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TheUniversityofTexasPan‐American
SeniorDesignMECE4360
September2011‐May2012
Elite4
OscarCantu
AdrianDelgado
JuanMendiola
JoaquinVaca
TheWireWindingMachine
Course Advisor: Dr. Kamal Sarkar Technical Advisors: Dr. Isaac Choutapalli, Dr. Young-Gil Park
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TableofContents
I.) Abstract…………………………………………………………………………………….……...….2II.) Introduction…………………………………………………………………….…..……………....3
Overviewofsituation………………………………………………………………...3 Companybackground………………………………………………………………..3 Proposedoveralldesign………………………………………………………….…3
III.) ProblemFormulation methodology………………………………………………………………………….....5 Proposedtimeline………………………………………………………….………....6 Needstatement………………………………………………………………………...7 Problemdefinition……………………………………………………………….......8
o Goal……………………………………………………………………………….8o Objectives………………………………………………………………………8o Constraints…………………………………………………………………….8o Needs…………………………………………………………………………….8o Wants…………………………………………………………………………….9o Competitor/similarproducts………………………………………….9o QFD……………………………………………………………………………...10
IV.) ConceptualDesign
o Methodology…………………………………………………………………….10o SystemConcept………………………………………………………………..12o ProductDevelopment……………………………………………………….13o PowerInput……………………………………………………………….…….22o PowerTransmission……….……………………………………….……….24o QualityAssurance…………………………………………………………….27o ComponentSupport…………………………………………………….......32o EnvironmentalProtection………………………………………….……..32
V.) FinalDesignAnalysis
GivenParametersandInitialEquations……………………………………………..…37Pullingmechanism……………………………………………………………………………….38WindingMechanism…………………………………………………………………………….39PowerTransmission(Gears,shaft,Bushingsandbearings)……………….…….39Control……………………………………………………………………………………………..…...43ResistanceMeasurement……………………………………………………………………44
VI.) Summary………………………………………………………………………..………….………….48VII.) FutureWork………………………………………………………………………………………….48VIII.) Acknowledgments………………………………………………………………………….………49IX.) References……………………………………………………………………………….………....50X.) Appendices………………………………………………………………………………..…….….51
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I.AbstractDeltaHeatLLC,manufacturerofheatingproductsforviscositycontroland
freezeprotection,contactedtheUniversityofTexasPanAmericanduringthesummerof2011fordesignandprototypingofawirewindingmachine.Thecompanystatedthattheparticularproducttheywishthemachinetoproduceisresistivewirewithafiberglasscore.Theproductiscurrentlyusedwithintheirflexiblerubberheatersproductline.Thistypeofresistivewireiscurrentlyavailableinthemarket.However,purchasingmustbemadeinbulkandshippingisalsoamajorissueduetotimeconstraintsoftheordersplaced.DeltaHeatLLCcurrentlybuysmaterialinbulksizesandisconstantlyleftwithasurplusofrawmaterial.Thewirewindingmachinedesiredwastoproduceresistivewirebasedoninputandbothdecreasesurplusandincreaserevenue.
Thisprojectwasdividedintotwophases,adesignphaseandaprototypingphase.Thedesignphaseincludedproblemformulation,conceptualdesign,andfinaldesignanalysismethodology.Researchwasconductedtobegindraftinganinitialdesignofthewirewindingmachine.However,itwasnotedthattheinformationaboutthemachineswaslimitedduetothefactthatthesemachinesareusuallytradesecrets.Theteamtookadifferentapproachandresearchedsimilarproductionmethodsandbasedonthesemethodsdevelopedafinaldesign.ThedesignphasewaseffectivelycompletedonDecember2012andprototypingbeganinJanuary2012.Theprototypingphaseincludedprototyping,calibrating,andredesignofmachine.ItwasagreedthattwoidenticalmachinesweretobeconstructedwithonetobedeliveredtothecompanyinMay2012.ThesecondmachineistostayatTheUniversityofTexas‐PanAmericanwherefurtherresearchwillbeconductedtoimprovebothitsproductionandqualitycontrolaspectsaswellasimplementautomation.
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II.Introduction
OverviewofSituation
Thisprojectdealswiththedesignandprototypeofawirewindingmachine.Itwasdividedintoadesignandprototypephasewitheachlastingapproximately15weeks.Aprototypecapableofproducingresistivewirewithafiberglasscorewascompleted,calibratedanddeliveredtoDeltaHeatLlconMay2012.AsecondprototypewasalsocompletedbyMay2012tobekeptatthemechanicalengineeringdepartmentforfurtherresearchanddevelopment.
CompanyBackground
DeltaHeatLLCisalocatedinRioHondo,Texasthatcurrentlyproducesheatersforfreezeprotection,condensationandviscositycontrolaswellasotherapplications.Theirlineofproductincludesflexiblerubberheatersandinsulatedfuelpipes.Currentcustomersarefrom(butnotlimitedto)marketsinmilitary,aerospace,medical,automotive,andvendingequipmentduetothemultipleapplicationsofeachproductline.[1,2,3]
ProposedOverallDesign
Thedesignofthewire‐windingmachineshouldbeabletowindresistancewirearoundafiberclasscore.Itshouldbecapableofusingdifferenttypeofwirematerialsandmeasuretheresistanceofthewireveryaccurate.Theusermustbeabletocontrolthemotorvelocitiesandsubsequentiallycontroltheamountofloopsaroundthefiberglasscore.Themachinewillusearealtimeresistancemeasurementdevicewhichtheteamistodesigntoensureproperproduction.Finallyallpartsusedintheprototypeshouldbeeasilyobtainedfromthemarket.
Figure3:ExamplesofsomeoftheproductsthatDeltaHeatLLCproducesusingtheHeatingResistanceWire:DrumHeaters,PadHeaters,FuelHeaters.Courtesyofwww.electroflex.com,andwww.deltaheatllc.com.
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ConstraintsThemainconstraintinthisprojectiscreatingaccurateresistancewireswitha+or–3%resistancetolerance.Anotheristhatwhenwindingfromto2to3wireswemustmakesurethewiresstayparalleltoeachotherastheywind.Constantspacingandmaintainproperwiretensionisimportantsothatourmachinecanproducequalityproduct.Ourmachinedesignmustalsobecompatiblewithin‐marketparts.[1,2]NeedsTomeetourcustomers’requirementsourmachineneedstobeabletocreateresistancewiresforvariableresistances.[1,2]
Figure4:ExampleoftheHeatingResistanceWire.Therearedifferentmaterialsusedforeachandhavedifferentresistancesduetotheloopsofwirearoundthecore.Alsonoticethedoublewirewindontheright
Figure3:Inthisfigureweshowthedifferentmaterialandspoolsthemachinewillhandletocreatetheresistancewire.
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Wants Someofthewantsthataregoingtobeenforcedinourmachinewillbeameasuringsystemthatwilldisplaytheresistanceforcurrentwirebeingproduced.Also,analarmwillbeintegratedtoinformtheuserthatparametersstaywiththenorms.[1]
Researchwasconductedtobegindraftinganinitialdesignofthewire
windingmachine.However,itwasnotedthattheinformationaboutthemachineswaslimitedduetothefactthatthesemachinesareusuallytradesecrets.Theteamtookadifferentapproachandresearchedsimilarproductionmethodsandbasedonthesemethodsdevelopedafinaldesign.ThedesignphasewaseffectivelycompletedonDecember2012andprototypingbeganinJanuary2012.Theprototypingphaseincludedprototyping,calibrating,andredesignofmachine.ItwasagreedthattwoidenticalmachinesweretobeconstructedwithonetobedeliveredtothecompanyinMay2012.ThesecondmachineistostayatTheUniversityofTexas‐PanAmericanwherefurtherresearchwillbeconductedtoimprovebothitsproductionandqualitycontrolaspectsaswellasimplementautomation.
III.ProblemFormulation
Methodology
Ourseniordesignteamhasbeguntoresearchsimilarmachinesorprocessesthatwindwireorperformothersimilartasks.Webeganourdesignformulationbyfirstgettingtoknowourcustomer.Theteammetwiththecompanyattheirplantandobservedboththeirfinishedproductsaswellasthewiresthatthemachineistoproduce.Wrappingwirearoundafiberglasscoreaddsflexibility,whichiswhatthecustomerneedsforhisproducts.Therearemanyfactorsthatmustbecalculatedaswellasdesignconstraints.Weneedtodeterminethenecessarytorqueandwiretensionforthewindingprocess.Thisisbecauseweneedagoodestimateofthehorsepowerneededinthemotorsinordertoaccuratelydesignourmachinewiththerightparts.Theuseofdifferenttypesofmaterialswillalsohavetobetakesintoconsiderationduetothefactthateverymaterialhasadifferenttypeofresistivity.Implementationofthesefactorsandconstraintsthroughoutthenextfewmonthswillleadustoafinaldesign.PartswillbeorderedafterwardsandprototypingaswellasthefinalmachinewillbebuiltbyMay2012.
AnotherproblemwitheachproductrequiringaspecificresistancewireisthatwiremanufacturerssellonlyinpresetamountsofresistivewiretentativelylockinginprofitfortheDeltaHeatLLC(untiltheremainingwireisused)aswell
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asaddingrawmaterialstotheinventoryforwhichstoragealsobecomesadilemmainthelongrun.
Implementationofthemachinethatourseniordesigngroupwilldesignandconstructwillhelpthecompanyovercomethecurrentsituationofexcessiverawmaterialandcost.Itwillgivethecompanymorefreedomfordevelopmentofnewproductlinesandincreasethecompany’sprofit.[1,2]
ProposedTimeline
GanttChart
IntheGanttchartabove,weshowtheproposedtimelineaswellasthestepsitwilltakefortheprojecttobesuccessful.ThisGanttcharthoweverispreliminaryandissubjecttochange.
WestartedwiththeProblemFormulationandthestepsrequiredtocreateourfirstpresentation.Wewillbeconductingsomeplantvisits,researchonexistingproducts,scheduling,andaswellastheQFD.
Following,weincludedtheConceptGeneration.Heretheteamwillcreateideasandcomparethemwiththeiradvantagesanddisadvantages.Thedrawingsfortheseideaswillbeincludedsowecananalyzethem,andaprototypeofeachwillbemadesowecanobservetheirbehavior.
