Conceptual Design Review

Senior Design 2004-2005

University of Idaho

College of Engineering

Overview

1. Functional requirements and constraints2. Material Flow

– Remove cartridges from tray– Presentation of cartridges in front of camera– Gage wheel– Put cartridges into 50ct tray

3. Cartridge Inspection– Lighting– Inspection Software

4. Future focus5. Budget6. Schedule

1. Functional Requirements and Constraints

Minimal change in height desired from 500ct to 50ct tray

Minimize risk of incurring incidental and other defects while processing product

Cost of x-y positioning systems

2. Material flow considerations

2.1 Remove cartridges from tray• Gravity feed from 500ct tray

– Freefall acceleration velocities are sufficient for 600parts/min requirement

– How do we get them back up higher in elevation?

• Vertical ascent out of 500ct tray– Vacuum and air blast alternatives considered– Air is readily available– Experimental results

Vertical ascent: Air jet and tube array• Remove cartridges from

500ct tray– 20 tube array, 1-D

positioning system

– 500ct tray gets positioned, tubes are stationary

– Varied length tubes, cartridges arrive at different times

– Ten cartridges pulsed every 1 second with an air jet array below the tubes

Where the tubes end

• Cartridge queue– Accepts cartridges from feed tube– Advances cartridges to inspection area– Provides better advancement control than

gravity feed tube

2.2 Presentation of cartridges in front of camera

• Dropping

• Contact Rolling– Single Roller– Multiple Roller

Dropping

• Image: 3 images within one picture

• Pros– Gravity is consistent and does work for us – Gravity produces proper orientation

• Cons– Scaling issues, consistency in falling distance– Mirrors in place to give 360 degree view

• Image: 3 images taken 120o apart• Pros

– Consistent image in front of camera– Multiple parts within picture window

• Cons– 3 images taken 120o apart cause long process

time– High transfer rates, rotational and linear

Single Roller

Single Roller

Multiple Roller

• Image: 1 unrolled image of entire cartridge

• Pros– Consistent image in front of camera– Multiple parts within picture window

• Cons– High transfer rates, rotational and linear– Complex apparatus

Multiple Roller

2.3 Gage Wheel

Pros– Gages parts for proper diameter– Outputs bad parts to separate

bin– Produces timing interval

between parts

Cons– Limited to one type of defect– Allows minor defective parts to

pass

2.4 50-ct Tray Package Machine

• Existing Prototype to be utilized for project

• Electromechanical device that can be controlled by camera processor

• Built for existing tray configuration

3. Cartridge Inspection3.1 Lighting

1. Front lighting

2. Back lighting

3. Structured lighting

Things to Consider

• Metallic reflective surface

• Curved shape of case

• Surface defects on case

• Measurements of dimensions of entire bullet

Applications

Lighting Techniques Application Areas

Front lighting-directional-darkfield 3D surface features

Front lighting-directional-brightfield Surface scratches

Backlighting 2D object shape and dimension

Structured lighting 3D objects

Omni-directinal lighting Shiny objects

Front lighting

Brightfield illumination Darkfield illumination

Front lighting

Diffused Front light Omni-directional illumination

Shiny Object

Reflective surface

Back lighting

Optical Diffuser

Structured lighting

Lighting options for material flow

Rolling Falling

3 pictures

Panoramic

*Structured *Backlighitng and

frontlighting

*Structured *Backlighting and

frontlighting

*Structured *Frontlighting

Not sure this is possible

3.2 Inspection Software

• Three ways to use software to inspect bullets– Intensity– Edges– Shapes

Inspection Software

• Intensity - Use multiple polygons to look for dark areas (flaws) on the cartridge surface.

This sensor is looking for the amount of “white space” inside the red box

Inspection Software

• Intensity– Pros

• Easily detect major defects• Checks areas• Easily manipulate intensity values

– Cons• Smaller sensors are better, but more work to

make them• Hairline fractures can cause problems if

intensity settings aren’t sensitive enough

Inspection SoftwareIntensity Pass

Inspection SoftwareIntensity Fail

Inspection Software

• Edges - Use multiple sensors to look for edges (flaws) inside areas that are white on the cartridge surface.

These sensors are looking for edges on the red lines

Inspection Software• Edges

– Pros• Easily detect major defects• Checks for all edges• Easy to make multiple sensors in different places

– Cons• Smaller sensors are better, but more work to make

them• Hairline fractures can cause problems if edges are too

far apart

Inspection SoftwareEdge Pass

Inspection SoftwareEdge Fail

Inspection Software

• Shapes - Use a single or multiple sensors to look for “perfect” cartridges or parts of the cartridge.

This sensor is looking for the “white” shapes on the cartridge

Inspection Software• Shapes

– Pros• Easily detect major defects• Checks for all white “blobs” larger than a specified

size.

– Cons• Smaller sensors are better, but more work and more

processing time• Smaller defects including hairline fractures and

small dents are difficult to see

Inspection SoftwareShape Pass

Inspection SoftwareShape Fail

4. Future Focus

Based on recent discussion with ATK, focus will be on the inspection process

• Further testing– Material handling– Lighting

• Combination of front and back lighting

– Software inspection• Combination of intensity and edge sensors

4.2 Lighting

• Combination of front lighting and back lighting– Pro

• Cheaper

• Works well with dropping

– Cons• Hard to adjust

• Reflection

4.3 Software

• Combination of intensity and edge sensors– Pros

• Both sensors work well on different sections of the cartridge

• Inspects entire cartridge

– Cons• Multiple sensors

• Increased processing time

5. Phase 1 Budget

• Expected expenses– Materials– Controls

• Motors

• Microcontroller

– Lighting

• Expected date for budget approximation– December 6, 2004

6. Short Term Schedule

• Experiment (to be completed by December 3rd)– Take pictures

• Different lighting• Different transfer methods

– Detect defects• Implement different sensors• Minimize processing time

• Deliverables (December 17th)– Preliminary design of phase 1

Questions