Team Introductions NameMajorRole Matthew ClarkMELead Mechanical
Engineer Marley Collier Sears MEME Interface Manager Sarah
DumanIEProject Manager Richard KalbEELead Electrical Engineer
Joseph PostEEEmbedded Controls Zoe RabinowitzMEDocumentation
Manager Kevin RichardEEEE Interface Manager Our Senior Design
Team
Slide 4
Problem Statement RIT students need rapid prototyping for
creation of unique circuit boards Requires multiple revisions to
perfect each circuit board Currently each iteration must be created
off campus Long lead times Expensive Limits circuit refinement
Students not involved in process
Slide 5
Problem Statement (Continued) Isolation Routing System Rapid
prototyping Inexpensive In-house fabrication Students control
production process Proposed System Create boards to accommodate
through hole components Ex. Improved Radiation Meter (Elektor PN
110538-71) Debris management system
Slide 6
Benchmarking- Scott Systems Isolation Router Able to produce
double-sided Board Smallest bits used -.016 Minimum width between
traces - 5mm Stepper control for Z-axis Stepper control for X-Y
movement Alignment pins and double sided tape used to secure board
Sacrificial plastic layer Uses an air gun to blow dust out during
the drilling PVC with shop-vac sucks up debris Data Flow Eagle
design file G-code Flashcut CNC Motors
Slide 7
Benchmarking- Scott Systems Isolation Router
Slide 8
Pros, Cons, Potential Improvements Pros: Can etch double-sided
boards Easy to switch bits 5mm minimum trace width Cons: System
lacks real time feedback sensors X,Y, and Z, axis alignment is done
manually. Improvements Improve debris management Replace or repair
Z-axis motor Enclose system
Slide 9
Benchmarking- RIT Robotics Lab Milling set-up is not used
regularly because its a pain Zeroing the plane is highly mechanical
Smallest tolerance is 10 mil Floor of the mill is warped Difficult
to change drill bits Interface software include expensive Isopro
Manual debris management Utilizes two alignment pins Board is
secured down with tape
Slide 10
Pros, Cons, Potential Improvements Pros: Relatively Inexpensive
Cons: Difficult to swap bits Poor board alignment process Z-axis
solenoid Improvements Debris management system Z-axis zeroing
Slide 11
Customer Requirements
Slide 12
Most Critical Customer Requirements
Slide 13
Engineering Requirements
Slide 14
Most Critical Engineering Requirements
Slide 15
Functional Decomposition
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Slide 20
Process Flow Chart Turn on Device / Computer Open Design File
Align / Secure Bare Board on Base Run Program Program Prompts For
Drill Bit Change Program Pauses / Swap Drill Bit Program Prompts
for Mill Bit Change Program Pauses / Swap Mill Bit Program Alerts
User it has Finished Flip Board Remove Completed Etched Board Is
There Another Side to Etch? YES No
Slide 21
P14311 Morphological Analysis
Slide 22
Slide 23
Pugh Analysis
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Slide 26
Concept #1 X-Y axis Control of Spindle Assembly Spindle
Assembly Vacuum Nest with Alignment Pins Upper and Lower Acrylic
Guards Z axis Control of Base Cyclone Separator Electronic Waste
Collection + Combination nozzle/vacuum with cyclone separator
effectively manages debris + Straight forward design easy to
understand + Vacuum nest and alignment pins ensure accuracy and
repeatability Pressurized Air Nozzle - Minimal guards allow access
to moving parts during operation - Difficult to relocate, much
larger than Ryans and Robs systems - Large weight of gantry limits
maximum accuracy - Redundant systems increase complexity
Slide 27
Concept #2 + Collet for holding tooling + Suction debris
removal + Alignment Template system - DC motors with encoders for
X,Y,Z - Horizontal Vice for mounting
