process improvement for drill bit blanks for mn twist drill
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Process Improvement for Drill Bit Blanks For MN Twist Drill. University of Minnesota Duluth. Department of Mechanical and Industrial Engineering. The Three Orienteers Scott Anderson – Project Leader Andy Johnson – Mechanical Engineer Tony Niemczyk – Industrial Engineer. - PowerPoint PPT PresentationTRANSCRIPT
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Process Improvement for Drill Bit Blanks
For MN Twist Drill
The Three OrienteersScott Anderson – Project LeaderAndy Johnson – Mechanical EngineerTony Niemczyk – Industrial Engineer
Department of Mechanical and Industrial Engineering
University of Minnesota Duluth
Report Number UMDMIE-CD-2006WPDK12
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Problem Statement
• Blanks are coming off of machine without orientation
• Manually sorted to bins• Blanks manually moved
approximately 10 feet to coning machine
• Manually loaded into coning machine
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Problem Statement
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Scope of Project
• Orientate drill bit blanks from cut-off machine
• Directly feed blanks into coning machine
• Increase throughput• Reduce work in progress
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Functional Requirements
• Require little maintenance, less then $2,000/year• Reduces manual handling labor• Simple in design • Utilizes gravity as much as possible• Maintains or improves throughput • Adaptable to varying lengths and diameters• Efficient• Implemented with little risk due to offline testing
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Constraints & Limitations
• The speed of the cutting and coning machines which for the cuttingmachine is 200 parts per minute
• Budget is a 2 year payback on a $20,000 a year salary based on the reallocation of labor
• Material type being cut which includes cobalt and various types of steel.
• Drill bit diameter and length varying from 1/4” to 1/2” and 2 ½” to 6” respectively
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Constraints & Limitations
• Set up time as it relates to throughput for the entire system
• Control Systems which include a PLC and relays• Space available• Factors that involve the safety of the workers and
the plant.• Type of power supplied (AC/DC, Mechanical, etc)• Weight of the drill bits
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Project Organization
• Scott Anderson – Project Leader• Andy Johnson – Mechanical Engineer• Tony Niemczyk – Industrial Engineer• Work in parallel whenever possible• Crucial decisions made as group• Frequent group meetings
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Design Concepts & AlternativesAlternative 1: Vibratory Feeder
• Ability to orientate blanks • Remove blanks that do not meet
specifications• Can Handle up to 200 parts per minute • Automatic feed of blanks into coning
machine
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Design Concepts & AlternativesAlternative 1: Vibratory Feeder
Design of Alternative 1
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Design Concepts & AlternativesAlternative 2: Vibratory Table
• Slight vibration from a vibratory motor would break binding
• Vibration agitates the drill bits so that gravity brings them into alignment
• Would not allow relocation of labor
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Design Concepts & AlternativesAlternative 2: Vibratory Table
Design of Alternative 2
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Design Concepts & AlternativesAlternative 3: Vibratory Table + Rail System
• A vibratory table aligns and feeds blanks into a movable transport hopper
• Transport hopper feeds directly into the coning machine
• Eliminates the handling of blanks• Many possibilities for automation
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Design Concepts & AlternativesAlternative 3: Vibratory Table + Rail System
Design of Alternative 3
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Design Concepts & AlternativesAlternative 4: Conveyor Methods
• Conveyor takes blanks directly off cut-off machine or from vibratory hopper
• Allows for automatic rejection of parts • Provides blanks sequential order of
alignment• Requires little operator interface
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Design Concepts & AlternativesAlternative 4: Conveyor Methods
Design of Alternative 4
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Design Concepts & AlternativesAlternative 5: Chute & Hopper
• Blanks orientate on vibratory hopper and slide down channels to coning hopper
• Coning hopper uses rake mechanism• Logic senses when blanks are in hopper
waiting to be fed into coning machine
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Design Concepts & AlternativesAlternative 5: Roofing & Hopper
Design of Alternative 5
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Preliminary Design Recommendations
• Preliminary recommendation was the hopper and rail system
• Met all functional requirements and was simple in concept and design
• Reduced labor intensity but did not enable relocation of personnel
• Blanks still needed to be loaded into hoppers and hoppers removed when emptied
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Design Evaluation
• Previous concepts were broken down into features
• Features were given a quantitative value and weight
