Summary 

Talked with Sponsor Aaron and Prof. Gillett about both design ideas and project progress. We understand that the project progress is behind schedule. To catch up to our expectations, we need to: 

1. Determine the design track direction 

2. Get tools on hand 

3. Start testing 

Current Status 

Sorting 

• We realized the DIY feeder bowl track does not align with the project timeline. 

• DIY feeder bowl halted 

• New track is to focus on bowl design 

• Purchase order done for a used drive unit and a new control unit 

• Material selection currently focus on UHMW polyethylene study 

• Reading instructions for simulation 

Conveying/transporting 

• X-Y gantry, place on pan with holes 

• Aaron doubt, could test and give a try 

• Capillary tube with timing belt 

• Aaron relucted spending money on this, could test and give a try 

Force Sensing 

• DFG arrived on campus this week. 

• Will be doing a force analysis on springs with a custom fixture made in our machine shop.  

• We will sample the spring in one orientation and then flip it 180 degrees to determine if orientation impacts reading of force.  

• Our current plan is to test 40 pins 5 times in each orientation. Giving us 200 points of data for each orientation.  

Inspection 

• Met with Keyence to get a quote on a camera/lens system 

• Quoted at $5000 pretax 

• Seems to do everything we would want it to do, however it seems to be overkill for the goal of the project. 

• The software provided can measure critical dimensions and check for imperfections.  

• Will be meeting with a representative at COHU with camera selection.  

Todo Before Next Week 

1. Component research on all needed parts for prototype 

2. Organize a purchase list and send to Roxanne & Gillett 

3. Determine design track direction 

Summary 

Talked with Sponsor Aaron about both design ideas and project progress. Our purchasing is still behind schedule. We have been sending out purchasing orders gradually throughout the past week. We need to:

1. Get tools on hand

2. Start testing

Current Status 

Sorting 

• Working on bowl design CAD

  • 1. Talked to Machine Shop staff Tom & Steve for bowl manufacturability

    2. Manually-machined test jig

    3. Realized static force between pins, looking for ESd UHMW polyethylene.

• Waiting for the used drive unit and a new control unit

Conveying/transporting 

• X-Y gantry, place on pan with holes 

  1. 1. Parts order submitted and approved by Aaron, waiting for UCSD

• Capillary tube with timing belt

  • 1. Parts order submitted and approved by Aaron, waiting for UCSD

    2. The capillary tubes are not viable, however, we can seriously try to manufacture them ourselves with laser cuter and glass-grade acrylic. 

• Vacuum transportation

  • 1. Vacuums ordered- waiting on Roxanne ( orders through Amazon- should be quick)

    2. Vacuum tip design done - need an opinion on manufacturability

       1. 1. 3D printing

          2. Machining

    3. Pre-ordered vacuum tips usability TBD

  • Magnetic transportation. 

    1. The pins are found to be highly magnetic, a property that can be useful, but may also possess potential risk. 

Force Sensing 

• DFG arrived on campus this week. 

• Will be doing a force analysis on springs with a custom fixture made in our machine shop.  

• We will sample the spring in one orientation and then flip it 180 degrees to determine if orientation impacts reading of force.  

• Our current plan is to test 40 pins 5 times in each orientation. Giving us 200 points of data for each orientation.  

Inspection 

• -

Todo Before Next Week 

1. Submit a major list of purchase order

2. Manufacture prototypes 

Summary 

Talked with Sponsor Aaron about both design ideas and project progress. In short, we are behind schedule and need to work on a prototype ASAP. We need to:

1. Get tools on hand

2. Prototyping

Current Status 

Operation

• Team decided to meet more often as a whole.

  • 1. Formed 2 focus teams which meets more often than the group

       • Vibratory feeder bowl with (after feeder bowl) conveying/transporting.

       • Force sensing with camera inspecting.

Sorting 

• Working on static elimination

  • 1. Placing order for ESd grade UHMW polyethylene from Boedeker Plastics.

    2. Placing order for Static Eliminator Bar without air blower from Exair.

• Working on feeder bowl

  • 1. CADing in progress.

    2. Advised by Daniel’s engineer friend who is working on a feeder bowl, got advised for a 10°-15° helix track incline angle.

       • Verifying the angle with research paper.

    3. Will machine the current bowl for prototyping uses before UHMW material arrives.

• Accessibility

  • 1. Placing order for digital camera for easier visualization of pin movement in operation.

