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Automated Adhesion System

Sponsor: Team members: Phil Jaquish Kevin Lakowski Cliff Lewis. Joel Oostdyk Chris Spikes Jeff Willner. Automated Adhesion System. Project Objectives. Automate an adhesive application process at American Seating. Minimize the amount of adhesive used during operation.

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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

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