Electronic Module Extraction Tool

Final ReviewUniversity of Delaware

December 12, 2003

Team 7: Allison Bruton, John Fitzgibbons Rich Herseim, & Greg

Spalding

Sponsors: John Dean & Ann Rickle

OutlineOutline

Project Background Benchmarking Summary Project Scope Preliminary Concepts Design Recommendations Extraction Tool Testing and Analysis Project Management Transition Plan Questions

Project Background

Northrop Grumman Worldwide leader in

global defense electronic systems

No handheld tools exist for extraction of electronic modules in horizontal configuration

Purpose of tool Extract electronic

modules within tight tolerance for repair Electronic Module

Cap Board

Ceramic Base

** Module size relative to half dollar

Ring Frame

Critical Issues

Tight Spacing Tight Spacing

Fragile PartsFragile Parts

Module is Module is composed of composed of metallic & non-metallic & non-metallic layersmetallic layers

Cap Board: Non-Metallic

Ring Frame: Metallic

Ceramic Base: Non-Metallic

Side View of Electronic Module

Constraints

Minimize damage to cap board & module

Maintain tight position tolerance

Meet OSHA regulations

Mission StatementMission Statement

“To design a To design a handheld handheld

extraction tool extraction tool for electronic for electronic

modulesmodules”

Lessons Learned from Lessons Learned from BenchmarkingBenchmarking Phase OnePhase One

Variety of Integrated Circuit (IC) extractor devices on the market

Advanced Tweezer Extractor

Dual In-Line Package IC Extractor Tool

Self-Contained Vacuum Pickup Tool

Basic IC Extractor

Lessons Learned from Lessons Learned from Benchmarking Benchmarking (continued)(continued)

Phase Two Gained greater understanding

of:• Material properties of each

layer within electronic module• Electromagnets• Magnetic analysis

Phase Three Gained greater understanding

of:• Ergonomic design - OSHA• Magnet pull force• Plate analysis

Rare Earth Magnet

Electromagnet

Customers, Wants & Metrics

Northrop Grumman Sponsors Northrop Grumman Sponsors & &

TechniciansTechnicians

Extract ModuleExtract ModuleAssemblyAssembly

Manual Manual OperationOperation

Simple Simple OperationOperation

Metrics

Wants

Extraction force (lb) Extraction force (lb) >3.6>3.6Stress on ring frame (psi)Stress on ring frame (psi) <50,000 Bending force on pins/tubes (lb) <50,000 Bending force on pins/tubes (lb) <0.17 <0.17Tolerance fit checkTolerance fit check Yes Yes

Target Value

Project ScopeProject Scope

Operation Manual

Repair SystemRepair System

Repair Operation

ErgonomicsExtract Module

Extractor Extractor

Interface Force Application

Simple Superstructure

Design recommendations for new electronic module

4 Preliminary Concepts4 Preliminary Concepts

•Hook DeviceHook Device

Analysis predicted tool interface would deform

•Clamping Clamping DeviceDevice

Physical testing proved required extraction force (3.6 lbs) was not met

•Suction DeviceSuction DeviceInteraction between suction & cap board could damage module

•Magnetic Magnetic DeviceDevice

Needed further investigation

After further development……

2 Concept Finalists

Design recommendations Design recommendations for electronic modulefor electronic module

Ceramic

Base

RingFrame

CapBoard

•Ceramic Board

•Two chamfered corners

•Allows pin placement

•Capboard

•Cutouts

•Accommodates magnetic interface

•Capacitors and Fuses

•Realignment

•Optimizes capboard cutouts

Revised Electronic Module

Capacitors & Fuses

Extraction Tool – PrototypeExtraction Tool – Prototype Force ApplicationForce Application

– Human poweredHuman powered– Push rod and knobPush rod and knob

SuperstructureSuperstructure– Linear ball bearingLinear ball bearing– Linear guidesLinear guides– Support pinsSupport pins

Magnetic InterfaceMagnetic Interface– Rare earth Rare earth

magnetsmagnets

10”

3.5”