Conveying/transporting 

• X-Y gantry, place on pan with holes

  1. 1. Aaron doubt, could test and give it a try. (Parts order submitted and approved by Aaron, waiting for UCSD)

     2. THIS IDEA IS NOW ABANDONED.

• Capillary tube with timing belt

  1. 1. Aaron reluct spend money on this but could test it and give it a try (Parts order submitted and approved by Aaron, waiting for UCSD)

     2. The capillary tubes are not viable, however, we can seriously try to manufacture them ourselves with laser cuter and glass-grade acrylic. 

     3. THIS IDEA IS BEING PERSUED FOR THE FOLLOWING REASONS:

     4. 304 SS TUBES WERE FOUND ON McMasterCarr and ordered. Tubes will satisfy the desired dimension of 0.33mm ID. 

     5. This does require adjustments on timing belt selection and thus also requires pulley and motor adjustment. 

     6. Parts will be ordered by Jan 24. 

     7. Aluminum extrusion for the system structure will also be ordered. (5ft 1” extrusion with 20 corner brackets and sliders.)

• Vacuum transportation

  1. 1. Vacuums ordered- waiting on Roxanne ( orders through Amazon- should be quick)

     2. Vacuum tip design done - need an opinion on manufacturability

     3. 3D printing

     4. Machining

     5. Pre-ordered vacuum tips usability TBD

Force Sensing 

• DFG arrived on campus this week. 

• Will be doing a force analysis on springs with a custom fixture made in our machine shop.  

• We will sample the spring in one orientation and then flip it 180 degrees to determine if orientation impacts reading of force.  

• Our current plan is to test 40 pins 5 times in each orientation. Giving us 200 points of data for each orientation.  

Inspection 

• -

Sponsor Meeting Note

• Summary: Need actual prototype ASAP.

Advisor Meeting Note

• Discussed tube pin holder.

  1. Suggested SU-8 to create stencil for pins.

• Discussed inspection mechanism.

  1. Suggested research on manifold.

Todo Before Next Week 

• Submit a major list of purchase order

• Team decided to meet more often

• We actually have no time left

• Manufacture PROTOTYPES!

Summary 

Talked with Sponsor Aaron about both design ideas and project progress. In short, we are behind schedule and need to work on a prototype ASAP. We need to:

1. Get tools on hand

2. Prototyping

Current Status 

Operation

• Team decided to meet in-person during Tuesday & Thursday from 2pm - 5:30pm.

Sorting 

• • Static elimination

    1. Talked with Steve and built a set up to find air pressure that causes pins to move.

       • Finding if air jet style static eliminator is a valid method.

    2. Emailed Roxanne to confirm the order of ESd grade UHMW polyethylene from Boedeker Plastics.

    3. Discussing with engineers at Exair to reduce the price of Static Eliminator.

  • Feeder bowl

    1. Bowl CAD finished, CAM 90% finished. Tom will check on 01/30/2024.

    2. Tested trap designs on the current bowl.

       • Realized trap design might have to be manual & will high precision

    3. Designing CAD for pin exit variations.

    4. First bowl prototype will be machined on 01/30/2024.

  • Accessibility

    1. Designing and CAD a Camera system to view processes.

Conveying/transporting 

• X-Y gantry, place on pan with holes

  • • Aaron doubt, could test and give it a try. (Parts order submitted and approved by Aaron, waiting for UCSD)

    • THIS IDEA IS NOW ABANDONED.

• Capillary tube with timing belt

  • • Aaron reluct spend money on this but could test it and give it a try (Parts order submitted and approved by Aaron, waiting for UCSD)

    • The capillary tubes are not viable, however, we can seriously try to manufacture them ourselves with laser cuter and glass-grade acrylic. 

    • THIS IDEA IS BEING PERSUED FOR THE FOLLOWING REASONS:

    • 304 SS TUBES WERE FOUND ON McMasterCarr and ordered. Tubes will satisfy the desired dimension of 0.33mm ID. 

    • This does require adjustments on timing belt selection and thus also requires pulley and motor adjustment. 

    • Parts will be ordered by Jan 24. 

    • Aluminum extrusion for the system structure will also be ordered. (5ft 1” extrusion with 20 corner brackets and sliders.)

• Vacuum transportation

  • • Vacuums ordered- waiting on Roxanne ( orders through Amazon- should be quick)

    • Vacuum tip design done - need an opinion on manufacturability

    • 3D printing

    • Machining

    • Pre-ordered vacuum tips usability TBD

Force Sensing 

• Data collected showed that the pin orientation does not matter in force testing. 

• Found a suitable load cell to inspect the pins. 

• CAD model will be made this week. 

Inspection 

• Had a meeting with Michel a camera expert, pointed us in the right direction for camera and lens selection. 

