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P12555 Systems Design Review

The VAR (Vacuum Arc Re-Melting) process aims to enhance metal quality by removing defects and impurities in a controlled melting environment. This project focuses on creating a non-contact measurement system to determine the diameter of metal billets throughout their length, thereby enabling precise calculations of the current needed for re-melting. The measurement system must operate effectively under harsh factory conditions, with an accuracy of 0.1 inches and the capability to handle varying billet sizes and dimensions, ensuring seamless integration into existing processes.

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P12555 Systems Design Review

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  1. P12555 Systems Design Review Michael Imhof (EE) Michael Cheney (ME) Michael Hvorecny (ME) Jared Dodge(ME) Brandon LaQuay (ME)

  2. VAR Billet Measuring System Project Overview • The VAR ( Vacuum Arc Re-Melting) process is a continuous melting vacuum process designed to remove defects and impurities. • The amount of electrical current required to melt a metal billet varies according to the cross-sectional area of the billet being melted. • This area can vary greatly from beginning to end of each billet. • The goal of this project is to design a measurement system to accurately find the billet diameter along the length of the billet. • The information can then be used to more accurately calculate the necessary current required for the re-melting phase.

  3. Billet Processing • Begins as a cast proprietary alloy, 160 inches in length and 17-22 inches in diameter. • Weighing 2-8 tons • Billet is removed from the cast and transported to a grinder to remove scale and other surface impurities. • Ground billet is transferred to the VAR process area. • Measurements must be taken prior to VAR process but after the grinding process.

  4. Project Goals • Non-contact measurement system that can be integrated into the existing process. • Accuracy of .1 inch for diameter and linear position. • Minimum of 1 measurement every 3 inches. • Must be useable for different size billets ranging in length and diameter.

  5. Project Constraints • Use of commercially available materials is allowed. • Remaining within ultimate budget, and minimizing costs wherever possible • Must be robust enough to handle harsh factory conditions

  6. Team Member Roles

  7. Functional Decomposition&Concept Generation

  8. Measure Diameter • Purpose: To obtain diameter measurements to calculate A • How: Variety of sensor solutions: • Keyence® Beam Sensor • Kinect® Sensor • Ultrasound Sensor • Laser Scanner • National Instruments® Machine Vision* • Infrared Sensor • Specifications: • Resolution: 0.1 inch • Positioning: Remote/Non-contact (≈ 6 feet) • Sensor Speed: 5 seconds • Comparison: • Solution: Ultrasound Sensor • Measure Diameter • Measure Total L • Report All Sensor Data Every ΔL • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  9. Measure Total L • Purpose: To obtain length measurements summing up to a total length • How: Variety of solutions • Velocity solutions: • V vs. T – Assumes constant velocity • Radar sensor • Position solutions: • Laser range finder • Ultrasound sensor • Cable-drive linear position transducer • Specifications: • Resolution: 0.1 inch • Positioning: Remote/Non-contact (≈ 6 feet) • Comparison: • Solution: TBD • Measure Total L • Measure L • Report All Sensor Data Every ΔL • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  10. Measure L • Report All Sensor Data Every ΔL • Purpose: To report length and diameter measurements every ΔL in order to output useful data • How: Software conditioning using length sensor solution • Specification: • ΔL = 3-4 inches • Sensor sampling period ≤ 5 seconds • Solution: • Sensor sampling periods « 5 seconds (generally) • Report All Sensor Data Every ΔL • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  11. Move Sensors or Billet? • Decision: To gather diameter measurements down the length of the billet, either the billet needs to move or the sensors need to move • Comparison: • Solution: Mount stationary sensors in the grinder • Measure Total L • Map D vs. L • Sensor Guards • Purpose: To protect the sensors from possible damage • How: • Steel box/enclosure • Metal cage • Plexi guards • Comparison: • Solution: Steel box/enclosure • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  12. Build Motorized Track for Sensors • Purpose: Move the sensors down the length of the billet • How: A few motorized track solutions: • Stepper Motor + Leadscrew • Stepper Motor + Rack & Pinion • Stepper Motor + Sprocket & Chain • Specifications: • Track length ≥ 160 inches • Positional accuracy ≤ 0.1 inches • Comparison: • Solution: Stepper Motor + Rack & Pinion • Measure Total L • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  13. Mounting Solutions • Purpose: Mount the sensors to measure the billet along its length • How: • 8020 • Angle steel • Bar/tube steel • Brackets for the grinder head (sheet metal) • Comparison: • Solution: Brackets for the grinder head • Measure Total L • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  14. Output Sensor Data • Purpose: To interface with the sensors and produce a useable output data file • How: • Sensor interface – MCU via low-level software • Low-level software: Specific to each MCU (ex. Arduino® C) • High-level software: OO language to create a simple GUI (ex. Python or Java) • Output data format: • CSV • XML • JSON • Measure Total L • Map D vs. L • Build Motorized Track for Sensors • Mount Sensors • Move Sensors or Billet? • Mount Stationary Sensors • Output Sensor Data

  15. System Architecture Operator Computer Sensor Interface/Control Unit Diameter Measuring Sensor Length Tracking Sensor

  16. Feasibility Analysis - Programming void setup() { Serial.begin(9600); float last_distance = 0, last_length = 0, start_length= 0; float last_report= 0, delta_L = 3; } void loop() { float distance, length, total_length; distance = ultrasound_measurement(); length = length_measurement(); if (distance < max_distance) && (distance > min_distance) {

  17. if (last_distance > max_distance) || (last_distance < min_distance) { start_length = length; last_report = start_length; Serial.write(distance); Serial.write(length-start_length); } else if (length-last_report >= delta_L – (.01*delta_L)) { Serial.write(distance); Serial.write(length – last_report); last_report = length; } } else if (last_distance < max_distance) && (last_distance > min_distance) { total_length = last_length - start_length; Finish_measurement_report(); } last_distance = distance; last_length = length; }

  18. Preliminary Budget Sensor Budget • Ultrasound Sensor - $30 - $1,000 • Length Sensor - TBD • MCU - $40 • Host Computer - $400-$600 • Misc. Cabling - $20-$50 • Total = $490 - $1,690+TBD Mounting Budget • TBD

  19. Schedule Breakdown

  20. Risk Assessment

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