Matt “I love the fit birdz” Zapotoski Project LeaderBob “try doin that” Shackelford Lead EngineerSharif “double shot” HdairisElectrical/Computer

EngineerJoe “I got lost in traffic” Jennings Mechanical Engineer

Sponsored by:

ItineraryOverview of Project

Product Design

Risk Assessment

Questions

Project DescriptionPlan and assembly a test prototype to oil tool holdersMarket: ParlecKey high level customer needs / engineering specs:

Product versatility will handle Cat 30, 40, and 50s

with diameters up to 7”

lengths ranging from 2-18”

up to 40 lbs

Will not damage part surface Maintains 60 millionths of an

inchEfficient, consistent coverage Complete exterior of part oiled

and cleaned off

Current State of Machine Product meets all desired customer

needs Machine meets all engineering specs

for fully integrated system and subsystems

Met project budget

Machine Internals

Air Knife integration Final Orientation

Modifications

Grinding of guide Milling of pin

Validation/Complications

Oil pan channeling oil back to bin Conveyor restricting adjustability of air knife

part saturated with oil part after blowoff process Difference 1058.950 g 1052.425 g 6.525 g1058.975 g 1052.60 g 6.375 g1059.875 g 1054.25 g 2.625 g1058.325 g 1053.85 g 4.475 g1058.575 g 1054.30 g 4.275 g

AVG 4.855 g* un-oiled part weighs an average of 1051 g

By saving 4.855 grams of oil per part, and producing 1400 tool holders per shift, the expected savings of oil per day is approximately 1.98 gallons.

Oil Removal Efficiency

Cups with oil off of finished part, and part dipped into oil

Test ResultsTest # Description Criteria Result

Mechanical Tests

1 Oil removal effectiveness

Oil removal effectiveness is acceptable, there is little oil left on the part after it passes through the air knives. No

excessive continous dripping. YES

2 air knife positionsrotation at 90, 60, 45, 30 30angle at 0, 10, 25 10

distance from pin from every locationas close as

possible

3 Part versatility

Ensure that a good range of CAT 30, 40, and 50 parts can be placed on the fixture, and that they do not fall off while the

machine operates (run it through once). YES

4 Oil collection

The oil tray properly collects and returns the oil to the system tank. All oil dripping from the parts is caught and

nothing reaches the floor. YES

5 Parts distancing

The parts do not come in contact with each other or other parts of the machine, this would damage the surface tolerance. Run the machine and observe that there is reasonable clearance around the parts in all stages. YES

6 Pin durabilitySimulate improper loading of the parts onto the fixtures,

ensure that none of the pins are damaged or broken. YES

7

Oil curtain effectiveness on entrance and exit of air

chamberNo oil escapes the enclosure at any side or at the

entrance/exit YESElectrical Tests

8 Control PanelStart switch: this switch will begin the machine's operation in

the given mode. YES

9 Load powerVerify that the system power requirements can be handled

by the power supply, and that the power specs are met. YES

10 Sensors / Airknife

Air knives operate for a period long enough to perform the cleaning, the timing will adjust to accommodate the various

speeds the system supports. YESIndustrial & Misc. Tests

11 Loading/Unloading

utilize the NIOSH lifting equation to determine if any risks are associated with operator loading and unloading parts for

an entire shift.no potential

risks

12 Decibel level of the air knifeEnsure that the noise level of the the air knife is less than 90

dB 85, YES

Demonstration of the machine in action.

Future Implementation