Transcript INTELLIGENT TOOLING
INTELLIGENT TOOLING
Progress Review
• • • • • • Introduction Updated Customers/Wants/Constraints Metrics Benchmarking Concept Evaluation Schedule
Project Summary
Team 99.08
Members:
Jeff Roushey, Glenn Gardner, Andy Graybill, Joe Staley
Customer:
Fraunhofer Resource Center – Delaware (FRC-DE)
Mission:
To develop a sensor system to indicate the completion of the metal foaming process for aluminum and steel foams using a LabVIEW interface. This project will be completed for FRC-DE by April 1999.
Approach:
We plan to complete our project by cooperating as a team, working efficiently, and utilizing all of the available resources.
Background
• • • • • Powder Metallurgy Semi-finished product Metal working Foaming Material Properties
Problem Description
• • • • Over-aging Technicians rely upon experience Material waste Molding defects
Customers
• • • • Fraunhofer Resource Center, DE Automotive Industry Aerospace Industry Building Industry
Prioritized Wants
1) High Percentage of Successful Foams 2) System Reliability 3) Simplicity of System 4) Low Cost
Constraints
• Operating Temperature - 1400 C • Oven Size • Cost - $8000 • LabVIEW Interface
Metrics
Quality Metrics
Maximum Operating Temp (C) Sensor System Life (years) Cost (Dollars) Dimensions (inches) # Surface Defects # Signal Altering Devices Training Time (hrs) Programming Time (hrs) Set-up Time (min) # Mold Alterations
SSD Weighted Percentage Target Values
11.93
1400 11.01
11.01
10.09
10.09
9.17
9.17
9.17
9.17
9.17
5 <5000 4 x 4 x 1 0 1 2 40 30 0
System Benchmarking
• • • • • High Speed Temperature and Process Signal Measurement System Bricesco Pyrotrace Material Level Monitoring System Die Casting Injection Molding
Temperature & Process Signal Measurement System
System Includes: - Sensors - “Black Box” - Voltage Input Digital Output - Software and user interface
Temperature & Process Signal Measurement System
• Advantages: - Only one signal altering device - Low setup time Cost ($2000) • Disadvantages: - Interface is not LabVIEW
Bricesco Pyrotrace
• • • • Designed for kilns Monitors temperature Presents data in graphs Uses a software package called Pyrographics
Bricesco Pyrotrace
• • Advantages according to Metrics – Small # of signal alterations - 0 – Max operating temperature - 1350 C – Programming time Disadvantages according to Metrics – Set up time - thermocouple attachment – Cost - High ($6000) – Doesn’t use LabVIEW
Functional Benchmarking Sensors
• • • • • Circuit Completion Piezo-electric Transducer Thermocouple Optical Fiber Linear Position
Concept Evaluation
1) Electrical Circuit Completion 2) Piezo-electric Transducer
Electrical Circuit Completion
Electrical Circuit Completion
• • • Electrodes are isolated by ceramic material on side and top of mold. Metal foam rises to touch top electrode Foam acts as a medium to conduct current.
• • Advantages – Simple program to interpret signal – – – Small size Low cost - $1000 Low set-up time Disadvantages – Mold alterations
Piezo-electric Transducer
Piezo-electric Transducer
• • • One-component quartz force sensor Deformation of sensor disrupts dipole orientation Temporary excess of surface charge seen as a voltage drop across crystal
Piezo-electric Transducer
• • Advantages – Small size – Minimum mold alterations Disadvantages – Requires large charge amplifier – Complex programming to interpret signal – High cost - $5000 – Calibration time required
Proposal Presentation
Preliminary Design and Progress Review
November 98 - Spring 99
Conclusion
• • Continue research on concept components Work more closely with resources at Fraunhofer • Purchase system components before winter break