156B Week 6

Overview of Status of Analysis, Design, Fabrication, Tests, etc.

• • Gauge Holders:

    • Sent maching orders on 4/28 with detailed drawings to ReoTemp for 40 gauge holders. Desired to have the horizontal rods press fitted and the vertical rods secured to the base with a flathead screw. Requested the gauges ideally to be manufactured by 5/15 latest.

    • Sponsor replied 5/1 that the base be machined from one piece, hence combining the base plates. Moreover, sponsor suggested having an indent at the funnel plate for air to escape and prevent back pressure.

    • Both the team and sponsor were satisfied with the final gauge holder design. All parts are scheduled to be manufactured by 5/15 latest.

• Heating Tape

  • • Heating tape arrived. The tape was able to raise the glycerin up to 31 degrees Celsius even with the lowest possible setting. 

• • Roller tracks

    • Half of the roller tracks were being assembled over the weekend. The roller mechanisms will be tested at Reotemp next week. 

  • Color sensor

    • Sponsor allowed for the purchase of color sensor (~$1600). Wiring has already been drawn out and the software integration with the PLC is still work in progress. 

Accomplishments from Previous Week

• • Finalized gauge holder designs with sponsor. The holders are ready to be manufactured latest 5/15.

  • Emailed and asked for a quote with an application engineer for a quote on the color sensor.

  • Tested Arduino with PLC integration. Had issues with the sensor mechanism as it was sending out seemingly random discrete output signals. 

  • Off-loading rollers were fully assembled and ready to be tested. 

  • Purchase requested color sensor. 

Goals for Next Week (list names after each item). Use specific and measurable objectives.

• • Test the off-loading rollers at ReoTemp (Elaine, Desi)

  • Collect data using heating tape (Elaine, Desi)

  • Continue expansion of wiring list (Ethan, Desi)

  • Purchase digital expansion module for color sensor (Justin)

  • Purchase color sensor (Ethan)

  • Troubleshoot PLC/Arduino code integration (Justin, Elaine, Desi)

  • Begin software design for color sensor integration (Justin)

Sponsor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)

• • 5/01/2020 Zoom Meeting with Eric (Sponsor)

    • Sponsor will make the holder rods next week

      • if press fitting doesn't work, other options are available.

      • raised concerns with 1/4'' press fit hole because the machine shop bit is too big

    • Conveyor was ordered, need to confirm when it will arrive.

    • 6 minutes filling time for the largest gauge is acceptable. 

    • Willing to supply thermometer to test heating tape's temperatures.

  • 4/28/2020 - 5/1/2020 3 Email exchanges with Eric

    • Sent updated drawings for CNC parts. Tolerance for the press fits were reduced to +0/=0.001''. Requested the 40 gauge stands to ideally be made by 5/15.

    • Sponsor replied with drawing suggestions:

      • Base being machined with one piece; the base would be 3/4'' thick.

      • Keep a funnel groove to allow air to vent out. 

      • Willing to try out the press fit method; glue may be added if necessary

  • Team agreed with the drawing suggestions with the tiered base plates and funnel plates with a venting gap.

Instructor Comments from Last Meeting and Actions Taken to Address these Comments  (indicate date of comments and if via email or in person)

• • 5/2/2020 Email with Professor Tustaniwskyj

    • Purchase request for new gauge holder design. The team wanted to order precision aluminum shafts and flanged sleeve bearings for a full set of 40 gauge holders.

    • Professor responded with concerns of overconstraints. suggested that it's not good design practice to rely on precision for keeping systems from binding. 

    • Will have follow-up meeting to further discuss design intents and good engineering practices.

Comments from Other Students in the Class (indicate date of comments and if via email or in person)

• • Students' response to Proof of Concept presentation 4/27/20

    • Slides with derivations and equations were quite dense and not explained clearly enough.

    • Test results and graph references were not thoroughly described in detail.

    • The test procedures were well documented and clearly explained. 

    • Great visuals and videos.

Risks and Areas of Concern

• • Some last minute changes to gauge holder design

    • Initial design was over-constrained, need to make a decision about which way to go with this ASAP to get parts ordered & production started

  • Roller mechanism not performing as intended

    • Will see how testing goes next week and adjust design accordingly.

  • PLC integration with color sensor

    • Will need to see how to integrate the color sensor mechanism as it significantly changes the current code. May pose extra challenges as software and hardware team members are working separately and remotely. 

Resources or Information Required but not Available

• • N/A

Schedule

• • 5/18/2020 Preliminary Design Review

  • 5/18/2020 Second draft of Report due

  • Gantt chart updated.

Budget (list amount spent and amount remaining)

• • Total spent: $2449.25

  • Remaining: $7550.75

Progress on Report and Webpage

• • First draft of report completed. The homepage and final design pages for the website were also updated.