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