Extraction Tool - OperationExtraction Tool - Operation

3 Simple Steps

1) Obtain proper extraction position

2) Compress knob until contact is made with the exposed ring frame

3)Pull knob up extracting the module

Extraction Tool - OperationExtraction Tool - Operation

Testing and AnalysisTesting and Analysis

Magnetic Interface TestMagnetic Interface Test Finite Element Analysis on Ring Finite Element Analysis on Ring

FrameFrame Bending AnalysisBending Analysis Tolerance Fit CheckTolerance Fit Check

Magnetic Interface Magnetic Interface TestTest

Tested Magnet Sample

.25” Dia x .75”

Load Cell

Ring Frame

Magnet Holder

Test Fixture

Purpose:– Prove that the magnetic

interface can withstand the required extraction force

F

Magnetic Interface Magnetic Interface TestTest

Metric &

Target Value

Satisfied

Extraction force > 3.6 lbs

Conclusion:– Extraction force of 5.4 lbs achieved– Safety factor of 1.5 provided

Pull Force - .25" dia x .75" Neo 48 Magnet

0

1

2

3

4

5

6

700 900 1100 1300Time (ms)

Pu

ll F

orc

e (

lbs

)

~ 5.4 lbs

Required 3.6 lbs

FEA – Ring FrameFEA – Ring Frame

Magnet Locations Stress Distribution

Metric &Metric &

Target ValueTarget Value

SatisfiedSatisfied

Max stress in the ring frame < 50,000 psi

Purpose:Purpose:– Prove that the maximum stress in the Prove that the maximum stress in the

ring frame is below its yield strengthring frame is below its yield strength

Conclusion:Conclusion:– Maximum stress present in the ring frame ~14,000 psiMaximum stress present in the ring frame ~14,000 psi– Safety Factor of 3.57 providedSafety Factor of 3.57 provided

Bending AnalysisBending Analysis

Purpose:Purpose:– Prove that the ceramic base deflection Prove that the ceramic base deflection

will not plastically yield the module pinswill not plastically yield the module pinsMetric &Metric &

Target ValueTarget Value

SatisfiedSatisfied

Force on pins < 0.17 lbs

Conclusion:Conclusion:– Worst ceramic deflection ~1.82 E-4 in. Worst ceramic deflection ~1.82 E-4 in.

Resultant force on pins ~0.00025 lbsResultant force on pins ~0.00025 lbs– Provides a safety factor >>10Provides a safety factor >>10

Tolerance Fit CheckTolerance Fit Check

Rapid Prototype Module

Tool Fit Check

Support Pins

Purpose:Purpose:– Prove that the support pins of the extraction tool fit Prove that the support pins of the extraction tool fit

in the four corners of the rapid prototype modulein the four corners of the rapid prototype module

Conclusion:Conclusion: Passed tolerance fit checkPassed tolerance fit check

Device ErgonomicsDevice Ergonomics

Knob

2.0” diameter fell within acceptable diameter range for power grip use

Met OSHA regulations

Tool Design

Proper neutral wrist position

Horizontal work surface

Appropriately designed hand tool so wrist can remain straight

Met OSHA recommendations

2.0”

Project Completed in a Team Project Completed in a Team EffortEffort

Development

AnalysisTesting

& Prototyping

Project Management – Cost Project Management – Cost SummarySummary

QuantityQuantity DescriptionDescription Total Price ($)Total Price ($)

22 Push RodsPush Rods 1212

2020 Neodymium MagnetsNeodymium Magnets 6666

11 Linear Ball BearingLinear Ball Bearing 4343

22 Miniature Guide BlockMiniature Guide Block 110110

22 Rail for Mini Guide BlockRail for Mini Guide Block 4242

5858 Screws & WashersScrews & Washers 1616

22 KnobKnob 66

88 Support PinsSupport Pins 2323

22 HandlesHandles 66

10 parts10 parts Northrop Grumman MachiningNorthrop Grumman Machining 5,0005,000

Actual CostActual Cost 5,3245,324

800 hrs800 hrs Team 7 Labor Costs @ $20/hrTeam 7 Labor Costs @ $20/hr 16,00016,000

