conceptual design review senior design 2004-2005 university of idaho college of engineering
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Conceptual Design Review
Senior Design 2004-2005
University of Idaho
College of Engineering
Overview
1. Functional requirements and constraints2. Material Flow
– Remove cartridges from tray– Presentation of cartridges in front of camera– Gage wheel– Put cartridges into 50ct tray
3. Cartridge Inspection– Lighting– Inspection Software
4. Future focus5. Budget6. Schedule
1. Functional Requirements and Constraints
Minimal change in height desired from 500ct to 50ct tray
Minimize risk of incurring incidental and other defects while processing product
Cost of x-y positioning systems
2. Material flow considerations
2.1 Remove cartridges from tray• Gravity feed from 500ct tray
– Freefall acceleration velocities are sufficient for 600parts/min requirement
– How do we get them back up higher in elevation?
• Vertical ascent out of 500ct tray– Vacuum and air blast alternatives considered– Air is readily available– Experimental results
Vertical ascent: Air jet and tube array• Remove cartridges from
500ct tray– 20 tube array, 1-D
positioning system
– 500ct tray gets positioned, tubes are stationary
– Varied length tubes, cartridges arrive at different times
– Ten cartridges pulsed every 1 second with an air jet array below the tubes
Where the tubes end
• Cartridge queue– Accepts cartridges from feed tube– Advances cartridges to inspection area– Provides better advancement control than
gravity feed tube
2.2 Presentation of cartridges in front of camera
• Dropping
• Contact Rolling– Single Roller– Multiple Roller
Dropping
• Image: 3 images within one picture
• Pros– Gravity is consistent and does work for us – Gravity produces proper orientation
• Cons– Scaling issues, consistency in falling distance– Mirrors in place to give 360 degree view
• Image: 3 images taken 120o apart• Pros
– Consistent image in front of camera– Multiple parts within picture window
• Cons– 3 images taken 120o apart cause long process
time– High transfer rates, rotational and linear
Single Roller
Single Roller
Multiple Roller
• Image: 1 unrolled image of entire cartridge
• Pros– Consistent image in front of camera– Multiple parts within picture window
• Cons– High transfer rates, rotational and linear– Complex apparatus
Multiple Roller
2.3 Gage Wheel
Pros– Gages parts for proper diameter– Outputs bad parts to separate
bin– Produces timing interval
between parts
Cons– Limited to one type of defect– Allows minor defective parts to
pass
2.4 50-ct Tray Package Machine
• Existing Prototype to be utilized for project
• Electromechanical device that can be controlled by camera processor
• Built for existing tray configuration
3. Cartridge Inspection3.1 Lighting
1. Front lighting
2. Back lighting
3. Structured lighting
Things to Consider
• Metallic reflective surface
• Curved shape of case
• Surface defects on case
• Measurements of dimensions of entire bullet
Applications
Lighting Techniques Application Areas
Front lighting-directional-darkfield 3D surface features
Front lighting-directional-brightfield Surface scratches
Backlighting 2D object shape and dimension
Structured lighting 3D objects
Omni-directinal lighting Shiny objects
Front lighting
Brightfield illumination Darkfield illumination
Front lighting
Diffused Front light Omni-directional illumination
Shiny Object
Reflective surface
Back lighting
Optical Diffuser
Structured lighting
Lighting options for material flow
Rolling Falling
3 pictures
Panoramic
*Structured *Backlighitng and
frontlighting
*Structured *Backlighting and
frontlighting
*Structured *Frontlighting
Not sure this is possible
3.2 Inspection Software
• Three ways to use software to inspect bullets– Intensity– Edges– Shapes
Inspection Software
• Intensity - Use multiple polygons to look for dark areas (flaws) on the cartridge surface.
This sensor is looking for the amount of “white space” inside the red box
Inspection Software
• Intensity– Pros
• Easily detect major defects• Checks areas• Easily manipulate intensity values
– Cons• Smaller sensors are better, but more work to
make them• Hairline fractures can cause problems if
intensity settings aren’t sensitive enough
Inspection SoftwareIntensity Pass
Inspection SoftwareIntensity Fail
Inspection Software
• Edges - Use multiple sensors to look for edges (flaws) inside areas that are white on the cartridge surface.
These sensors are looking for edges on the red lines
Inspection Software• Edges
– Pros• Easily detect major defects• Checks for all edges• Easy to make multiple sensors in different places
– Cons• Smaller sensors are better, but more work to make
them• Hairline fractures can cause problems if edges are too
far apart
Inspection SoftwareEdge Pass
Inspection SoftwareEdge Fail
Inspection Software
• Shapes - Use a single or multiple sensors to look for “perfect” cartridges or parts of the cartridge.
This sensor is looking for the “white” shapes on the cartridge
Inspection Software• Shapes
– Pros• Easily detect major defects• Checks for all white “blobs” larger than a specified
size.
– Cons• Smaller sensors are better, but more work and more
processing time• Smaller defects including hairline fractures and
small dents are difficult to see
Inspection SoftwareShape Pass
Inspection SoftwareShape Fail
4. Future Focus
Based on recent discussion with ATK, focus will be on the inspection process
• Further testing– Material handling– Lighting
• Combination of front and back lighting
– Software inspection• Combination of intensity and edge sensors
4.2 Lighting
• Combination of front lighting and back lighting– Pro
• Cheaper
• Works well with dropping
– Cons• Hard to adjust
• Reflection
4.3 Software
• Combination of intensity and edge sensors– Pros
• Both sensors work well on different sections of the cartridge
• Inspects entire cartridge
– Cons• Multiple sensors
• Increased processing time
5. Phase 1 Budget
• Expected expenses– Materials– Controls
• Motors
• Microcontroller
– Lighting
• Expected date for budget approximation– December 6, 2004
6. Short Term Schedule
• Experiment (to be completed by December 3rd)– Take pictures
• Different lighting• Different transfer methods
– Detect defects• Implement different sensors• Minimize processing time
• Deliverables (December 17th)– Preliminary design of phase 1
Questions