NextwehaveConceptSelection.Inthistimelinewewillshowourselecteddesign,andwewilldosomecalculations,Pro‐Engineerdrawings,FEAanalysisandsomepriceestimation.
FinallyforthissemesterwehavetheFinalPresentation.Bythistimewewillhaveafinaldesign,afinalcost,andwillbeginorderingthepartsforthenextsemestersowecanbeginassemblyofourmachinedesign.
Figure2:Inthispictureshowsthebulkthecompanywantstoavoid.
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NeedStatement
DeltaHeatLLCcontactedtheUniversityofTexasPanAmericanfordesignandprototypingofawirewindingmachinewhichwillcreatedifferentresistancewiresbasedontheneedofthecompany.Theresistivewireusedinthecurrentandfuturelineofproductsiscurrentlylimitingboththeexpansionandrevenuesofthecompanyduetofactthateachproductlinerequiresdifferentresistancewire.Foreachproductline,thecompanyisrequiredtoorderadifferenttypeofresistivewirewithanaveragecostof$70perpound.Flexiblerubberheatersrequirehavingthewirewoundaroundafiberglasscorewhichtypicallycostsanextra10%to15%.Productionoftheflexibleresistivewirebythewirewindingmachinewilleffectivelysavethecompany10%to15%perpound.
Figure 3: This is the Gantt chart. This is the proposed timeline for our project.
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ProblemDefinition
GoalsOurgoalinourseniordesignprojectistodesignawire‐windingmachinethatwillallowconstantresistancewireproduction.Themachineshouldbeabletorunsmoothlyatalltimeandhighlyprecise.Themachineshouldbeeasilyoperatedbyanexternalsourcesuchasacomputer.Itshouldbehighlyreliableandeasytomaintain.ObjectivesOurwire‐windingmachineshouldbeabletowind1to3resistancewiresaroundafiberclasscore.Itshouldbecapableofusingdifferenttypeofwirematerialsandmeasuretheresistanceofthewireveryaccurate.Wemustbeabletocontrolthemotorvelocitiesandcontroltheamountofloopsaroundthefiberglasscore.ThemachinewilluseLabViewtooperatethemachineandmusthaveanalarmifawireisbrokenduringproduction.Themachine’spartsshouldbeeasilyobtainedfromthemarket.[1,2,3,4,5]
ConstraintsSomeconstraintsinourseniordesignprojectiscreatingaccurateresistancewireswitha+or–3%resistancetolerance.Whenwindingfromto2to3wireswemustmakesurethewiresstayparalleltoeachotherastheywind.Constantspacingandmaintainproperwiretensionisimportantsothatourmachinecanproducequalityproduct.Ourmachinedesignmustalsobecompatiblewithin‐marketparts.[1,2]NeedsTomeetourcustomers’requirementsourmachineneedstobeabletocreateresistancewiresforvariableresistances.[1,2]
Figure3:Inthisfigureweshowthedifferentmaterialandspoolsthemachinewillhandletocreatetheresistancewire.
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Wants Someofthewantsthataregoingtobeenforcedinourmachinewillbeameasuringsystemthatwilldisplaytheresistanceforcurrentwirebeingproduced.Also,analarmwillbeintegratedtoinformtheuserthatparametersstaywiththenorms.[1]Competitive/SimilarProducts
Companiesthatmanufacturetheseflexibleheatingcable,havekepttheirmanufacturingmachinerysecret.Thereisnoinformationonhowthesemachinesworkandoperatebythesamereason.SomecompaniesthathavethecapabilitiestomakethesewiresareOmega.com,Kanthal,andJelliff.[3,4,5]QFD IntheFollowingTable,weshowtheQualityFunctionDeploymentChart.Inthischart,weshowtherelationshipbetweentheCustomerRequirementsandtheFunctionalRequirementsofourproduct.Forexample:TheLowCostReplacementPartshasaverystrongrelationshipwiththenumberofmotorssinceitmustbecheap;Numberofpartsbeingthesamereasonandsize.Thisalsohasamediumrelationshipwiththeweightsincewemustpickthecheapestandmostavailablepartsfromthemarketfortheproduct.Andtheeaseofuseisnotrelevantatall,sincetheyareonlyforreplacement.Inourfinaldesign,theteamhastriedtocomplytheserequirements.
Figure4:ExampleoftheHeatingResistanceWire.Therearedifferentmaterialsusedforeachandhavedifferentresistancesduetotheloopsofwirearoundthecore.Alsonoticethedoublewirewindontheright
Figure5:Competition:TheseareothercompaniesthatmanufacturetheHeating
resistancewire.
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Fu
nct
ion
al
Req
uir
emen
ts
Customer Requirements (Explicit and
Implicit)
1 | | | | | | | | | 19% 10 9
2 | 4% 2 3
3 | | | | | | 13% 7 9
4 | | | | | | 13% 7 3
5 | | | | | | 13% 7 9
6 | | | | 10% 5 9
7 | | | | | | | 15% 8 9
8 | | | | | 12% 6 9
M
axim
um
Rel
atio
nsh
ip
C
ust
omer
Im
port
ance
R
elat
ive
Wei
ght
R
ow #
W
eigh
t C
har
t
▽ ▽ ▽ ●● ○ ○ ▽
● ● ○ ▽
○ ○○ ▽ ▽ ○
○ ▽ ▽ ○
○ ○
▽ ▽
● ○
○ ○
Easy to Repair
○○
●▽●●
Operability
●▽
▽ ○
Tw
o M
otor
s
# of
Par
ts
Siz
e
Wei
ght
Eas
e of
Use
Must Wind 1-3 Spools onto Fiberglass Core
Alarm
Speed Control for Resistance Wires
Digital Device that reads Wire Resistance
Speed Control For Fiberglass core
Low Cost Replacement Parts
IV.ConceptualDesign
Methodology
OurSeniorDesigngroupbegangeneratingconceptsbyaskingourcustomer
onthenameofthecompanythattheypurchasedtheirresistancewiresfrom.JelliffisthenameofthecompanythatDeltaHeatLLCpurchasestheirresistancewiresfrom.DeltaHeatLLCneedstheirresistancewirestobewoundaroundafiberglasscorewhichaddsanextracosttothewires.Ourcustomeralsohadtobuytheirresistancewiresthroughbulksothisledtooverstockofproductattheirmanufacturingfacility.Thisledourcustomertoapproachustodesignawirewindingmachinesothattheycanproducetheirownresistancewire.
Figure 6: QFD Chart. This is the Quality Function Deployment chart that this project will base its design.
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Webeganbyresearchingcompaniesthatcreatedtheseresistancewires.Omega.com,Jeliff,SpringfieldWire,andKanthalaresomeofthesecompanies.Afterresearchingthesecompanies,ourseniordesignteamcouldnotfindanyinformationonthemachinesthatcreatethewires.Thecompanieswouldnotpostpicturesoranyotherinformationonthesemachines.Ourteamfoundoutthatthesemachinesarein‐housetradesecretsandcompaniesdonotreleaseinformationonthewirewindingmachines.Duetothisfact,ourteambeganresearchingothersimilarproductsandsimilarmethodsforwindingproducts. Onegreatexampleourseniordesigngroupfoundwasthewindingofrope.Ropeiscomposedofflexiblefiberswhicharethanbraidedtogether.
Theflexiblewiresarefirstformedintoyarnandthentwistedandbraided
intoarope.Ascanbeseeninthefigureabove,theyarnisfedthroughtheseplatesthatarespinningandarethanfedthoughadiewheretheyaretwistedandformedintoathree‐strandrope. Anotherperfectexampleareguitarstrings.Guitarstringsaremadeupofasteelwirethatisthancoatedwithbronzeornickel.Thereasonforthisistocreatetheperfectvibrationsforthetoneofmusic.Ascanbeseenbelowinthetwofigures,theguitarstringsarewindedaroundusingahookandaspinningaction.
Figure7:Thisconceptshowsropewinding.http://www.madehow.com/Volume‐2/Rope.html
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Withthehelpoftheseexamples,wewereabletogenerateideasforourwire
windingmachine.Weusedtheropeandguitarstringsasexamplesforformulatinganddesignthebestpossiblewirewindingmachinepossible.
SystemConcept
Theproblemformulationaspectsofthisprojectallowedtheteamtogetaninsightintowhatwasneededandaclearviewofthisproject’sobjectives.Thisinitselfallowedforagenerallistofcomponentrequirementsforthemachinetobedesigned.Theteamthentookthislistandbegandraftingpossibleconfigurationsforthemachinewhichwouldsatisfyalltherequirements.Thisdesign,althoughpreliminary,allowedforfurtheranalysisanddevelopment.Belowisalistofsomedesigncriteriathatthemachinehadtomeet: Windonetothreespoolsontoafiberglasscore MeasureResistanceofthewireproduced Beabletomanufacturedifferentresistancewirebasedoninput Havethefinalproductwindontoaspool Musthaveasimpleuserinterface Mustbehighlypreciseandeasytomaintain
Carefulobservationoftheserequirementsallowedtheteamtodevelopthree
possibledesigns.However,thereisawiderangeofconfigurationswhichmeetthisrequirement.Inordertooptimizethedesigntomeettheobjectivesattheminimumcostpossiblewithoutsacrificingquality,itwasnecessarytolookatalistofmaincomponentsthatageneralconfigurationofthewirewindingmachinewould
Figure8:Inthisfigureweshowanotheroftheconceptswetoolforourproject.Thisconceptisforguitarstrings.
www.howitsmade.com/guitarstrings
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require.Eachcomponentlistedwouldnotnecessarilybeusedinthefinaldesignbutratherprovideanacceptablestartingpointforapplicationofreverseengineeringmethodology.Thegenerallistofmajorcomponentsincludes:
Table Motors DriveTraincomponents ResistanceMonitoringDevices Housing WindingComponent/sTheabovelistedwasreverseengineeredandthemainfunctionsforthewire
windingmachinewasthenderivedbyusingafunctiondecompositionmethodologyprovidedbyDr.RobertFreemanonhiswebsite:mece.utpa.edu/~rafree.Whilethislistwaslatermodifiedastheprojectprogresseditwasnecessarytobegintheprocessforcomponentselectionaswellasamoreaccuratewirewindingmachineconceptselection.Thelistisasfollows:
ProductDevelopment PowerInput PowerTransmission QualityAssurance ProductDevelopment EnvironmentalProtection
Theconceptgenerationforthewirewindingmachinecalledforreverse
engineeringinordertoderivethefunctionaldecompositionofthisproject.Atthispoint,itwaspossibletomoveforwardintotheresearchingpossiblecomponentsforeachofthemainfunctionslistedabove.Theteamthenbeganselectingpotentialcomponentsforeachfunctionbylistingeachanddoingabriefadvantage/disadvantageanalysisinordertonarrowthelistofviablecomponentoptionsforthewirewindingmachine.
