matt “i love the fit birdz” zapotoskiproject leader bob “try doin that” shackelfordlead...
Post on 19-Dec-2015
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Matt “I love the fit birdz” Zapotoski Project LeaderBob “try doin that” Shackelford Lead EngineerSharif “double shot” HdairisElectrical/Computer
EngineerJoe “I got lost in traffic” Jennings Mechanical Engineer
Sponsored by:
Project DescriptionPlan and assembly a test prototype to oil tool holdersMarket: ParlecKey high level customer needs / engineering specs:
Product versatility will handle Cat 30, 40, and 50s
with diameters up to 7”
lengths ranging from 2-18”
up to 40 lbs
Will not damage part surface Maintains 60 millionths of an
inchEfficient, consistent coverage Complete exterior of part oiled
and cleaned off
Current State of Machine Product meets all desired customer
needs Machine meets all engineering specs
for fully integrated system and subsystems
Met project budget
Validation/Complications
Oil pan channeling oil back to bin Conveyor restricting adjustability of air knife
part saturated with oil part after blowoff process Difference 1058.950 g 1052.425 g 6.525 g1058.975 g 1052.60 g 6.375 g1059.875 g 1054.25 g 2.625 g1058.325 g 1053.85 g 4.475 g1058.575 g 1054.30 g 4.275 g
AVG 4.855 g* un-oiled part weighs an average of 1051 g
By saving 4.855 grams of oil per part, and producing 1400 tool holders per shift, the expected savings of oil per day is approximately 1.98 gallons.
Oil Removal Efficiency
Cups with oil off of finished part, and part dipped into oil
Test ResultsTest # Description Criteria Result
Mechanical Tests
1 Oil removal effectiveness
Oil removal effectiveness is acceptable, there is little oil left on the part after it passes through the air knives. No
excessive continous dripping. YES
2 air knife positionsrotation at 90, 60, 45, 30 30angle at 0, 10, 25 10
distance from pin from every locationas close as
possible
3 Part versatility
Ensure that a good range of CAT 30, 40, and 50 parts can be placed on the fixture, and that they do not fall off while the
machine operates (run it through once). YES
4 Oil collection
The oil tray properly collects and returns the oil to the system tank. All oil dripping from the parts is caught and
nothing reaches the floor. YES
5 Parts distancing
The parts do not come in contact with each other or other parts of the machine, this would damage the surface tolerance. Run the machine and observe that there is reasonable clearance around the parts in all stages. YES
6 Pin durabilitySimulate improper loading of the parts onto the fixtures,
ensure that none of the pins are damaged or broken. YES
7
Oil curtain effectiveness on entrance and exit of air
chamberNo oil escapes the enclosure at any side or at the
entrance/exit YESElectrical Tests
8 Control PanelStart switch: this switch will begin the machine's operation in
the given mode. YES
9 Load powerVerify that the system power requirements can be handled
by the power supply, and that the power specs are met. YES
10 Sensors / Airknife
Air knives operate for a period long enough to perform the cleaning, the timing will adjust to accommodate the various
speeds the system supports. YESIndustrial & Misc. Tests
11 Loading/Unloading
utilize the NIOSH lifting equation to determine if any risks are associated with operator loading and unloading parts for
an entire shift.no potential
risks
12 Decibel level of the air knifeEnsure that the noise level of the the air knife is less than 90
dB 85, YES