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Automated Adhesion System

Automated Adhesion System

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Automated Adhesion System

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  1. Sponsor: Team members: Phil Jaquish Kevin Lakowski Cliff Lewis Joel Oostdyk Chris Spikes Jeff Willner Automated Adhesion System

  2. Project Objectives • Automate an adhesive application process at American Seating. • Minimize the amount of adhesive used during operation. • Support an increase in production from 325 to 500 parts per 8 hr. shift.

  3. Functional Requirements (1 of 2) • Design, build, and install an engineering solution to gain part capacity, maintain adhesive application consistency and reduce material waste. • The system will be capable of producing a minimum of 500 parts per 8 hr. shift.

  4. Functional Requirements (2 of 2) • The fabric loading and unloading processes must be ergonomic. • Use “off the shelf” equipment, parts and materials where possible for ease of service and availability.

  5. Project Risks • Supplier miscommunication • Failure of parts during testing and assembly • Restrictions on necessary resources • Incorrect, damaged, or late parts

  6. Proposed Solution • Two-axis motion controlled linear actuators • Manual nozzle height adjustment • GE Programmable Logic Controller (PLC) for motion control • Vertical adjustable workstation • Operator interface for ease of changeovers and troubleshooting

  7. System Schematic • Adjustable base • Aluminum extrusion frame • 2 axis linear actuators

  8. Process Flow Diagram

  9. User Interface • Lighted “start” button • Selector switches for fabric dimensions and automatic or manual operation • Indicator lights for incorrect fabric, home position and in-cycle • Two zero-force palm buttons • E-stops

  10. Sub-system Schematic (1 of 2)

  11. Linear Actuators Sub-system Schematics (2 of 2)

  12. Calculations and Studies (1 of 2) • Time Study • Cycle time to load part, 10.77 sec • Cycle time to apply adhesive, 20.46 sec • Study of applied adhesive spray width • Desired, 3 inches • Measured, 2.16 inches

  13. Calculations and Studies (2 of 2) • Cycle Times (CT) • Overall Maximum Cycle Time, 46.8 sec • For 500 part per shift (shift = 6.5 hours) • CT of adhesive application for Seat, 30.03 sec • Not including Load CT or a 6 second safety factor • CT of adhesive application for Back, 21.47 sec • Not including Load CT or a 6 second safety factor • Velocity Analysis • Minimum velocity to achieve CT, 9.074 in/sec • Maximum velocity, 29.835 in/sec

  14. Environmental Impact • Reduction of over-spray from current 12 lbs per shift. • Electrical components compatible with current ASC standards. • Work cell has capacity to be reconfigured for future expansion.

  15. Cost Savings *Adhesive cost = $12.21/lb * Year based on 40 hr. weeks

  16. Adhesive Testing • Supplies • SC-5 Pail Unloader • Adhesive • Seat backs and seat bottoms • Variables • Nozzle height • Air pressure • Adhesive temp. • Nozzle flow settings

  17. Project Milestones • Proposal presentation: 4/10/01 • Final approval: 4/20/01 • Components ordered: 4/27/01 • Programming complete: 5/30/01 • Assembly/Debug: 7/03/01 • System test & review: 7/15/01 • Product presentation: 8/03/01

  18. Budget

  19. Personnel Assignments

  20. Deliverables • Product • Automated adhesive spray system • Locating boards to support the fabric during operation • Documentation • Training manuals for engineering, maintenance, and operator personnel • Preventative Maintenance manual • Drawing files • Bill of Materials • Hardcopies and electronic files of electrical schematics, layouts and flowcharts

  21. Questions and Answers