ProductDevelopment
ProductdevelopmentisaveryvitalfunctioninthedesignoftheWireWinderMachine.Forthesubfunction,theseniordesigngrouphasdeterminedthatwirewindingisaveryimportantaspectforthedevelopmentofourwires.
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Figure9:ProductDevelopmentDiagram
Thediagramabove,outlinestheadvantagesanddisadvantagesofourthree
methodsforwirewindingthatcouldbeusedfordevelopingourresistancewires.Thedetailsoftheanalysisthatresultedinthediagramareexplainedbelow.InitialConceptDesign#1:GearwithShaft
Figure10:
InitialConceptDesign#1:GearwithShaft
Thewayofthisdesignworksisthefollowing:theFiberglassCoreinthe
back,passesthedrivengearandthewindertubetoafinalspoolwheretheResistancewireiscollected.ThemainGearisdrivenbyanACmotorinwhichthevelocitycanbecontrolled.Attachedtothemaingearisaframemadeoutoftubes.Thisframehasthewirespoolonthetoppartoftheframe.Asthegearrotates,theexternalpartoftheframerotatesaroundthecore,andthismovementwillmakethewiretowindontothefiberglasscore.Advantages/DisadvantagesFigure10depictsasystemthatcanresultinapositivereactionforourproblem.Thishasacoupleofadvantagesthatmakethissystemveryefficient.Thissystemhasacapabilityofbeingverypreciseinwindingspacingandplacementwhilemaintainingverycosteffective.Themaindisadvantageforthisdesignisthatitmayintroducebendingloadstotheshaftmakingitverydifficulttocontrolandmightneedmaintenance.Having3wirespoolswoundedaroundthecoreinparallel,andinsymmetryisalmostimpossibletoachieve.
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InitialConceptDesign#2:DrivingGearwithBearing
Figure11:InitialConceptDesign#2:GearwithBearing
Inthisdesign,thecoreisattachedtothebackofthegearandthewiresarefurtherbackofthemaingear.Asthegearrotates,thecoreisfedinthemiddleofthegearandispulledbywirerollers.Themaingearalsohasatubeattachedtoabearingnwhichthewirespassthroughit.Thistubehelpsforthewiretobedrivenorguidethemtoacertainangletothecore.Thenasthemaingearisinrotation,thewiresarebeingwindedinthefiberglasscore.Afterthewinding,theresistancewireisbeingfedtoaspoolsothecustomercantakeit.AdvantagesandDisadvantages
Usingadrivinggearwithabearing(Fig55)willallowforprecisecontrolofthewindingofthewiresaroundthefiberglasscore.ThisisaveryimportantfeaturebecausetheprecisionrequirementsetbyDeltaHeatLlccouldbemet.Gearsarehighlypreciseandthemotorwillbeabletocontrolitwithease.Usingabearingalsohasanadvantagebecausebydoingso,thedistancebetweenthewirestobewoundcanbemanipulatedwithoutintroducingtwisttothewires.
Thedisadvantagesofimplementingthisdesignforthewirewindingprocessisthatthegearsizenecessarywasapproximatedtobecloseto12”.Whenlookingatpricesinthecurrentmarket,thesizerequiresthegeartobecustommadeandafterseveralinquiriestheaveragecostofthegearwas$4000‐$5000.Thishighcostreallyisahugesetbacknotonlybecauseofthebudget,butalsobecauseifitgetsdamageditcouldbehardtofindareplacementsinceitscustommade.Thebearingtobeusedforthisalsobringsupaconcernduetothefactthatithastofitinsidethedrivinggear,andtheinsideofthebearingmustbecustommade.Thiscouldsignificantlyraisethecostoftheinitialdesignwhichjustfromthegearwillbesignificantlyhigh.
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InitialConceptDesign#3:Satellite
Figure12:InitialConceptDesign#3.GearandSatelliteSpools.
Inthisdesign,thefiberglassisplacedbehindthehousingandmotor,anditwillpassthroughthe.Duringthistime,itwillpassthroughamountingplatewithspools,inwhichtheyrotatearoundthecoreandthewireisbeingwindedaroundit.Afterthewindingtheproductwillpassthrough2rollers,inwhicharecoatedwithrhodiumplating,tomeasuretheresistanceperfoot.Afterthattheproductisbeingspooledinthefinalspool.
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Themountingplateisoneofthemostimportantpartsofthemachine.Themountingplate’spurposeinthewirewindermachineistoholdupto4spoolsofresistancewire.Asitrotates,thesewireswillwindaroundthefiberglasscore,creatingthentheflexibleresistancewire.Thematerialthatwillbeusedfisaluminum.Thismaterialwaschosenbecausetherewillbeconstantadditionand/orremovalofspoolsandthetighteningandlooseningoftheboltsmaywearanyothermaterial.Alsothealuminumislighterthanothermetals,andthishelpstoreducetheangularmomentumandtorquerequiredtostopandorstartthemachine.
Themountingplatewillbeconnectedtoadrivengearwithatubularshaft(wheretheFiberglasscorewillpass).Theangularvelocitythemountingplateanddrivengearis460rpm.Thisspeedwasobtainedfromthedrawingspeedofthefiberglasscore(7.5in/min)andhowmanywindswerequireperinch(60windsperinchmax,6windsperinchmin).Thisvelocitywillremainconstantatalltimes.
Theadvantageofthemountingplatedesignisthattheuserwillbeabletohave2differentspoolplacements.Listedbelowaretheadvantagesanddisadvantagesofeachofthem:
Spoolswithcounterweight:Advantages
LinesEasiertobeparallel.Disadvantages
Maximumnumberofspools:4 Maycausevibration
Figure 12a: Mounting Plate: Picture on the right is the mounting plate without the spools, and the one of the left is with spools.
Figure 12b: Spools with Counter weight
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OppositeSpoolsAdvantages
Mayplaceupto8spools Maynotcausevibration Moreuniformrotation
Disadvantages Toomanywirescancause
intertwinementora“cable”effect. Harderto
haveparallelwire
Withthisdesignofflywheelwecanplaybetweenthe“Spoolswithcounterweight”andthe“OppositeSpools”todeterminethebestoptiontoobtainabetterwinding.
DesignCriteriaWeightingMatrix:0‐1Scale
WireWinding
#Spools Alignment Quality Control Precision Service #Parts Durability Cost
Score=RowSum
Weight
#ofSpools 1 0 1 0 1 1 1 1 60.166666667
Alginment 0 0 1 0 1 1 1 1 50.138888889
Quality 1 1 1 1 1 1 1 1 80.222222222
Control 0 0 0 0 1 1 1 1 40.111111111
Precision 1 1 0 1 1 1 1 1 70.194444444
Service 0 0 0 0 0 1 0 1 20.055555556
#Parts 0 0 0 0 0 0 0 1 10.027777778
Durability 0 0 0 0 0 1 1 1 30.083333333
Cost 0 0 0 0 0 0 0 0 0 0TotalNumberofComparisons=Sum
Scores 36 1
Theabovematrixshowsthedesigncriteriaweighingmatrixforthewire
windingmechanism.Afterseveralweeksofworkingondifferentdesignswehavecometotheconclusionofthethreedifferentwirewindingmechanisms.Wewereabletodetermine9differentdesigncriteria’s.Wefeltnumberofspools,alignment,quality,control,precision,service,numberofparts,durability,andcostwerethemostimportantcriteria’stoourwirewindingmechanism.Ascanbeseenonourmatrixabove,precision,numberandspools,quality,andalignmenthadthehighestweight.Wethancomparedeachofthedesignswhichweregeardesign,satellitedesign,andcrankdesigntoeachofthedesigncriteria’s.
Figure 12c: Opposite spools
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DesignVariantRankingwithRespectto#ofSpools
#ofSpools Gear Satellite Crank Score=RowSum Norm.ScoreGear 0 1 1 0.333333333
Satellite 1 1 2 0.666666667Crank 0 0 0 0
3 1
Theabovematrixshowsourdesignsinrespecttothenumberofspools.Itcanbeseenfromourmatrixthatthesatellitedesignhadthebestscoreinrespecttothenumberofspools.Wehavedeterminedthatwewillbeabletoaddmorenumberofspoolsinourdesignifyouuseasatellitedesigntoourmachine.Ourdesignmustbeabletowind1‐3wiresaroundafiberglasscore.
DesignVariantRankingwithRespecttoAlignmentAlignment Gear Satellite Crank Score=RowSum Norm.ScoreGear 0 1 1 0.333333333
Satellite 1 1 2 0.666666667Crank 0 0 0 0
3 1
Theabovematrixshowsourdesignsinrespecttothealignment.Itcanbeseenfromourmatrixthatthesatellitedesignhadthebestscoreinrespecttothealignment.Thecrankhadascoreof0whilethesatellitehadthehighestscorewith0.667.Wehavedeterminedthatthesatellitedesignwillhavethebestalignmentinrespecttowirewinding.
DesignVariantRankingwithRespecttoQualityQuality Gear Satellite Crank Score=RowSum Norm.ScoreGear 0 0 0 0
Satellite 1 1 2 0.666666667Crank 1 0 1 0.333333333 3 1
Theabovematrixshowsourdesignsinrespecttoquality.Itcanbeseenfrom
ourmatrixthatthesatellitedesignhadthebestscoreinrespecttothealignment.Thegeardesigngota0scoreduetothefactthatthewiresthatgothroughthebearinginourdesignaregoingtowearandaregoingtoaffecttheresistanceofthewiresduetothefrictiononthewires.Thesatellitedesignwasourbestcandidateinrespecttoqualityduetothefactthatthewirewillbewoundedwithlittlefrictiononthewires.