Theoretical CostTheoretical Cost 21,32421,324

Transition PlanTransition Plan

Operation Manual

Ergonomic issues– Improved handle

design

Tool Alterations– Improved support

pins– Reduced tool weight– Limited linear motion

Module Recommendations– Ceramic chamfers– Cap board redesign

CeramicBase

RingFrame

CapBoard

Capacitors & Fuses

SummarySummary

Reviewed Project Background Explored Benchmarking Presented Project Scope Explored Preliminary Concepts Provided Design Recommendations Discussed Extraction Tool Demonstrated Analysis & Testing Discussed Project Management Presented Transition Plan

Acknowledgements

Northrop Grumman Sponsors – John Dean & Ann Rickle

Advisor – Dr. Wilkins Senior Design Staff

– Dr. Glancey– Dr. Keefe– Mr. Cloud

Steve Beard Roger Stahl

Questions???

Extraction Force Calculation

ConnectoConnector Typer Type

Total Total ##

Required Extraction Required Extraction Force (lbs)Force (lbs)

Total Required Total Required Extraction Extraction Force (lbs)Force (lbs)

RFRF 55 0.50.5 2.52.5

PinPin 1010 0.110.11 1.101.10

TotalTotal ---- ---- 3.63.6

Extraction Force ~0.11 lbs

Temperature Temperature ConsiderationConsideration Maximum required operating Maximum required operating

temperature of extraction tool:temperature of extraction tool:

Neodymium Iron Boron rare earth Neodymium Iron Boron rare earth magnets maximum operating magnets maximum operating temperature:temperature:

80oC

≤ 60oC

Extraction Tool – Fabricated Extraction Tool – Fabricated

PartsParts Before After

Push Rod

Magnet Holder

Coupler

Top

Bottom

Side

Clamping Interface Clamping Interface Test Test

Tensile Force w/ Clamping Device (20lbs) Trial #1

0

0.5

1

1.5

2

2.5

3

3.5

4

4.5

500 510 520 530 540 550 560 570

Time (ms)

Fo

rce

(lb

s)

Max Extraction Force = 3.5 lbs < 3.6 lbs

Required 3.6lbs

FEA – Clamping ForceFEA – Clamping Force

Compressive Forces on Ring

Frame

Stress DistributionMax stress ~4000 psi << 50000 psi (ring frame)

Ring Frame Used in Clamping Test

Actual Ring FrameTested Ring Frame

Extraction vs. InsertionExtraction vs. Insertion

Insertion is considered a small Insertion is considered a small hand operationhand operation

Easier to insert correctly than Easier to insert correctly than extractextract

Northrop Grumman main Northrop Grumman main focus is extractionfocus is extraction

Magnet Interface Magnet Interface TestingTesting

Pull FOrce - .25" x .75" Neo 48 Magnet

-0.5

0

0.5

1

1.5

2

600 700 800 900 1000 1100 1200

Time (ms)

Pu

ll F

orc

e (

lbs)

~ 1.6 lbs

¼ the Required Extraction

Force

Tolerance AnalysisTolerance Analysis

Purpose:Purpose:– Prove that the support pins of the extraction tool fit Prove that the support pins of the extraction tool fit

in the four corners of the 0.017 inin the four corners of the 0.017 in22 area tolerance area tolerance

Support Pin Tolerances

Metric &Metric &Target ValueTarget Value

Satisfied Satisfied

Tool support pins fit in the 0.017 in2 area tolerance

Linear Motion TestLinear Motion Test

Purpose: – Ensure magnets move

in a linear fashion

Results:– Max deflection at

magnet holder 0.0035”

Conclusion:– Tool will extract in a

linear fashion

Dial Indicator

Test Set Up

Magnet Holder

Cost PerspectiveCost Perspective

Basic Design FeaturesBasic Design Features

•Grip/Handle-User Interface

•Extraction Structure

•Module-Tool Interface

Extraction Tool - PrototypeExtraction Tool - Prototype

Handle

Magnets

Knob

Linear Bearing 10”

3.5”