

Final Design  Hardware  LEGO NXT Brick as Microcontroller LCD Screen for Speed Display Limited I/O Ports  LEGO Servo Motors High Accuracy Compatibility  I 2 C Serial Communication Bus I/O Expander PCF8574

Final Design  Hardware (Continued)  Input (Buttons)  8-Segment LED Display Length Output

Final Design  Hardware (Continued)  Cutter Relay Control Power Transistor  LEGO NXT Brick Power Supply Step-Down Converter Circuit –LM7809 Voltage Regulator

Final Design  Software  LEGO Mindstorms NXT-G Time

Final Design Accepts User Input. Executes Commands Starts or Stops Cutting Process Contains Cutting Process Drives 8 Segment Display Displays Length and Speed on NXT Display

Results and Evaluations  Improved Accuracy  2008: 13.24% defects  2010: 1.46% defects  Reduced Percentage Error  2008: %  2010: 2.7%

Results and Evaluations  Enhanced Speed of Operation  For 100 Cycle Run: 2008: 7 min 49.7sec 2010: 2 min 27sec  3.19 Times Faster

Results and Evaluations  Capstan Feed Design  Removed Drift Factor  Smaller Size of the Machine  4.7 Times Smaller in Area  LEGO Servo Motors  Eliminated Overheating Issue  Sources of Error  Susceptible to Ribbon Feed Method Ribbon at Similar Elevation Improves Accuracy Significantly

Conclusion  Accomplishments  Maintain Simplicity of the Programming LEGO Mindstorms NXT-G  Better Accuracy and Consistency LEGO Servo Motors  Variable Speed Controller Implementation Higher Maximum Speed of Operation

Conclusion  Accomplishments (Continued)  LED Display and Speaker  Reliable and Robust Tracking Guards Prevent Jamming  Better Safety Safety Guards  Less Noise  Smaller Size  Aesthetics

Cost PartNumberCost Guillotine Knife1$ IC LED Driver1$2.80 LED Display1$ digit LED Driver with I2C Bus interface1$3.20 LED driver w/I2C1$ uF Capacitor1$0.83 A Voltage Regulator1$0.70 I2C interface 8 bit I/O Expander2$3.32 IC I/O Expander5$9.30 Tubing1$18.75 Valve1$19.75 Filter1$11.25 Regulator1$17.00 Pneumatic Lubricator1$12.25 Male Straight1/4NPT*1/4 inch1$4.50 Male Straight1/8NPT*1/4 inch2$5.00 Male Elbow1/8NPT*1/4 inch2$12.00 Shipping $32.64 *Lego Mindstorms NXT 2.01$ Total Cost: $ *Sponsored by Sponsor

Future Improvements Warning Message Detects Jam Number Pad Length Speed Faster More Range

Future Improvements  Audio (ISD 1400)  Louder  Adjustable Volume Control A4A5A6A

Demonstration

Questions