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DesignVariantRankingwithRespecttoControl
Control Gear Satellite Crank Score=RowSum Norm.ScoreGear 1 1 2 0.666666667
Satellite 0 1 1 0.333333333Crank 0 0 0 0 3 1
Theabovematrixshowsourdesigninrespecttocontrol.Itcanbeseenfrom
ourmatrixthatthegeardesignhadthebestscoreinrespecttocontrol.Thegeardesignprovidesthebestcontroldueprecisecontrolofthegear.Wefeltthatourcrankdesignhadtheworstscoreinrespecttocontrolduetotheweightofthespoolsonthecranknotprovidingagoodcenterofbalancewhenthecrankisspinningaroundthefiberglasscore.
DesignVariantRankingwithRespecttoPrecisionPrecision Gear Satelite Crank Score=RowSum Norm.ScoreGear 0 0 0 0
Satellite 1 1 2 0.666666667Crank 1 0 1 0.333333333
3 1
Theabovematrixshowsourdesigninrespecttoprecision.Itcanbeseenfromourmatrixthatthesatellitedesignhadthebestscoreinrespecttoprecision.Thesatellitedesignhasthebestprecisiondietotheplacementsofthespoolsontheflywheelandtheprecisionofthewindingaroundthefiberglasscore.
DesignVariantRankingwithRespecttoService Gear Satellite Crank Score=RowSum Norm.Score
Gear 0 1 1 0.333333333Satellite 1 1 2 0.666666667Crank 0 0 0 0 3 1
Theabovematrixshowsourdesigninrespecttoservice.Itcanbeseenfrom
thematrixthatthesatellitehadthehighestscoreinrespecttoservice.Thecrankdesignwouldrequirealotofserviceanditwouldtakeawhiletochangethespools.Wefeelthatthesatellitedesignwillbethebestdesigninrespecttoserviceduetotheeaseofchangingofspools.
21
DesignVariantRankingwithRespectto#Parts#ofParts Gear Satellite Crank Score=RowSum Norm.ScoreGear 1 1 2 0.666666667
Satellite 0 0 0 0Crank 0 1 1 0.333333333
3 1
Theabovematrixshowsourdesigninrespecttothenumberofparts.Itcanbeseenfromthematrixthatthegeardesignwillbethebestofchoiceforourmachine.Duetothefactthatthegeardesignwillhavetheleastnumberofparts,ithadthebestscore.
DesignVariantRankingwithRespecttoDurabilityDurability Gear Satellite Crank Score=RowSum Norm.ScoreGear 0 1 1 0.333333333
Satellite 1 1 2 0.666666667Crank 0 0 0 0
3 1
Theabovematrixshowsourdesigninrespecttothedurability.Duetothedesign,thesatellitegearhadthebestscoreinrespecttothedurability.Duetothebendingloadsinthecrankandthelifeofthegearsinthegeardesign,itwasconcludedthatsatellitewouldbethebestdesigntobedurable.
DesignVariantRankingwithRespecttoCostCost Gear Satellite Crank Score=RowSum Norm.ScoreGear 1 0 1 0.333333333
Satellite 0 0 0 0Crank 1 1 2 0.666666667 3 1
Theabovematrixshowsourdesigninrespecttothecost.Duethecrank
beingverycostefficient,ithadthehighestscore.Thesatellitedesignandthegeardesignhadthehighestcost.
22
SelectionMatrix
#Spools Alignment Quality Control Precision Service
#Parts Durability Cost Score
Gear 0.33 0.33 0.00 0.67 0.00 0.33 0.67 0.33 0.33
0.06 0.05 0.00 0.07 0.00 0.02 0.02 0.03 0.00 0.24Satellite 0.67 0.67 0.67 0.33 0.67 0.67 0.00 0.67 0.00
0.11 0.09 0.15 0.04 0.13 0.04 0.00 0.06 0.00 0.61
Crank 0.00 0.00 0.33 0.00 0.33 0.00 0.33 0.00 0.67
0.00 0.00 0.07 0.00 0.06 0.00 0.01 0.00 0.00 0.15
1Decision
Theabovematrixshowstheselectionmatrixwherewefindoutfromour
previousmatriceswhichdesignforthewirewindingmechanismisbest.Aftercomparingallofourdesigncriteria’stoourdifferentwirewindmechanismsitcanbeseenthatsatellitedesignhadthehighestscorewhichmeansthatrespecttoourcriteriaitwouldbeourbestchoiceforourmachine.Itbeatouttheotherwirewindingmethodsbymanypoints.Webelievethatthesatellitedesignwillprovideeverythingweneedforourwirewindingmachine.
PowerInput
Forpowerinputtheteamhaveacoupleofoptionstochoosefrom.ThereisagreatavailabilityformACtoDCmotors,butthereareadvantagesanddisadvantagestoeachproduct.DCMotors
FortheoptionofDCmotorstheadvantagesarethatwehaveagreatselectiontochooseformandcanhandleveryfastRPMs,thiscanbeverythankstothespeedcontrolusingagearbox.Eventhoughwehavetheseadvantagesthedisadvantagesarevitalduetotheprecisionrequirementsofourmachine.Thedisadvantagesincludeextensivemaintenanceduetobrushlifedeterioration,butthemostcriticaldisadvantageisthattherelationshipbetweentorqueandRPMareinverselyrelated.
Figure13:DCMotor.www.instructables.com
Figure14:DCMotorspeedvs.torquerelationship.www.Globalspec.com
23
ACMotors
ACMotorsareveryreliableandveryaccurateifusedappropriately.SomeadvantagesthatACmotorshavearethattheyareverycostlyeffectiveandneedsminimumamountofmaintenanceduetoachangeofpartswithinthemotor.Last,butveryimportant,isthatACmotorsmaintaintheirtorqueallthrutheirRPMrange.SomedisadvantagesarethatACmotorvelocitiesareabitmorecomplexwhencomparedtoDCmotors,butovercomingthisobstaclecanbeamatterofbuyingapreciseandaccurateVariableFrequencyDrive.
Figure15:ACMotor.www.globalspec.com
Figure16:Torquevs.%SpeedforACmotor.
www.globalspec.com
Figure17:PowerInputDiagram
24
Powerinputisthemajorfactortocontrolvelocitiesandprecision.ThecustomerrequirementsweretohaveanACmotorfortheinputofpower.Therearethreedifferenttypesofmotors.Becauseoftheapplicationtwooftheseoptionsarediscarded.ServomotorsareusedtocontrolangularpositioninaclockwiseandcounterclockwisemotionusingaPWM.Theobjectiveistocontrolspeedwhilemaintainingconstanttorque.Servomotorswillnotsatisfytheobjectiverequirements.Steppermotorsaremainlytocontroldirectionandpositionofthedriven.Thismotorisanexcellentprospectfortheapplication,theonlydeficiencyisitstorquecurveandrpmrelationship;whichareinverselyproportional.Thebestcandidatesareinvertermotors.ThistypeofmotorswillkeepconstanttorqueforallitsRPMrange.Also,theinvertermotorhasavarietyofcontrollersthatarecompatibletocontrolitsspeed,whilemaintainingprecision.
PowerTransmission
Thissectionwilldealwiththetransmissionofpowertothewirewindingmachine.Therearemanyoptionsbutthemostsimpleandaccurateoptionsarebelts,chains,andgears.Thesedifferentoptionscanbehelpfulandefficientondeliveringtheneededtorque,speed,oraccelerationstothesystem.
Belts:
Forbeltstheadvantagesarethattheyabsorbvibrationsduetothematerialsthattheyaremadeof.Thisalsomakesthemveryeconomical.However,afterlongperiodsofoperation,thebeltsloseefficiency.Also,ariseinthetemperatureaffectsitslife.
Chains:Chainsareaveryeffectiveindeliveringpower.
Thankstotheusageoflinks,sizesofchainsareveryeasytofind,makingthempriceproficient.Theproblemwithchainsisthatvibrationsthatareinductedtothesystemmayaccelerateanddeceleratetheshaftbeingdriven;thisisacrucialnegativeeffectthatwewanttoavoid.[10,11]Gears:
Gearsareanexcellentwayoftransmittingpower.Therearemanytypesofgears,buttheusefultypesforthewirewindermachinearespurgears.Spurgearshaveagreatcontactareathatdoesnotallowanyslip,thisallowsforconstant
Figure18:Belts.www.meyle.de
Figure19:ChainandSprocket.www.profromance.com
25
speedstobeeasilyachieved.Thenegativeeffectsthatgearscontributetothesolutionaretheamountofinertiaagearcontain.Massofagearisahugefactorthatcanresultontheimpactofmotorselectionsandcasingselection,thiscouldleaddirectlytoanegativeimpacttothebudget.[14]
Thefirstobjectiveforthisprojectistobepreciseandefficient.Costisnotamajorfactorduetoanextensivebudget.Sotheoutcomeforthisweightingmatrixwasthatmaintenanceandprecisionbeingequallyimportant.Thisdesigncriterionwasbasedoncost,maintenance,andprecision.
Figure20:HelicalandSpurGears. http://www.emerson‐ept.com/
Figure21:PowerTransmissionDiagram.
26
Forthefirstmatrixanalyzinggears,chains,andbeltsareveryimportant.Asfarascostgoes,chainsisthebestcosteffectivemechanismwecanutilize,secondbeingbelts,andthirdgears.
Nowcomparingthesamecomponentstomaintenance.Thisyieldsthatgears
arereallygoodatbeingmaintenanceefficient.Chainstendtowearthesprocketsandlubricationsisverycritical.Beltscomein2nd,thereasoningisthatbeltsaregooduntiltheystartwearing,butdonotneedanylubrication.
Thismatrixshowscomponentsversusprecision.Precisionplayingabig
factorinthisdesigncriteriaasshownbefore.Foroverallthatcanbeseenthatgearsarethemostprecisecomponentinthislist.Chainsfluctuatespeedduetothechainvibrations;thisisabigdisadvantageaffectingdirectlytheprecisionofourmachine.Beltswereagoodoptionbutwearisverycriticalandimpactsspeedsdirectly.
