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AML I Team A: FlashDriver Fall 2007

AML I Team A: FlashDriver Fall 2007. Updated Product Renders. Manufacturing Operations. Plastic Injection Molding Metalworking and Broaching Electrical Contact Punching. Top Case. Top Case Mold. Case Bearing Insert. Bottom Case. Bottom Case Mold. Button and Bit Cap.

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AML I Team A: FlashDriver Fall 2007

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  1. AML I Team A: FlashDriverFall 2007

  2. Updated Product Renders

  3. Manufacturing Operations • Plastic Injection Molding • Metalworking and Broaching • Electrical Contact Punching

  4. Top Case

  5. Top Case Mold

  6. Case Bearing Insert

  7. Bottom Case

  8. Bottom Case Mold

  9. Button and Bit Cap

  10. Button and Bit Cap Mold

  11. MasterCAM Picture of Mold Bottom Casing Male Mold Bottom Casing Female Mold

  12. Injection Molding Specifications Preliminary Specifications • Material: Polycarbonate • Injection Temp: 550 °F • Mold Temperature: 220 °F • Injection Pressure: 800 Bar • Shot Size: ~0.75 in3

  13. Mold Creation Specifications Preliminary Mold Machining Specifications • Machined on HAAS 4x mill • 6061 aluminum stock • 20+ hours machining time per part • Using ¼” to 1/32” end mills • High quality finishing required • Integrated core and ejector pins

  14. Through Pin • Metalworking Steps • Feed square bar stock into CNC lathe. • Turn stock down to desired diameter at appropriate locations. • Slit saw stock with CNC mill to obtain end slit on the pin for torsion spring. Cold Finished 1018 Steel Square Bar Stock

  15. Hex Shaft • Metalworking steps -Load bar into CNC Lathe -Rotary Broach in CNC Lathe -Mount in mill fixture for Square broaching Cold Finished 1018 Steel Round Stock

  16. Broaching Operation Square Broach Rotary Hex Broach Source: http://www.slatertools.com/

  17. Critical Tolerances and Quality Control • Critical Tolerances: • The 4 screw pins on the top and bottom casings • Broaching hole on hex shaft for through pin • Bit cap interface with casing halves • QC: • Go/no go gauges for top and bottom casings, broach for through pin will be applied to all manufactured parts. • Measuring 1st manufactured component on CMM and then every 3rd for the first 50 on calipers

  18. Adjustability of Mechanism Since the system will most likely need tuning, parts are easily adjustable -Removable mold insert can be changed to adjust bearing tolerances -Adjustable rig to change cut length of compression springs -Slit saw cut angle can be adjusted to change torsion spring pretension

  19. Battery Contacts Rapid Prototype Dies and Water Jet Pattern to get perfect contact shape Use Existing 1/4” copper material in AML

  20. Battery Contacts Proposed Plan: Use hydraulic press to make contacts Modify female and male press parts on press

  21. Battery Contact Press

  22. Battery Contact Pallet

  23. Assembly Operations • Electronics Subassembly • Spring Subassembly • Overall Construction

  24. Electronics Subassembly Final Electronics Subassembly Soldering Jig

  25. Electronics Subassembly continued Heat Staking Fixture

  26. Torsion Spring Placement • The Torsion spring requires one arm to be pre-tensioned one-half turn. • It would be loaded onto a slotted static shaft, and then bent, and slid into position by a simple collar.

  27. Assembly Overall Flow

  28. Final Assembly • Utilize Adept • 3 End Effectors Shaft Placement/Rotation Gripper/Flipper Screwdriver • Pallets/Feeders • Bottom, Button, Shaft Subassembly • Top, Bits, Bit Cap • Assembly Fixtures Top Fixture Clamping/Screwdriving

  29. Assembly Plan View

  30. 1 2 3 4 5

  31. Screw Feeding

  32. 6 7 8

  33. AML Budget • Broken down into Component, Manufacturing & Assembly • Component has 15% overhead for shipping costs. • Manufacturing & Assembly has 30% overhead for additional purchases. • Best Case • The best case AML budget was created taking into account the items that may already be in stock in the AML or available at no charge. • Worst Case • The worst case AML budget was created by using the suggested AML budget values as found in the course syllabus.

  34. Component Budget

  35. Manufacturing and Assembly Budget Part I

  36. Manufacturing and Assembly Budget Part II 30% overhead added for purchase of some materials

  37. Summary • Sum of Best Case AML Component, and Manufacturing & Assembly Budget • $4,346 • Sum of Worst Case AML Component, and Manufacturing & Assembly Budget • $10,759

  38. Proposed AML II Schedule

  39. We give thanks to our sponsors

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