Transcript INTELLIGENT TOOLING

INTELLIGENT TOOLING
Progress Review
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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
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Powder Metallurgy
Semi-finished product
Metal working
Foaming
Material Properties
Problem Description
• Over-aging
• Technicians rely upon
experience
• Material waste
• Molding defects
Customers
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Fraunhofer Resource Center, DE
Automotive Industry
Aerospace Industry
Building Industry
Prioritized Wants
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High Percentage of Successful Foams
System Reliability
Simplicity of System
Low Cost
Constraints
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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
11.01
11.01
10.09
10.09
9.17
9.17
9.17
9.17
9.17
1400
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<5000
4 x4 x1
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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
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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
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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
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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