Inconclusion,gearsaresuitableforthemachineapplication.Thematrixshowsthewinningcomponentwitha.67
27
QualityAssurance
DeltaHeatLlc,requestedthatthewirewindingmachinebehighlyprecisewhenproducingresistancewire.Thetoleranceallowedforthefinalproductisaresistancewithin+/‐3%oftheresistanceinputbytheuser.Thisrequirementisduetothefactthattheheatingproductsthatwillbemanufacturedusingthewireproducedbythemachineareverypreciselymanufacturedandhavearesistancetoleranceof+/‐5%. Inordertoensuretheproductionofhighlyaccurateresistancewire,theteamwillimplementarealtimeresistancemeasurementsystemasoneofthemajorcomponentsofthewirewindingmachine.Theresistancemonitoringwillrequireadevicemusthaveoutputcapabilitiesinordertosetoffanalarmsystemwhichwillalerttheuserofresistivereadingsoutsidethesettolerance.Forthispurpose,twoeasilyacquirabledevicescanbeused:oscilloscopesandmulti‐meters.Theuseofanoscilloscopeasaresistivemeasurementcomponentwasanalyzedfirstanduseofamulti‐metersubsequently.
Figure22:QualityAssuranceTreeDiagram
Theabovetreediagramoutlinestheadvantagesanddisadvantagesofbothmulti‐metersandoscilloscopeswhenbeingconsideredasresistancemonitoringcomponents.Thedetailsoftheanalysisthatresultedinthediagramarelistedbelow.
28
UsinganOscilloscopeforResistanceMonitoring
Oscilloscopescanbeusedforawiderangeofapplications.Thisincludes
observationsofelectricalsignals,waveshape,risetime,periodandpulsewidth.Oscilloscopescanalsoaccuratelymeasurevoltage,currentandresistance.Theonlyapplicationtobeanalyzed,however,willberesistancemeasurementforimplementationasaresistancemonitoringcomponentinthewirewindingmachine.
Abriefoverviewofthefunctionsoftheoscilloscopedemonstratesthatitcanaddressonemainfunctionofthewirewindingmachinewhichisqualityassurancebyresistancemonitoring.However,inordertoforittobeconsideredasapotentialcomponenttheadvantagesanddisadvantagesofitsusehadtobeanalyzedandweighed.AdvantagesandDisadvantages
Oscilloscopeshavehighprecisionreadingswhentakingmeasurements.Theresolutionandaccuracyoftheoscilloscopewilldetermineitsprecision.Thetablebelowdemonstratesthedifferentresolutionsavailableandthehighprecisionassociatedwitheachresolution.
Figure23:FrontviewofanOscilloscope.www.worldtechpub.com
Figure24:TypesofOscilloscopesandResolution.http://www.picotech.com/applications/resolution.
29
Forthepurposeofthisproject,itisalsonecessarytonotethatoscilloscopes
haveanoutputcapabilitywhichisanecessaryfunction.Oscilloscopesalsoencompasslcddisplayswhichdisplayallthemeasurementreadingsitisgenerating. Thesetbacksofusingoscilloscopesarecost,size,andUI.The8bitoscilloscoperesolutionisthemostcommonresolutionforoscilloscopesanditishighlyprecise.Theaveragecostofan8bitoscilloscoperangesfromroughly$400to$1200dependingonbrand,samplingrate,andbandwidthaswellasotherfactors.Thesizeofanoscilloscopeisalsotobeconsideredadisadvantagebecausewhilehighlyprecise,oscilloscopesaretypically2’x2’x1’.Thisisconsiderablylargeconsideringthatthewirewindingmachinewithallthecomponentsistobe6’inlength.However,userinterfaceisthemostimportantsetbackbecauseDeltaHeatLlchasrequestedasimpleuserinterfaceforthemachinewhichwillrequirelittleornotraining.Thisbecomesanissuebecauseoscilloscopesareverycomplexequipmentwhichrequiresextensivetrainingfortheuserbeforetheycanbeused.UsingaMulti‐meterforResistanceMonitoring
Amulti‐meterhasvariousmeasurementfunctionsincludingvoltage,currentand
resistance.Whileamulti‐meterdoesnotincludehavethesamefunctionalityofanoscilloscope,itmeetsthesub‐functionalrequirementofresistancemonitoringandthereforeshouldbeconsidered.
AdvantagesandDisadvantages
Multi‐metershaveasimpleuserinterfacewhichrequiresverylittletonotraining.ThisisabigadvantagewhichmeetsthesimpleuserinterfacerequirementforthewirewindingmachinerequestedbyDeltaHeatLlc.Highlyprecisemeasurementscanalsobeobservedandacquiredfrommulti‐meters.Multi‐meterspreciselymeasuredatawithanaccuracyoffsetof+/‐0.5%.TheyallowtheusertomonitorthemeasurementsvisuallyonthehardwareitselfonanLCDandthrough
Figure25:Multi‐meter.http://www.fluke.com/fluke/uken/bench‐
30
anoutputtoacomputer.Theoutputcapabilityisabigadvantagebecausethiswillallowforeasierdatamonitoringbythealarmsystem.
Thedrawbackofamulti‐meteristhatinordertogetpreciseresistivemeasurementreadingsitmusthavedataoffsetcapabilities.Aswithanyotherproduct,morefeatureswillleadtohighercost.
Afterconsideringtheadvantagesanddisadvantagesforbothoscilloscopesand
multimeters,itwasnecessarytofurtheranalyzebothresistancemonitoringcomponentsinordertoselectthebestoptionforourdesign.Selectionmatriceswereusedforthispurposebeginningwithoutliningthemaindesigncriteriaforthefunctionandcomparingeachcriterionagainsttheothers.Thiswasnecessaryinordertodeterminehowmuchweighteachdesigncriteriaheld.Theresultsaredisplayedinthetablebelow
.
DesignCriteriaWeightingMatrix:0‐1Scale
Cost SizeEasyUserInterface
OutputCapacity
Precision
Score=rowSum Weight
Cost 1 0 0 0 1 0.1
Size 0 0 0 0 0 0
EasyUserInterface 1 1 1 0 3 0.3
OutputCapacity 1 1 0 0 2 0.2
Precision 1 1 1 1 4 0.4
Totalnumberofcomparisons=SumoftheScores 10 1Thenextstepinthisprocessistostartwiththefirstdesigncriteriaandbasedon
justthisonecriteria,theoscilloscopeandmultimeterwerecomparedinordertoobtainthenormativescorewhichistobeusedintheselectionmatrix(thelastmatrixinthisset)toselectthebestcomponentforthedesign.Itisimportantthatthenextmatrices[size,easyuserinterface,outputcapacityandprecision]followthissamelogic.
DesignVariantRankingwithrespecttoDC1(Cost):0‐1ScaleCost Oscilloscope Multimeter Score=RowSum Norm.Score
Oscilloscope 0 0 0.00Multimeter 1 1 1Col.Sum 1 1.00
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DesignVariantRankingwithrespecttoSize:0‐1ScaleSize Oscilloscope Multimeter Score=RowSum Norm.Score
Oscilloscope 0 0 0Multimeter 1 1 1
1 1
DesignVariantRankingwithrespecttoEasyuserinterface:0‐1Scale
EasyUserInterface Oscilloscope Multimeter Score=RowSumNorm.Score
Oscilloscope 0 0 0Multimeter 1 1 1
1 1
DesignVariantRankingwithrespecttoOutputcapacity:0‐1ScaleOutputCapacity Oscilloscope Multimeter Score=RowSum Norm.ScoreOscilloscope 0 0 0Multimeter 1 1 1
1 1DesignVariantRankingwithrespecttoPrecision:0‐1Scale
Precision Oscilloscope Multimeter Score=RowSum Norm.ScoreOscilloscope 1 1 1Multimeter 0 0 0
1 1Usingthenormalizedscoresfromthematricesabove,andmultiplyingeachby
theweightofthedesigncriteria(fromfirstmatrix)thefinalscorewasdrawnandthebestcomponentforthemachinewasdeterminedtobethemultimeter.Theresultsaredisplayedinthetablebelow.
SelectionMatrix
Cost
SizeEasyUserInterface
OutputCapacity
Precision Score
Oscilloscope 0 0 0 0 1
0 0 0 0 0.4 0.4
Multimeter 1 1 1 1 0
0.1 0 0.3 0.2 0 0.6
1
Decision HighScoreWins
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ComponentsSupport
Componentssupportwasimplementedinordertoensurethatourmachinehasastablebasewhereallthecomponentswillplaceatop.Ourteamhasdecidedtouseawoodtable
Figure27:WoodenTable
EnvironmentalProtection
Environmentalprotectionwasimplementedinordertoensurethatthemachinerunswithoutanystrainfromitsenvironmentandthatitdoesnotbecomeadangerhazardtoanybodyaroundit.Theteamdecidedtobuildorbuyahousingunitforthewirewindingmachine.Threedistinctmaterialswereconsideredforthehousingunit.Thisincludesaluminum,woodandsteel.Thegeneralpropertiesofeachmaterialwereobservedandatreediagramwasderived.
