Summer Internship Presentation

Nathan EastburnMechanical Engineering Intern

5/11/2015 – 8/14/2015

OverviewProjects What I Learned

Advanced SolidWorks Skills

Drafting techniques Manufacturing information

IR Heater Digital Rebuild Task The Situation Progress Moving forward

Endeavor Frame Redesign Task The Situation Progress Moving forward

PRF Rebuild And Improvement Task The Situation Upgrades Progress Moving forward

Platen Rebuild And

Improvement Task The Situation Problems Progress Moving forward

Standard Parts Creation Task

Gallium SIM Parts Task Result

IR Heater Digital RebuildTask

To build an accurate Endeavor IR heater attachment in SolidWorks from outdated drawings and pictures.

IR Heater Digital RebuildThe Situation

The IR heater was made by SFI a very long time ago and as such all the engineering drawings for it’s components were outdated and used obsolete components.

Using recent pictures and old drawings I updated all of the drawings to match current demand and available parts.

I also made sure that my models were accurate enough to be used in creating a build procedure.

IR Heater Digital RebuildProgress

Completed 3D models of all parts Completed 2D drawings of all parts Completed 3D model of Heater Assembly Completed 2D drawing of Heater Assembly Generated an accurate BOM from top level assembly

Moving Forward Update current documentation Implement changes made to assembly Use assembly to update build procedure Utilize the above in the next Endeavor tool

Endeavor Frame Redesign Task

Digitally capture the improved endeavor frame with expert precision.

Endeavor Frame RedesignThe Situation

Many changes had been made to the Endeavor frame since the last accurate drawings were produced.

There were frequent corrections being made with vendors over the phone to ensure these changes were upheld as the old drawings did not show them.

These corrections included cost saving measures that save the company hundreds of dollars on each frame.

Endeavor Frame RedesignProgress

Completed 3D model of frame Completed 2D drawings of frame Generated an accurate BOM from3D model Released updated endeavor frame drawings

Moving Forward Update current documentation Implement changes made to frame Utilize the above in the next Endeavor tool

PRF Rebuild And Improvement Task

Utilizing existing drawings, pictures, and build procedures; reproduce the PRF PM lid in SolidWorks with accurate BOM structure, making improvements as needed.

The Situation The PRF was the most complicated assembly I had worked on. Most

of the parts that were in the assembly when I got it needed updated, remodeled, or replaced. And many simply weren't there. I used the existing build procedure and BOM to digitally rebuild the assembly from the ground up.

Upgrades Pneumatic fittings updated Aluminum manifolds replaced with triple elbow 1 touch fittings & street elbows. 1 touch T fitting replaced withY fitting mounted to the cover. Electrical weirs re-spec’ed CPC pins resized Solenoid orientation change Electrical diagram recreated

PRF Rebuild And Improvement

Progress Completed 3D models of all parts Completed 2D drawings of sheet metal parts Completed 3D models of PRF Assembly, upgrades, &

subassemblies Completed 2D drawings of PRF Assembly & subassemblies Generated an accurate BOM from top level assembly &

subassemblies Moving Forward

Update current documentation Implement changes made to assembly Use assembly to update build procedure Utilize the above in the next Endeavor tool

PRF Rebuild And Improvement

Task Much the same as with the PRF I needed to rebuild this assembly however the

lack of documentation on the platen was prominent and as such I needed to collaborate with manufacturing to ensure my assembly was accurate.

Platen Rebuild And Improvement

The Situation I started work on the platen with only pictures and a severely outdated BOM to

work with. After a few conversations with manufacturing I discovered a number of

problems with the way the platen was being constructed.

Platen Rebuild And Improvement

Platen Rebuild And Improvement Problems

The bellows and pistons facilitating the actuation of the platen were improperly spec’d out As a result the bellows was being over extended and compressed constantly causing it to fail.

The finish spec’d out on the platen cover and many other aluminum sheet metal parts was formulated using toxic hexavalent chromium

The platen hub which acts as a rod connecting the platen to the actuator plate was being made out of OFHC copper 101 which I believe to be an unnecessary expense.

The drawing for the mounting cover was done poorly with many inconsistencies. The acrylic cover was being screwed to the cover panels without the use of PEM

nuts or any other type of fastener. The platen assembly was non-structured meaning it lacked proper subassemblies.

Progress Completed 3D models of all parts Completed 2D drawings of sheet metal parts Completed 3D models of Platen Assembly, upgrades, & subassemblies Completed 2D drawings of Platen Assembly & subassemblies Generated an accurate BOM from top level assembly & subassemblies Initiated a company wide change for all part finishes containing

hexavalent chromium All upgrades and updates have been reflected on part models and

drawings.Moving Forward

Update current documentation Implement changes made to assembly Use assembly to update build procedure Investigate changes to bellows, pistons, and platen hub. Utilize the above in the next Endeavor tool

Platen Rebuild And Improvement

Standard Parts Creation Task

As I worked through my main tasks I frequently found that I needed standardized configuration controlled parts like screws, pneumatic fittings, PEM nuts, and wire terminals.

These parts needed design tables to effectively model hundreds of parts all at once. Using the values in the table to determine there dimensions.

Gallium SIM PartsTask The engineering team lead requested that the teem create simple

shape models for a tool named the Gallium. He would use these models to create an interactive controller for the tool. I was tasked with the process module and all its possible configurations.

Gallium SIM PartsResult I managed to create all 71 process module configurations and add

them to the virtual Gallium tool within the week time frame given by the teem lead.

What I Learned Advanced SolidWorks Skills

Routing (from to lists, tube creation, library management, trouble shooting) Design tables (advanced excel techniques, linking variables) Sheet metal parts (the continuity of error) Licenses management (swapping out the premium licenses on the fly) EPDM (part reference management and repair, work flow, vaults, advanced

searching)

Drafting techniques BOM (linking, omission, importance) Rev management

Manufacturing information Sputtering processes Function of Endeavor Pneumatic methods Steel bellows Cable designations A bit of devnet and MAS Finishing