• Aaron has told us that we no longer need to purchase the camera and only spec out the camera for the ECE team. 

• Pixels needed > 3100. 

Sponsor Meeting Note

• Discussed conveyor belt design & its manufacturability.

  1. Glue might fail on turning points, doubt about glue idea.

  2. Suggested glue on one side only.

• Discussed arm type inspection idea

  1. Doubt about arm idea.

  2. Leaning toward simple push & pull or other mechanisms.

Advisor Meeting Note

• Discussed conveyor belt design & its manufacturability.

  1. Suggested research on stainless steel vacuum conveyor belt system.

  2. Suggested a kind of plastic film for outer wrap to constrain the tubes

  3. Agreed rubber band is a good proof of concept.

• Discussed tube pin holder.

  1. Liked the protection holder for crown tip of the pin.

  2. Will think about possible ways for 

• Discussed inspection mechanism.

  1. Worried about vacuum mechanism.

  2. Suggested convex mirror.

Todo Before Next Week 

• Manufacture PROTOTYPES!

• Order Load Cell

• CAD for vacuum, servo motor and linear slider. Also orders for these parts

Summary 

3/4 individual prototypes are done. Testing assembling and design modifications. First assembly in progress.

Current Status 

Operation

• Team decided to meet in-person during Tuesday & Thursday from 2pm - 5:30pm.

• Team will have at least 2 practices for Proof-of-Concept presentation.

Sorting 

• • Static elimination

    • Secured a 15% off from the Exair air-jet style static eliminator.

    • Exair air-jet style static eliminator purchase request done.

    • Need to confirm with Roxanne about the order of ESd grade UHMW polyethylene from Boedeker Plastics and the Exair Static Eliminators.

  • Feeder bowl

    • Finished 1 testing bowl and 1 UHMW bowl.

      • Function properly with minor flaws.

    • Testing vibration characteristics of the bowl.

    • Designing pin exit variations.

    • Bowl design refining based on current model.

    • REORIENTATION: Talked to an CV engineer student for possible solution

      • Assessing time/effort required for this solution

  • Accessibility

    • Designing and CAD a Camera system to view processes.

Conveying/transporting 

• Capillary tube with timing belt

  • • Aaron reluct spend money on this but could test it and give it a try (Parts order submitted and approved by Aaron, waiting for UCSD)

    • The capillary tubes are not viable, however, we can seriously try to manufacture them ourselves with laser cuter and glass-grade acrylic. 

    • THIS IDEA IS BEING PERSUED FOR THE FOLLOWING REASONS:

    • 304 SS TUBES WERE FOUND ON McMasterCarr and ordered. Tubes will satisfy the desired dimension of 0.33mm ID. 

    • This does require adjustments on timing belt selection and thus also requires pulley and motor adjustment. 

    • Parts will be ordered by Jan 24. 

    • Aluminum extrusion for the system structure will also be ordered. (5ft 1” extrusion with 20 corner brackets and sliders.)

• Vacuum transportation

  • • -

Force Sensing 

• Received 4 different quotes from different companies. Need to ask Aaron for approval. 

• Using an amazon load cell to make a prototype. Wiring and testing in progress. 

• Cad model completed. 

Inspection 

• -

Sponsor Meeting Note

• TBD

Advisor Meeting Note

• TBD

Todo Before Next Week 

• Manufacture PROTOTYPES!

Summary 

Most individual proof of concept done. Working on connecting individual parts together.

Current Status 

Operation

• Team will now collaborate and concentrate team effort on individual tasks.

Sorting 

• • Static elimination

    • Waiting on static eliminators.

  • Feeder bowl

    • New design of feeder bowl done, ready to be manufactured Tuesday.

    • Designing pin exit variations.

    • REORIENTATION: Waiting on Jetson Nano, studying openCV.

  • Accessibility

    • Designing and CAD a Camera system to view processes.

Conveying/transporting 

• Capillary tube with timing belt

  • • Aaron reluct spend money on this but could test it and give it a try (Parts order submitted and approved by Aaron, waiting for UCSD)

    • The capillary tubes are not viable, however, we can seriously try to manufacture them ourselves with laser cuter and glass-grade acrylic. 

    • THIS IDEA IS BEING PERSUED FOR THE FOLLOWING REASONS:

    • 304 SS TUBES WERE FOUND ON McMasterCarr and ordered. Tubes will satisfy the desired dimension of 0.33mm ID. 

    • This does require adjustments on timing belt selection and thus also requires pulley and motor adjustment. 

    • Parts will be ordered by Jan 24. 