Figure28:EnvironmentalProtectionTreeDiagram
33
Theabovetreediagramoutlinestheadvantagesanddisadvantagesofaluminum,woodandsteeltobeconsideredforuseinthemachinehousingcomponents.Thedetailsoftheanalysisthatresultedinthediagramarelistedbelow.UsingAluminumasPrimaryHousingComponentMaterial
Aluminumisoneofthemostcommonusedmetalsforawiderangeofapplications.Dependingonthestrength,tensileandotherpropertyrequirements,aluminumisalloyedorforged.Typicalapplicationsforthismaterialincludeoutershellsformechanicalandelectricaldevicesrangingfromcars,tocomputersandevenfoilsheets.Sincealuminumiswidelyusedforoutershellsinequipment,itwasconsideredavalidcomponentmaterialforthewirewindingmachinehousing.[15,16]AdvantagesandDisadvantages Aluminumislightweightanddoesnotrequireweldedcornersduetothefactthatalthoughstrong,italsohasductileproperties.Itiscorrosionresistantandwillnotwearwhenexposedtoenvironmentalfactorssuchaswater,dew,anddirt.Aluminumisalsoanimpermeablematerialwhichisapropertynecessarytoavoidoutsidefactorsinfluencingthewirewindingmachineoperations. Somedisadvantagestotheemploymentofaluminumforthemachinehousingisthatsincealuminumisametal,ittendstohavethermalandelectricalconductivitywhichissomethingthattheteamwantstoavoidasthiswillbecomeahazardtotheoperator.Aspreviouslymentioned,ductilitycanbethoughtofasadoubleedgedswordwhileitmaybegoodforbuilding,itmightalsoleadtodeformationsinthemachinehousing.[15,16]UsingWoodasPrimaryHousingComponentMaterial Woodservesmanypurposesintoday’smarketandindustryincludingitsuseinconstruction,furnituremaking,paper,andforfueltocookandkeepwarmduringcolddays.Thematerialwasconsideredapotentialcomponentmaterialbecauseitcanbeusedtobuildthehousingforthemachinewhichispartoftheenvironmentalprotectionfunction.[18]AdvantagesandDisadvantages Woodiseasytoacquireatanyhardwarestoreandwithagoodprocedure,itisagoodmaterialfromwhichthehousingcomponentcanbemade.Itisalsolowcostwhichstandsoutduetothefactthatthetotalcostofthemachineistobeminimized.However,themaincharacteristicthatmakesitavalidcandidateisthatithashightoleranceforverticalpressures.Thismaterialpropertywillensurethatnodeformationoccurstothehousingcomponentandthereforeensurethewirewindingmachineoperatesefficiently. Thedisadvantagesofthismaterialarethatithasalowstrengthtoweightratiomeaningthatitcouldpossiblybeheavy.Ithasnoflexibilitywhichmightnotbeanissueforthisapplicationbutwasconsiderednonetheless.Finally,themainconcerntodrawoutofusingwoodforthecomponenthousingisthatitisflammableandwillnotprotectthemachineincaseofafirebreakout.[18]
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UsingSteelasPrimaryHousingComponentMaterial Steelisone,ifnotthemostcommonmaterialusedineverydayapplications.Itisanalloyofironandcarbonwithcarboncontentbeingonlyabout0.2%.Steelproductioniseverywhereinthe21stcenturyandtheapplicationsforitsusearelimitless.Forthisreason,Steelwasconsideredforananalysistodetermineifitmetthedesigncriteriatobeusedforthehousingcomponent.[16,17]AdvantagesandDisadvantages Typicalpropertiesofsteelindicatethatithasahighstrength.Thisisimportanttonoteascomponentstrengthissomethingofgreatimportancewhenconsideringenvironmentalprotection.Steelisalsoverydurable. Thedisadvantagesofusingsteelisthatcorrosioncanoccurbasedoninfluencefromexternalfactorssuchaswater.Italsotendstobeheavyanditscostisconstantlyrisingduetoitsmanyapplicationswhichresultsinhighdemand.Onelastthingtonoteisthatlikealuminum,itisbothelectricalandthermalconductive.Ifusedforthehousing,carefulplanningmustoccurinordertoensurethattheselasttwopropertiesdonotpresentahazardtotheoperatororanyonearoundthemachine.[16,17]
Theabovematrixshowsthedesigncriteriaweighingmatrixforthe
environmentalprotectionwhichwouldbeourhousing.Wewereabletodetermine5differentdesigncriteria’s.Wefeltthatcostefficiency,easeofconstruction,safety,size,andnointerferencewiththeequipmentwerethemostimportantcriteria’stoourhousingofourmachine.Ascanbeseenonourmatrixabove,safetyandnointerferencewithourequipmenthadthehighestweightforourhousing.Wethancomparedeachofthedifferentmaterialsforourhousingandcomparedittoourcriteria.
DesignCriteriaWeightingMatrix(Housing):0‐1Scale
Cost
EfficientEasytoConstruct Safety Size
NoInterference
Score=rowSum Weight
CostEfficient 0 0 1 0 1 0.1EasytoConstruct 1 0 1 0 2 0.2Safety 1 1 1 1 4 0.4Size 0 0 0 0 0 0
NoInterference 1 1 0 1 3 0.3Totalnumberofcomparisons=SumoftheScores 10 1
35
DesignVariantRankingwithrespecttoCostEfficient:0‐1ScaleCostEfficient Aluminum Wood Steel Score=RowSum Norm.ScoreAluminum 0 1 1 0.33Wood 1 1 2 0.67Steel 0 0 0 0.00 3 1.00
Theabovematrixshowsourdesignmaterialsforthehousinginrespectto
thecost.Duetotheeaseofgettingwoodatlocalhardwarestoreandthelowcostofwood,thisledtowoodhavingthehighestscore.
DesignVariantRankingwithrespecttoEasytoConstruct:0‐1ScaleEasytoConstruct Aluminum Wood Steel Score=RowSum Norm.Score
Aluminum 0 0 0 0.00Wood 1 1 2 0.67Steel 1 0 1 0.33
Col.Sum 2 0 1 3 1.00
Theabovematrixshowsourdesignmaterialsforthehousinginrespecttotheeaseofconstruction.Duetotheeaseofconstructionofwood,ithadthehighestscoreinourmatrix.
DesignVariantRankingwithrespecttoSafety:0‐1ScaleSafety Aluminum Wood Steel Score=RowSum Norm.Score
Aluminum 1 0 1 0.33Wood 0 0 0 0.00Steel 1 1 2 0.67
Col.Sum 1 2 0 3 1.00
Theabovematrixshowsourdesignmaterialsforthehousinginrespecttosafety.Duetosteelhavingahigherstrengthithadthehighestscoreinourmatrix.
DesignVariantRankingwithrespecttoSize:0‐1ScaleSize Aluminum Wood Steel Score=RowSum Norm.Score
Aluminum 1 0 1 0.33Wood 0 0 0 0.00Steel 1 1 2 0.67
Col.Sum 1 2 0 3 1.00
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Theabovematrixshowsourdesignmaterialsforthehousinginrespecttosize.Allthesewereequallyweighedbutsteelhadthehighestscoreduetoavailabilityofweldingourhousingandcreatingthesizethatwewant.
DesignVariantRankingwithrespecttoDC5(NoInterference):0‐1ScaleNoInterference Aluminum Wood Steel Score=RowSum Norm.ScoreAluminum 1 0 1 0.33Wood 0 0 0 0.00
Plexiglass 1 1 2 0.67Col.Sum 1 2 0 3 1.00
Theabovematrixshowsourdesignmaterialsforthehousinginrespecttono
interferencewithourmachine.Steelendeduphavingthehighestscoreinourmatrixabove.
SelectionMatrix CostEfficient EasytoConstruct Safety Size NoIntereference ScoreAluminum 0.33 0 0.33 0.33 0.33
0.033 0 0.132 0 0.099 0.264
Wood 0.67 0.67 0 0 0
0.067 0.134 0 0 0 0.201
Steel 0 0.33 0.67 0.67 0.67
0 0.066 0.268 0 0.201 0.535
Decision HighScoreWins
Theabovematrixshowstheselectionmatrixwherewefindoutfromourpreviousmatriceswhichdesignforthehousingwouldbebest.Aftercompletingallofourdesigncriteria’stoourdifferenthousingoptions,itwasdeterminedthatsteelwasthewinner.Webelievesteelwillbeagreatcandidateforourhousingduetothegoodstrength.
V.FinalDesignAnalysisTheConceptualDesignsectionofthisprojectwasimperativeinorderto
analyzeallthepossiblesolutionstobuildingahighlyprecisemachine.Itledtheteamtoafinallistofpossiblecomponentstouse.ThefinaldesignwasfirstdepictedinProEngineerandthenSolidworks.Afterwardsadetailedanalysiswithcalculationsforeachcomponentwasdoneinordertoensurethatthepartsorderedexceedtheirapplicableloads,torque,etc.
37
Fig.29FinalDesignmodelinSolidworks
Givenparameters
Inanyengineeringproblem,wehaveourgivenparametersorinitialboundaryconditions.Inthiscase,thecustomer,DeltaHeatLLCgaveussomeparameterstostartfrom,butalsowehadtocreatesomeofthemfromourobservationofthefinalproduct.TheParametersarethefollowing;
1. ProductionVelocity:6in/min=.1in/sec2. AlltheResistancesoftheAlloys3. AreasoftheMinimumandMaximumgauges(40and22)4. MaximumandMinimumnumberofturnsperinch:60and4turnsperinch.
InitialEquations
Takingintoconsiderationthegivenparameters,wehavetosearchforformulastoobtainotherinformationorvalues.
1. NumberofWindsforgivenresistanceperfoot.
……
38
WhereAisthecrosssectionalareofthewireinin2,RistheResistancein
Ohms, istheResistivityofthewire,Listhelengthofthewireininches,DistheDiameteroftheCoil,Pisthepitchininches,andNistheNumberofturns.WiththisformulawecanfindoutthenumberofTurnsperfootthatawiremusttakearoundtheCoreinordertoobtainthewantedresistanceperfoot.Thisformulaisimportantforthecontrollersaswelltopredicttheresistanceofacoil.
2. VelocityoftheMotorDependingofthefrequency120
WhereVistheVelocityofthemountingplateinRPM,fisthefrequencyinHertzandPisthenumberofPolesofthemotor.ThisformulaisalsoimportantinthecontrollerinordertovarytheresistancewevarytheRPMofthemountingplate.
3. NumberofWindsdependingonthelinearvelocity
0.1
So:60 10
6010
6601
360
Thisformulawastoobtainthemaximumvelocity,forthe60turnsperinch.
Thatisthemaximumresistance.
PullingMechanism
The resistive wire production rate is dependent on pulling speed equally associated with the pulling mechanism. The pulling mechanism will always stay at constant angular velocity; this will enable flexibility when producing wire. Making the pulling mechanism independent allows for easier control with respect to the amount of winds being produced. The correlation between number of winding and faceplate angular velocity will determine running speeds at which product can be looped around. The initial mechanism failed due to excess required torque, due to this we had to modify our design. Assigning multiple driving points will decrease the amount of torque required by the pulling motor, and deliver minimal stresses to the product. The use of a quality control system is active during production this delivers friction, which directly impacts the
39
amount of toque required by the pulling mechanism. This quality control mechanism is composed of 3 idlers which 1 ft of material wraps around in s-shape forcing material to make contacts with idlers enabling resistance measurements to be taken. This is very crucial step towards delivering a expected product and meeting customer expectation. For the modified pulling mechanism, 3 rubber rollers are used to sandwich the final product and eliminate slippage. The addition of idlers close to the faceplate will contribute to drive the fiberglass straightly to the center of the shaft, prevent hanging of the string. This is a crucial parte because if tension is not kept properly the string will hang and touch the shaft and rotate with it, delivering an unwanted product. These idlers also get wrapped in and S-shaped form, which allows constant tension. The same mechanism will be in effect in back of the motor, and this will deliver the fiberglass core to the system while maintaining constant tension. The main problem we saw due to experimentation is tension, in order to deliver a good quality product the tension of the fiberglass has to be constant while maintaining speed production speed.
