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DECO Windshield Repair Project: Interim Design Review #1

DECO Windshield Repair Project: Interim Design Review #1. Mechanized filling of Syringes for Windshield Chip Repair. Jun Kim Jay Lafond Robyn Paul Chris Pho Harhari Sharma Thejas Srinivasan. Contents. Project Overview Overview of Finalized System

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DECO Windshield Repair Project: Interim Design Review #1

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  1. DECO Windshield Repair Project:Interim Design Review #1 Mechanized filling of Syringes for Windshield Chip Repair Jun Kim Jay Lafond Robyn Paul Chris Pho Harhari Sharma ThejasSrinivasan

  2. Contents • Project Overview • Overview of Finalized System • Manufacturing Progress – prototyped part • Valve connection solutions • Reservoir update • Next steps • Testing Plans • Budget Plan • Manufacturing Schedule

  3. Project Overview • DECO Windshield Repair • Currently fills syringes by hand • Requirements • Cost – <18¢ / syringe • Accuracy – ±0.01mL (ideally less) • Speed – >900 syringes/hour • Reliability • Compatibility

  4. Overview

  5. Cap Removal

  6. Fluid Delivery

  7. Alternate Plan

  8. Alternate Plan

  9. Manufacturing – Moulded Tray

  10. Issues with Powerade Cap • Not commercially available on its own • Wears out over time • Loss of elasticity of flaps • Risk • Slightest opening in flaps will cause leakage • Size

  11. Proposed Solutions • Snifter Valve (bike tire connection) • Lotion Pump • Check Valve

  12. Check Valve • Advantages • plastic • tubing fits perfectly with syringe • commercially available • replaceable • Minor Disadvantages • cost ($3) • Require 25 = $75 for system

  13. Reservoir and Delivery System • Original Reservoir Design – Vertical Pipe mounted with reservoir moving resin to delivery seals • Design Challenge – Reduce Pressure at seals • New Design – Horizontal reservoir connected to Delivery Pipe containing seals

  14. Piping System Original Design • Vertical Pipe (circular) for easier connection. • Horizontal pipe (Square) for seal. • Open to air at one end. New Design • Closed square horizontal pipe with a drain valve connected to the reservoir with a stop valve for controlling the resin flow.

  15. Testing - Trials Do multiple trials with multiple users for 1 hour each • Speed • Success >900 syringes/hour • Accuracy • Measure random 20 syringes from each trial • Success = 0.15mL +/- 0.01mL • Reliability • Determine failure rate (# failures / # trials) • Success < 2%

  16. Testing – Force Analysis Determine force required to • remove 25 caps • put 25 syringes into filling tubes • pull back 5 syringes in system • remove 25 syringes from filling tubes • replace 25 caps Use Newton meter to determine above forces, compare with literature (allowable repetitive force)

  17. Cost Breakdown

  18. Cost Budget

  19. Manufacturing Schedule 7 6 2 6 4 3

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