Slide 28
Concept #3
Slide 29
Concept #4
Slide 30
Concept #5
Slide 31
Concept #6 + X- and Y-axis control using steppers and lead
screws, which offers great resolution + Fully enclosed unit
provides a much safer operating environment + Interlock would
safely disconnect power in case of emergency/unit malfunction +
Unit is overall very easy to use (assuming board is aligned) -
Incineration not a feasible method of debris management - Rack and
pinion Z-axis movement control would cause unnecessary backlash -
Board alignment not very easily performed with electromagnets
Slide 32
Concept #7
Slide 33
Hybrid Design
Slide 34
Pugh Total Scores Scott Systems Robotics Lab Concept 1 Concept
2 Concept 3 Concept 4 Concept 5 Concept 6 Concept 7 Hybrid Design
Total +0234443434 Total S0332014225 Total -0544653451 Total
Score0-30-200-23 Total Rank21062862281
Slide 35
Hybrid Solution- Selected Concept Stepper Motor with Lead Screw
for Y Axis Control Stepper Motor with Lead Screw for X Axis Control
Stepper Motor with Lead Screw for Z Axis Control Vacuum Clamping w/
Replaceable Sacrificial Layer Guide Rails Vacuum Attachment
Pressurized Air Nozzle Spindle Motor and Collet Assembly Vacuum
Clamp Sourced From Main Vacuum X and Z Axis Wire Management Debris
Management Vacuum Assembly
Slide 36
Emergency Kill Switch Door Interlock Acrylic Door Assembly To
Spindle VFD and X, Y, and Z Axis Stepper Motor Control To Vacuum
Assembly with HEPA Filter To Pressurized Air Source Metal Casing
Door Handle Hybrid Solution- Selected Concept
Slide 37
System Block Diagram Motor X Motor Controller Computer Design
file G-code Motor Z Motor Y USB, serial, Ethernet, etc GUI Power
Source Main Logic Board USB, serial, Ethernet, etc Debris
Management System Interlock Power conditioning Motor Theta
Slide 38
A system that creates negative pressure to hold down work
pieces during machining Will allow for easy set up by user Work
pieces will be held down after being cut Collect debris being cut
from board. Engineering Analysis Vacuum Table
Slide 39
Slide 40
Engineering Analysis Spindle vs Router Commercial Routers High
Speed (~25,000+ RPM) but with manual control Large run out, not
published as they are typically hobbyist and woodworking Run
directly from 120 VAC line power Heat problem, not designed to be
run continuously Low average cost (Free - $200) Brand specific
collets Loud
Slide 41
Low to Medium Speeds (usually 400 to 24,000 RPM) Extremely low
run out (typically less than 0.005mm/0.0002) Need an inverter
(capable of producing 0-400Hz @240VAC) Air or Water cooled options
available Higher average cost ($100 - $700) Standardized collet
sizes (ER11, ER20, R8, 3MT, etc.) Quiet Spindle Motors Engineering
Analysis Spindle vs Router
Slide 42
Higher cost of spindle motor justified by advantages Inverter
vs. speed control, ~ equal complexity (VFD) More professional look
and results from spindle Justifies laser centering upgrade in the
future Engineering Analysis Spindle vs Router
Slide 43
Engineering Analysis- Direct Material Cost Estimate
Slide 44
Slide 45
Future Engineering Analysis Weight analysis Can the Z motor
handle the weight of spindle? Vacuum Analysis- Can one shop vacuum
both collect debris and secure board? Does the vacuum have enough
suction to keep the board secure while milling the outline?
Slide 46
Potential Test Plans PCB Trace Accuracy Analysis Attach pen to
Gantry to draw board on paper Test movement of carriage Check
condition power
Slide 47
Risk Analysis
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Project Schedule Update
Slide 51
Problem Definition Systems Design Subsystems Design Detailed
Design MSD I Gate Review
Slide 52
Project Schedule Update Problem Definition Systems Design
Subsystems Design Detailed Design MSD I Gate Review