WindingMechanism
PowerTransmissionGears
The gear transmission is the mechanism used to transmit rotational energy from the motor to the Wire Winding Mechanism. This Transmission comprises of three gears: a pinion, an idler gear and a driven main gear, and there is a speed reduction ratio of 4:1.
40
1. FEA Analysis
The team included FEA analysis using the boundary conditions of the Lewis Equation to find the gears’ maximum Bending stresses.
Gear Outside Diameter
(in)
Pitch Diameter
(in)
Bore (in)
No. of Teeth
Pitch Material
Pinion 1.37 1.47 0.59 15
10.2 AISI 1045 Idler 3.14 2.95 0.59 30
Driven 6.1 5.9 1 60
Figure 3: FEA analysis of the Pinion
Figure 2: FEA analysis of the Idler gear
Table 1: Transmission Properties Characteristics
Figure1: Gear Transmission
41
Some of the assumptions for the FEA Model analysis are: 1.-The gear’s bore are pinned. 2.-There is an acted force on the tip of the teeth. These
assumptions are important in order to set the boundary conditions on the model.
2. Lewis Equation and Bending endurance strength
Gear No. of
Elements Von Misses Stresses (ksi)
Maximum Principal
Stresses (ksi)
Pinion 8337 13.205 12.183 Idler 13134 2.614 2.496
Driven 15910 3.33 1.75
Gear Specifications
Precision Grade
JIS Grade N8 and JIS grade 4
Gear Teeth Standard Full Depth
Pressure Angle 20 degrees
Material Specifications
Material AISI 1045
Hardness HB165‐194
Yield Strength 73.2 ksi
Tensile Strength
111.6 ksi
Figure 3: FEA analysis of the Driven Gear
Table 2: FEA Results
42
Lewis Eq
Pinion: Idler: Driven:
As we can see from the Lewis Equation, the bending stresses came out lower than our Yield Strength. Also, since the Fatigue Strength (Sn) is 52.44 ksi, and the Bending Stress is only 1848 psi acted on the gears, the gears are usable for infinite life.
KeylessBushings
Since the Wire Winder Machine has a tubular shaft to pass the fiberglass core through, it automatically discards the possibility to install a key bore. The team researched for a way or method to attach the gears and mounting plate in place and came out with the Keyless Bushings. The following illustration explains the mechanism behind the Bushings.
1112
1 1 . 75 . 9 1 1.4
=52.44 ksi
≫1920psi
Figure 4: Trantorque Keyless Bushing. www.fennerdrives.com
∙ .
∙.1.3 1.25 1.6 2652
= ∙ .
∙.1.3 1.25 1.6 2062
= ∙ .
∙.1.3 1.25 1.6
′
Table 2: Gear Properties
43
WindingVelocityControl
Withthepurposetocontroltheresistanceofthewireproduced,thewirewindingmachineneedstoaccuratelyvarythenumberofwindingsaroundthefiberglasscore.Anthreephase,½H.P.ACmotorwillbeusedforthisfunction.However,tobeabletovaryitsvelocityandthereforethenumberofwindings,thereneedtobeacontrolsystemforthemotor. AYaskawaG7seriesVariableFrequencyDrive(VFD)willbeusedtocontrolthefrequency.Thefrequencyislinearlyproportionaltotherpmofthemotorsobyimplementingavariablefrequencydriveasacontrolmechanismforthewinding,theteamwillensurehighlyprecisewindsaroundthefiberglasscore.ThemainrequirementsfortheVFDarethatitcancontrolathreephasemotorandthatithasaporttoreceiveinputfromtheresistancemeasurementalarmsystem.TheVFDselectedhasalltheserequirements.
Calibration During the design phase, the team calculated the torque, power, and possible
behavior of the machine, however a great deal of information was missing and many assumptions were taken in order to proceed with the design, this could be from factors of safety, speculation and possible behavior. Therefore a calibration analysis is needed in order for it to perform as desired. This analysis is dependent in the number of variable components and options. The next table shows a list of factors that affect the proper winding of the wire around the core:
Image Factor Variation Result
1 Distance of Alloy
Spools to Fiber glass Core
From 12’’ to 3” Tension of wire varies according to distance.
Compression on Alloy
spools Tightness Variation
Tension of wire vary according to tightness
2 Direction of wire on
Alloy Spools Right or Left
Direction of wire unwrapping affect the proper alignment between wires. Also affects the winding around the core
Power on sequence
Winding Mechanism Pulling Mechanism
Time=0 1. ON, ON 2. ON, OFF
Variation of alignment of wires.
Figure 5: Yaskawa G7 VFD
44
ResistanceMeasurement(QualityControl)
Thecomponentselectedforresistancemeasurementwasthemultimeter.Whiletherearemanydifferenttypesofmultimeters,itwaspossibletonarrowdownourselectionbasedthecustomerobjectives.Thebestselectionwasthennarroweddowntopanelmountresistancemeterswhichincorporateanalarmsystemintotheirdesign. Forthisproject,theLaurelsResistanceMeterwillbeused.Itishighlyaccuratewitha+/‐0.01%tolerance.Italsohashighreadratesatupto50‐60conversionspersecondofanalogtodigitalsignal.Thiswillallowforaccuratereal
time
resistancemeasurements.Finally,withthecontactrelaybuiltin,itcanmeasureresistancestobewithinagiventoleranceandiftheresistancereadisoutsidethespecified,itwillopenorclosetherelayandsendanalarmtotheVFDwhichwillthenstopproduction.BelowisaQAexamplefromlaurels.com
3. OFF, ON
Pre-Union of wires
before operation (two or more)
Direction of initial winding by hand Wire winds around the core, or core slips through the wires
Material and thickness
of Alloys
Possible variation of all of the above and may behave differently with different number of spools.
3 Number of Spools
Possible variation of all of the above and may behave differently with different number of spools.
45
Fig31.QAApplicationwithRelayOptioninPassbandMode
<http://www.laurels.com/ohms.htm>RollersusedforResistanceMeasurement
Inordertomeasuretheresistanceofthefinishedproduct,themachinewilluseasetofrollersasalocationforresistancemeasurement.Theresistancewillbemeasuredinohms/ftandafootofwirewillwraparoundtherollers.Animportantthingtonoteisthatthecrevicesandsidesoftherollermustbealigned.Therollerswillbemadeoutofaluminum.Thealuminumwillsufficefortheapplicationoftheexcitationvoltagetomeasureresistance.Asketchofthesetupcanbeseeninfigure32.1”
L=4.43”
RollerPlacementEquationat90ͦ45ohms90ͦ1 2L1”
RollerDiameter(D)=1”L=4.43”
Figure32.ResistanceMeasurementSetup
46
Figure32.4‐WireResistance
Laurels.com
Asseenabove,thelaurelsresistancemeterwillbeusedinthe4‐wireresistanceconfigurationaroundtheroller.Twowireswillbeconnectedatoppositeends(theprobeslocationsinfig32)toapplyanexcitationvoltageandtheothertwowillbeusedforsignalreadings.Bytheresistancewillbemeasuredinternallybytheohmmeterbymeasuringthedifferencebetweentheappliedvoltageandthevoltageread.Test Plan
Once the prototype was completed, we began testing of the machine. Below is the list of tests that were done on the machine to make sure it was working properly. As can be seen below, from the tests that we have conducted, most have worked properly. The pulling mechanism still has to be tweaked. We noticed that the roller had to be higher to properly pull the final product. This is something that we will continue to work on and perfect to make the machine work properly. Also, the resistance measurement still needs to be tested while running.
Testing Pass/Fail/Recommendation
Proper Gear Alignment with Clean Turning Pass
Motor and VFD Properly Functioning Pass
Pulling Motor and Final Spool Placement
Motor Functioning
Pass
Wire Winding Around Fiberglass (2 wires)
running
Pass
Wire Winding Around Fiberglass (1 wire)
running
Pass
47
Pulling Motor Function (running) Pass
Resistance Measurement Working/ Relay Setup still remains to be
configured
Overall Design Summary
The final prototype has been constructed and all the pieces that have been discussed in this report have been working. Overall we were very pleased with the final prototype. After some initial testing, the overall objective was completed by being able to wind wires around a fiberglass core. As they were being wound around the fiberglass core, the wires were staying parallel to each other which is what we wanted in our resistance wires. The machine met our expectations and we will continue to perfect it. Conclusion and Recommendations Our recommendation is to continue to work on the tension of the wires of the fiberglass core and the wires to ensure quality products are being manufactured. This will include more work on the feeding of the fiberglass core and the perfecting of the motors used in the pulling mechanism.
48
VI.ComponentAssembly
GEAR/BEARINGS ASSEMBLY
As previously discussed the power transmission consists of a 4:1 gear ratio. The pillow blocks that lead to the mounting plate were centered and driving gear was placed on the opposite end of the mounting plate. The gears were aligned with each other and sub sequentially with the mounting plate (as seen above) using 5/8” pillow mount bearings and hardened steel shafts.