• Feature values and weights of each alternative were summarized and options were compared
• Hopper and chute was determined to be the best option
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Evaluation Scores
CostSimple Design Maintenance
Reallocation of
Manual laborUtilizesGravity Adaptable
Maintains or
improvesthroughput Total
Weighted Score
Vibratory Table 10 10 10 1 5 1 5 42 319
Vibratory Feeder 1 1 1 10 1 5 10 29 273
Vibratory Table + Rail System 10 5 5 1 5 5 5 36 295
Conveyor Methods 1 1 1 10 1 10 10 34 318
Vibratory hopper/Slide/Modified Coning Hopper 5 10 5 10 10 5 5 50 400
Do Nothing 10 10 5 1 1 1 5 33 270
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Economics
• Installed Cost: $10,297.55 • Annual Benefits of:
– System by itself: $37,070.00 – System with reduced setup time: $747,070.00
• Annual Maintenance (10% of installed cost): $1,029.76
• Payback Period of:– System by itself: 108 working days– System with reduced setup time: 5 working days
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Mechanisms
• Vibratory Hopper– The first step in aligning the blanks from the existing
conveyor– Half cylinder shaped hopper attached to a base plate
that has a vibratory motor attached – The shape of the hopper and the vibrations from the
motor will force the blanks to align– The hopper will align the bits – Hopper serves as a place for the blanks to build up if
the coning machine stops
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Mechanisms:Vibratory Hopper
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Mechanisms
• Chute– Provides channels for the blanks to slide down– Provide further alignment of the blanks – The optimized angle of the chute was
experimentally determined to be 30°
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Mechanisms:Chute
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Mechanisms
• Coning Hopper– Aligns blanks for feeding to the coning
machine – When blanks enter the hopper they need to be
aligned by pneumatic actuator and “rake.”– Allows for full range of blanks without any
insert in the hopper – Gates on bottom regulated by the PLC slide
open and shut
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Mechanisms:Coning Hopper
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Procedures
• Setup procedures for when:– Both coner and cut-off are off– Cut-off machine is running– Both coner and cut-off are running– Cut-off machine has completed coil– Both machines have completed coil
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Procedures
• Programmable Logic Controller Procedure– Sensors in the system check the system for
out of control circumstances – Ensure that the hoppers never overflow with
material – Determine the operation of the slider plates
Inputs Outputs
Sensor in coning hopper to detect height Turn off vibratory motor
Sensors in coning hopper to move plates Move plates in and out to prevent damage to coning belt
Sensor in Vibratory hopper to detect height Turn off conveyor
Pushbutton to determine if setup is happening Sensors are not used until pushed
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PLC Flowchart
No
Setup
EnableSensors
All SensorsDisabled
Yes NO
TMRPart In top of
Vibratory HopperYes
Part?
TMR
Yes
Part?
Turn offConveyor
Yes
No
No
No
TMRPart In top of
Conning HopperYes
Part?
TMR
Yes
Part?
Turn offVibratory
Motor
Yes
No
No
TMR
Part In ConningHopper
Yes
Part?
TMR
Yes
Part?
Move Plate
Yes
No
No
No
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Testing Procedure
• Build the physical components one at a time starting with the coning hopper
• Test the coning hopper• Build the chute and the vibratory hopper• Send blanks through the system
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Testing Procedure
• Attach the system to the coning machine itself
• Test the feeding of the blanks into the coning machine
• Connect the PLC and the sensors to the system
• Check that the correct timings occur • Check that Out of boundary conditions do
not occur
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Implementation Procedure
• Build all support structures for the system • Make modifications to the coning machine • Remove all connections to the coning
machine • Move coning machine to its new location
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Implementation Procedure
• Reestablish all connections to the coning machine
• New system should be attached and powered up for use
• All elements should be tested for proper running conditions and for proper safety precautions
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Setup Improvements
• A standard process for setup would be very beneficial to process flow
• Identify external operations • Identify internal operations
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Acknowledgments• We would like to thank Matt Mattson for contacting the
University of Minnesota Duluth with a senior design project and for accommodating all of the needs of the group in a respectful and timely manner
• We would like to thank Scott Allison for giving Matt Mattson the capabilities to go to the University and finance the project
• Finally we would like to thank our professor’s Dave Keranen and Bill Pedersen for all of their help and advice in the development of the project and for guiding us to not only get the project to completion, but also in a manner to help us learn new skills on our own
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MN Twist Drill
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