1. ATK Automated Bullet/Case Loading University of Idaho, Mechanical Engineering Dept.
Team FMJ
Chris Doudy, Ryan Kahre, Adriana Foreman, Ryan Bowen, Jordan Maag
Faculty Advisor: Dr Jay McCormack

2. Overview Problem Definition Design Inspirations Design Concepts
Background Information
Problem Statement & Design Criteria
Deconstruction of Components
Design Inspirations
Design Concepts
Current Developments
Build and Test
Optimization Experiment
Future Work
Final Deliverables
Budget

3. Background Information
Shaker tables are used to fill trays of 500 for bullet assembly
Current methods cause ergonomic concerns
Heavy lifting
Repetitive motion
Lack of adjustability

4. Problem Statement
Develop a working prototype to automate the labor intensive processes (lifting, pouring, orienting) currently being performed

5. Design Criteria 9mm caliber Automated Process
Bullets: TMJ, GDHP
Cases: Aluminum, Brass
Automated Process
High Reliability: <1 incorrect for every three 25x20 trays

6. Deconstruction of Components
Feeder – subsystem that accepts bullets/cases into the assembly; arranges bullets as necessary for delivery to the sorter
Sorter – subsystem that takes input bullets/cases from random orientation to an upright position (base down, nose up)
Delivery – subsystem that feeds upright bullets/cases from the sorter to the final tray

7. Design Flow Chart Collection Bin & Crane Feeder Final Tray 5x5 Upright
Random/ Aligned Output
Queuing Lane(s)
Sorter
Input Feed Control
Uniform, Upright Output
Delivery
Line/Array Output: 5x or 5x5
Sensor & Controller
Collection Bin & Crane Feeder
Final Tray
5x5 Upright

8. Inspiration – Case Shaker
Available for hand loaders
Orients cases upright using center of gravity – COG towards the base causes a moment that keeps cases from falling into the holes upside down

9. Inspiration – Bullet Tipper
Used for hand loaders
Flips bullets from binary input
Upside down: groove in the floor catches tip and flips bullet over
Right-side up: base passes over the groove

10. Design Concepts– CAD Models

11. Key Components – Bullet
Feeder
Flipper
Drop Tubes

12. Feeder Hopper limits amount of bullets over the holes
Rocker arms allow only one bullet to be dropped from each tube at a time
Drops 25 bullets at a time

13. Flipper
Flips bullets that are upside down in the boxes while ignoring the upright ones
Flipping is accomplished by the groove and ramp
Works with all 9mm bullets

14. Drop tubes Drops flipped bullets into bullet plate row by row
Ensures that bullets are dropped with precision
Overcomes offset center to center distances of Flipping lanes

15. Key Components – Case Shaker
Shaker Tray
Feeder Mechanism

16. Key Components – Shaker Tray
Cases slide down ramp
Shaking action forces cases to fall into holes at bottom of ramp
The case’s center of gravity causes it to fall case head down

17. Key Components – Feeder Mechanism
Cases stack up in lanes
Friction wheels control feed rate into tray
Mechanical switch rotates the wheel, drops one row of cases into tray below

18. Current Progress – Prototyping

19. Optimization Experiment
Input Variables (Bullet Flipper) A
Bullet Orientation -
Down + Up B
Channel Lane Angle 0°
30° C
Channel Grove Depth
0.02"
0.06"
Input Variables (Case Shaker) A
Vibratory Plate Angle -
12° +
15° B
Vibration Motor Rotational Velocity (rpm)
3000
5000
Input Variables
Replicates (Success Rate)
Treatment Combo A B C 1 2 3 4 5
(1) - a + b ab c ac bc
abc
2^k Factorial Statistical Analysis

20. Future Work – 2nd Semester
Module optimization
Module integration
Development of control systems
Overall integrated system testing and debugging

21. Final Deliverables Working Prototypes
Automated process from Feeder to Delivery
Capacity to fill 5x5 plates
9mm TMJ, GDHP, Brass & Aluminum Cases
High Success Rate: > 99.5%
Additional Features (as possible)
Calibers: .45, .40, .38, etc.

22. Budget- Case Feeder Item Quantity Price Cost
Polycarbonate sheet (12"X12") 1
$4.45
Polycarbonate strip (1.5"X3/64") 4
$0.53
$2.12
Electrical Components
$80.00
Electric Motor 2
$5.00
$10.00
Solenoid Actuator
$45.00
$90.00
Various Hardware
$50.00
Construction Materials
$120.00
Various Sensors
Total
$356.57

23. Budget- Bullet Flipper
Item
Quantity
Price
Cost
Various Electronics 1
$80.00
Electrical Controller
$100.00
Flipper
Electric Motor
Flipper channels 5
$1.60
$8.00
Chassis Materials
$33.41
Box Material
$2.58
$12.90
Pinion Gear
$30.00
Rack Gear
$20.41
Hopper
$16.70
Bullet Chute
Tubes 25
$1.54
$38.50
Pinch Plate
$11.00
Drop Plate
$20.58
Rocker 2
$16.00
Bottom Plate
$6.68
$13.36
Drop Chute
Sheets
$31.75
Coil
$4.36
Total
$547.97

24. Total Budget Case Shaker Prototype Budget 1 $356.57
Bullets Flipper Prototype Budget
$547.97
Poster 2
$100.00
$200.00
Travel
$311.44
Total
$1,415.98

25. Questions?