Component Specifications Quantity
Driving Gear - 6.1” outer diameter with 5/8” inner diameter 1
Idler Gear – 3.14 outer diameter with 5/8” inner diameter 1
Pillow Block Bearing - 5/8” inner diameter with 5/16” holes for mounting 4
Bolts - 5/16” x 3” Galvanized Steel 4
Nuts 5/16” galvanized steel 4
Washers 5/16” galvanized steel 4
Shaft 5/8” diameter with 1ft length hardened steel 4
Prototyping Challenges
49
WINDING MECHANISM
Component Specifications Quantity
Mounting Plate 8” Aluminum with 4- ½” holes placed at 90˚ 1
Arms 10” length by ¼” width Aluminum with 1/2” holes 1” apart 4
Wire Guides ¼” diameter by 2.5” length 4
Helical Springs Steel Compression Spring Zinc-Pltd Wire, 1.00" L,.970" OD,.080" Wire 4
Keyless Bushing Trantorque Mini. Shaft Diam. .6250 In. Length 1.1250 in 1
Bolts ½” diameter bolts with 5” length 4
Washers ½” galvanized steel 4
Nuts ½” galvanized steel 4
Motor 1/2 hp Elektrimax Motor, 1800 RPM, three phase - 38CF-3-.50-18 1
50
RESISTANCE MEASUREMENT
The resistance measurement assembly utilized three aluminum rollers with a 1”in diameter and 3” in length. These were machined to also have an extra ½” diameter by ¾” length on both ends to be able to place them inside the Plexi glass enclosure.
Component Specifications Quantity
Roller 1” Diameter Rollers 3” length with two ½”x 3/4” ends and .283” inner diameter
3
Unistrut Leg 2ft high with ½” holes for mounting 4
Panel Meter Laurels ohm meter 1
Rotary Connectors with wires
Mercotac 105A- 0.283” diameter 2
Bolts ½” diameter bolts with 5” length 2
Washers ½” galvanized steel 2
Nuts ½” galvanized steel 2
Enclosure 10” x 6” front and back ½” thick Plexiglas ; 6”x4” top and bottom ½” thick Plexiglas
1
51
Prototyping Challenges
PULLING MECHANISM
Component Specifications Quantity
Motor Jameco 3
Unistrut Leg 2ft high with ½” holes for mounting 4
Panel Meter Laurels ohm meter 1
Rotary Connectors with wires
Mercotac- 0.283” diameter 2
Bolts ½” diameter bolts with 5” length 2
Washers ½” galvanized steel 2
Nuts ½” galvanized steel 2
Enclosure 10” x 6” front and back ½” thick Plexiglas ; 6”x4” top and bottom ½” thick Plexiglas
1
52
DATA COLLECTION
53
VI.Summary AsperrequestedbyDeltaHeatLlc,themachinewasdesignedandprototypedtoproducethedesiredresistivewirewithafiberglasscore.Theprototypewasdevelopedbyreverseengineeringanddevelopmentoffunctiondecompositionprocedures.Theteamresearcheddifferenttypesofsubcomponents(e.g.gears,belts,chains)anddifferenttypesofmaterials(e.g.aluminum,steel,wood)forthethreeinitialconceptualdesigns.Accordingly,dependingontheiradvantages,disadvantages,andoperation,properselectionofcomponentsfulfilled.Selectionmatriceswereusedduringthecomponentselectiontoselectthepropercomponentbasedonapplication.Theoutcomeswereobservedandthewinningcomponentforeachfunctionwasthenpurchasedandusedduringtheprototypingofthewirewindingmachine.
Afinaldesignwasdraftedandeachindividualcomponentwasresearchedandcalculationsforeachcomponentwerecarriedoutinordertoensurethatthefinalizedselectionofmaterialswastheadequateandexceededthenecessarytorque,applicableloads,etc.Theteamhasnowcompletedallthepartsofthedesignprototypingphaseoftheproject.Themachinehasbeentestedandcalibratedandtheteamhasdemonstratedthemachinesabilitytoproducethewiredesired.Finally,withthebuiltinrealtimeresistancemeasurementdevice,notonlywilltheusermeasuretheresistanceoftheproductbutensurethatthequalityofthematerialissustained.
VII.FutureWork
TheprojectwassuccessfullycompletedinMay2012.However,DeltaHeatLlc.requestedthatfurtherresearchanddevelopmentbeconductedonthesecondprototypewhichistostayatTheUniversityofTexas‐PanAmericantoimprovebothitsproductionandqualitycontrolaspectsaswellasimplementautomation.
54
VIII.AcknowledgementsThisprojectwasundertakenbytheseniordesignteamconsistingofJoaquin
Vaca,AdrianDelgado,OscarCantu,andJuanMendiola.Dr.IsaacChoutapalliandDr.YoungGilParkprovidedinvaluabletechnicalexpertiseasthetechnicaladvisorsassignedtothegroup.SpecialthankstoDr,KamalSarkarfortheremarkableguidanceandadvisingonthisproject.
VIII.References
1. CarlosCardenas,DeltaHeatLLCOwner2. www.deltaheatllc.com3. CoiledNickel‐ChromiumAlloyResistanceWire,www.omega.com4. Iron‐chromium‐aluminum(FeCrAl)wirealloys,www.kanthal.com
55
5. ResistanceWire,www.jelliff.com 6. GlobalSpec:“TheEngineeringSearchEngine”;
http://www.globalspec.com/reference/10795/179909/chapter‐3‐ac‐and‐dc‐motors‐ac‐motors‐control‐of‐speed‐torque‐and‐horsepower
7. UnderstandingDCMotorCharacteristics.MIT2007MechanicalEngineer.2006.http://lancet.mit.edu/motors/motors3.html.10/28/2011
8. Lesson#1LectureonMechanics;DR.FrancescoBecchi,http://www.lira.dist.unige.it/IIT_school/CICLOXXIII/courses/slides/MECH_LECTURES/MECH_LECTURES_01.pdf10/27/2011
9. Module13:BeltDrives.IITKharagpur,Version2ME.http://nptel.iitm.ac.in/courses/Webcourse‐contents/IIT%20Kharagpur/Machine%20design1/pdf/mod13les1.pdf.10/28/2011
10. ThecompleteguidetoChain.TsubakimotoChainCo.2006.http://chain‐guide.com/.10/28/2011
11. NotesonSprocketsandChains.TheGizmologist,2011.http://www.gizmology.net/sprockets.10/28/2011
12. Howitsmade:GuitarStrings.DiscoveryChannel,2011http://www.youtube.com/watch?v=rMaVPN_E_iY.10/28/2011
13. Rope.HowProductsareMade,2011.http://www.madehow.com/Volume‐2/Rope.html.10/28/2011
14. GearDesign:Learneverythingyouneedtoknowaboutgears.GearDesign,2008.http://www.geardesign.co.uk/.11/1/2011
15. ChemicaloftheWeek:Aluminum.Shakhashiri,Bassam,ScienceisFun,2007.http://scifun.chem.wisc.edu/chemweek/Aluminum/ALUMINUM.html11/1/2011
16. EngineeringMaterials2.Ashby,MichaelF.andJones,DavidR.H.ISBN0‐08‐032532‐7.11/1/2011
17. Steelin20thCenturyArchitecture.Ochshorn,Jonathan,EncyclopediaofTwentiethCenturyArchitecture.2002.http://www.ochshorndesign.com/cornell/writings/steel.html.11/1/2011
18. AdvantagesofWoodenFurniture.IanPerryment,2009.http://ezinearticles.com/?Advantages‐of‐Wooden‐Furniture&id=2196083.10/28/2011
VII.AppendixTables
56
QFD: House of QualityProject: Wire Winding MachineRevision: 1Date: 9/27/2011
Fu
nct
ion
al
Req
uir
emen
ts
Customer Requirements (Explicit and
Implicit)
1 | | | | | | | | | 18% 10 9 5 3 4 2 4 1
2 | 4% 2 3 4 - - - - 2
3 | | | | | | | | | 18% 10 9 5 - - - - 3
4 | | | | | | 13% 7 3 4 - - - - 4
5 | | | | | | 13% 7 9 5 - - - - 5
6 | | | | 9% 5 9 4 - - - - 6
7 | | | | | | | 15% 8 9 5 - - - - 7
8 | | | | | 11% 6 9 5 - - - - 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
+++
+ + −−
13
+
11 12
Wind 1-3 Spools onto Fiberglass Core
Alarm
Speed Control for Resistance Wires
Digital Device that reads Wire Resistance
Speed Control For Fiberglass core
Low Cost Replacement Parts
Tw
o M
otor
s
# of
Par
ts
Siz
e
Wei
ght
Eas
e of
Use
●▽●●
Operability
●▽
▽ ○
Easy to Repair
○○
▽ ▽
● ○
○ ○ ○ ○
○ ▽ ▽ ○
○ ▽ ▽ ○○ ○
● ● ○ ▽
● ○ ○ ▽▽ ▽ ▽ ●
C
ust
omer
Im
port
ance
R
elat
ive
Wei
ght
R
ow #
W
eigh
t C
har
t
Direction of Improvement
Column #
Tar
get
for
Fu
nct
ion
al
Req
uir
emen
t #1
Tar
get
for
Fu
nct
ion
al
Req
uir
emen
t #2
Tar
get
for
Fu
nct
ion
al
Req
uir
emen
t #3
1
▲2 3 4 5 6
▼ ◇ ▼ ▲1614 15
616.36 463.64 256.36
|||||||||||||||||||||||
|||||||||||||||||
|||||||||
46% 35% 19%
1 2 3 4 5 6 7
- - - -
Technical Importance Rating
Target
Max Relationship 9 9
149 10 11 12 15 16Column #
Weight Chart
Relative Weight
4 5 5
8 13
▲◇▼
Maximize
Target
Minimize
9 3 9
7 8 9 10
Correlations
Positive +Negative −
No Correlation
Direction of Improvement
Relationships
Strong ●Moderate ○
Weak ▽
5
R
ow #
5
1 2 3 4
O
ur
Pro
duct
Je
llif
f: R
esis
tan
ce W
ire
S
prin
gfie
ld W
ire:
Cu
stom
K
anth
al:
Res
ista
nce
Hea
t W
ires
O
meg
a.co
m:
Ni-
Cr
All
oy R
es.
Wir
e
0
- - - -
- - - -
- - - -
Template Revision: 0.9 Date: 4/23/2010
Christopher Battles
Tec
hn
ical
Com
peti
tive
Ass
esm
ent
Customer Competitive Assesment
M
axim
um
Rel
atio
nsh
ip
32
10
Jelliff: Product Name
Springfield Wire: Product Name
Kanthal: Product Name
Omega.com : Product Name
54
5
-
-
-
-
Our Product
Our Product
Competitor #1
Competitor #2
Competitor #3
Competitor #4
Our Product
Competitor #1
Competitor #2
Competitor #3
Competitor #4
Figure7:QualityFunctionDeploymentChart
57