    • Aluminum extrusion for the system structure will also be ordered. (5ft 1” extrusion with 20 corner brackets and sliders.)

• Vacuum transportation

  • • -

Force Sensing 

• -

Inspection 

• -

Sponsor Meeting Note

• TBD

Advisor Meeting Note

• Conveying ideas explored

  1. All agreed that tubing no longer needed due to the perfect fit of pin in groves.

Todo Before Next Week 

• Manufacture PROTOTYPES!

Summary 

Need working on connecting individual parts together. Behind project progress.

Current Status 

Operation

• Aaron advises the team to not have everyone working on the same part, but return to the 2-person-team strategy due to the lack of time.

Sorting 

• • Static eliminators arrived. Ordering pump supplies.

  • Feeder bowl

    • Version 2 bowl manufactured.

    • Designing exit track.

    • REORIENTATION: Jetson Nano arrived, studying openCV.

  • Accessibility

    • Designing and CAD a Camera system to view processes.

Conveying/transporting 

• Capillary tube with timing belt

  • • THIS IDEA IS BEING PURSUED FOR THE FOLLOWING REASONS:

    • Aluminum extrusion for the system structure delivered. 

    • The belt and pulley work together. 

    • Glue idea is changed. Rubber band purchased and tested. Doesn’t work so well. Structure integrity affected by large tension force. Will need reinforcement. 

    • Connect with Feeder Bowl. 

• Vacuum transportation

  • • -

Force Sensing 

• -

Inspection 

• -

Sponsor Meeting Note

• Team changing working strategy

• Tasking replanning needed

Advisor Meeting Note

• TBD

Todo Before Next Week 

• Manufacture PROTOTYPES!

Summary

Replanned project.

Current Status

Operation

• Split back to 2 small groups to tackle problems. Collaborating as a whole team for critical issues.

• Replanned and determined priorities.

Sorting

• Static eliminators arrived. Ordering pump supplies.

• Feeder bowl detailing

  • Exit track manufactured.

  • REORIENTATION: Jetson Nano arrived, studying openCV.

• Accessibility (good to have, not priority for now)

  • Designing and CAD a Camera system to view processes.

Conveying/transporting

• Capillary tube with timing belt

  • Main structure finished, programmed to move a step each 2 second.

• Vacuum transportation

  • Support and mount for vacuum tip, linear actuator and motor built. 

  • Works, with some shortcomings

    • Need to remanufacture the vacuum tip mount

      • The current one leaks air

• Motor connection needs to be better, possibly use bearing

• To Do:

  • Controller for motor, actuator and pump/vacuum

Force Sensing 

• -

Inspection

• -

Todo Before Thursday

1. Test - redesign - repeat 

Summary 

Connecting components & testing assembly. Report & presentation is now another priority. 

Please check out our WIP Final report.

Current Status 

Operation

• The team is now focusing on the main deliverables.

• The final report and poster are being constantly updated.

Sorting 

• • Working on a pump ESd elimination system.

  • Feeder bowl

    • New exit track track designed.

    • Connection with conveyor belt first success achieved -> updating the design for improvement

  • REORIENTATION -> now a Good-to-have functionality.

Conveying/transporting 

• Stepper Motor Driven Timing Belt

  • • The main structure is finished, and programmed to move a step each 2 seconds. 

    • Will Make things more shiny and fancy looking. 

Force Sensing 

• The Futek load cell arrived, however, it did not work with the current setup for reading load cells. Will have to order their ecosystem. 

• The final design of force inspection is nearly finalized. 

• Alignment and calibration are needed. 

Inspection 

• -

Sponsor Meeting Note

• TBD

Advisor Meeting Note

• TBD

Todo Before Next Week 

• Test - redesign - repeat

• Final report & poster constant update

• Schedule final presentation with Aaron

Summary 

Final Assembling.

Current Status 

Operation

• -

Sorting 

• • No testable result from the ESd elimination system.

    • Decided to pause progress to focus on Main Assembly.

  • Feeder bowl

    • ESD bowl machined and mounted.

    • Connection with conveyor belt achieved with Exit track & Exit block pair.

Conveying/transporting 

• Stepper Motor Driven Timing Belt

  • • Cleaned up with electronics mounted.

    • Maintained precision with 30 minutes continuous testing.

Force Sensing 

• The Futek load cell data read success. 

• The final design of force inspection finalized. 

• Alignment and calibration. 

Inspection 

• 3D printed parts, assembled.

Sponsor Meeting Note

• TBD

Advisor Meeting Note

• TBD

Todo Before Next Week 

• Test & Tuning.

• Final report & poster constant update

• Final presentation scheduled with Aaron