Manufacturing Commons^™

Developing Control System For Manufacturing Processes, Md Shahriar Forhad

Theses and Dissertations

Process control has been a critical component in today's manufacturing industry. Industrialists nowadays want reliable control to assure precision manufacturing. Modern control systems must be more dynamic, so that any needed modifications may be made quickly to accomplish the desired product change. For innovative research and development, system customization is critical to ensure freedom for experimental works. In addition, full control of manufacturing systems is necessary to realize and implement Industry 4.0. Often, it is difficult to achieve such control due to limited access to proprietary equipment. To this end, this thesis focuses on developing a custom control platform for …

A Benchtop Robotic Automation Approach For Manufacturing Prefilled Syringes, Yehua Zhong

All Theses

Automation and robotics have become a staple in the biological manufacturing sector due to their ability to efficiently work without operator inputs, with a high degree of accuracy and repeatability. Industrial robotic arms, in particular, present themselves as valuable tools for biological manufacturing scenarios that require customized solutions due to their ease of programming and flexibility. The traditional hospital-focused healthcare system was organically developed to address acute conditions, however, in recent years, due to the unprecedented occurrence of emergencies happening more frequently, fast and efficient drug production becomes important [17]. This thesis represents the use of a benchtop robot and …

Eagle Medical Tray Denesting & Debris Removal Process, Nicholas Allen Ungefug, Noah Chavez, Susana Shu-Lin Okhuysen, Michael Augustine Pennington

Industrial and Manufacturing Engineering

Eagle Medical Incorporated is a contract medical device packaging and sterilization company. The company purchases thermoformed medical packaging trays, which maintain the sterility of medical devices, from various manufacturers. To ensure packaging quality and to prevent cleanroom contamination, Eagle Medical inspects and sterilizes each blister tray that they order. This process is an essential non-value-added activity that creates a bottleneck. Cleanroom employees must stop packaging medical devices and attend to the processing of blister trays and packaging solutions. The blister trays arrive at Eagle’s facility in nested stacks. Vibration and movement during shipping further compresses the stacks, which makes separation …

Chemical Clean Automated Loader, Jordyn Bryner

Williams Honors College, Honors Research Projects

TTM Technologies (TTM) is a global printed circuit board (PCB) manufacturer. The work described in this report was completed in the TTM North Jackson, Ohio location. This plant focuses primarily on the manufacturing of rigid and rigid-flex PCBs for the aerospace and defense industry. TTM North Jackson has an ongoing labor dependency issue due to the shortage of workers the nation is facing. To solve this problem, TTM has focused the efforts of their new engineers and interns on automating processes that are labor dependent. The goal is to provide design guidance to be used later by TTM to automate …

Grinding And Super-Finishing Test Machine Project, Michael Simon

Williams Honors College, Honors Research Projects

A research project in The University of Akron to study grinding and super-finishing of silicon nitride ceramic was initiated by Dr. Siamak Farhad and sponsored by the Timken Company, with the assistance of undergraduate students Michael Simon, Ryan Hosso and Mathew Rozmajzl. The study required analysis of forces and scratches generated during grinding processes of silicon nitride samples. A testing assembly was designed and constructed to record the forces generated during grinding and super-finishing of silicon nitride samples in a computer-numerical-control machine. Silicon nitride samples were subjected to desired grinding and super-finishing operations and all forces generated during the process …

Cnc Feed Drive Control, Ryan J. Funchess, Caleb P. O'Gorman, Nick J. Desimone, Juan M. Majano, Samuel K. Wong

Mechanical Engineering

This document serves as the Final Design Report (FDR) for a senior project developed by our team: four senior Mechanical Engineering students and one computer engineering student at California Polytechnic State University, San Luis Obispo (Cal Poly). While the project was completed for, and sponsored by, Professor Simon Xing of Cal Poly, the remainder of the university’s controls professors will be indirectly benefited from this project. Our goal was to design and implement a functional CNC Feed Drive to be used for educational demonstrations and data collection. This document discusses our early product research and benchmark goals, which established constraints …

Implementation Of An Autonomous Guided Vehicle (Agv), Allen St. Myers, Alan Miller

Williams Honors College, Honors Research Projects

This report thoroughly represents a proposal to AAM Metal Forming Minerva for the implementation of an AGV (Autonomous Guided Vehicle) Unit. Our recommendations are made with consideration to existing manufacturing processes and demonstrate how using an AGV would be a net positive investment for the company. By first examining the current operating costs, a three-tiered proposal is tailored based on increasing investment cost. Each tier increase encompasses the previous tiers’ proposed improvements while also growing in complexity and investment cost. The results of our research indicate that our Tier 2 proposal will provide the most benefit to our facility now …

Automated Drone Calibration System, Jackie Kelly Jong-Mee Paik, Zach Nathan Richter, Tyler Wilson Van Den Berg, Ryan Alexander Zhan, Matthew Ward Carlson

Mechanical Engineering

The final design review of the Inspired Flight Calibration Team senior project will detail the process used to complete a verification prototype of a drone calibration device and discuss lessons learned and suggestions for improving this device. Going from brainstorming and conceptual prototyping all the way through verification prototyping and testing, we were able to design a gyroscopic device that met Inspired Flight’s needs for the flight sensor calibration of their drones. The mechanical design involved comprehensive CAD models and hands-on manufacturing. The mechatronics side of the project worked heavily with electrical wiring and writing custom software to communicate and …

Fox Factory Bearing Assembly Rundown And Torque Automation Project, David Ethan Daley, Eric Michael Forrester, Christopher Enrique Hansen, Riley Jacob O'Connor

Mechanical Engineering

A machine design was created to partially automate the rundown and torque of a Fox Factory shock bearing housing. This machine is needed at the factory to keep line associates safe by reducing ergonomic strains associated with this stage in the shock assembly process. Due to the lack of applicable torque drivers for this operation, an open ended, geared drivetrain was designed to allow for engagement of the bearing housing while allowing clearance for the shock shaft that the bearing rides on. This open drivetrain is held by a structure of linear rails and bearings to allow the line associate …

Rinse Tank Salinity Automation, George Pahoundis

Williams Honors College, Honors Research Projects

Manufacturing processes are often consisted of many different processes and sub-processes. Each of these carries its own level of importance and impact to the overall picture. In this particular sub-process, salt is rinsed from a product via a rinse tank: a tank whose salinity may not exceed a certain level and whose temperature must not fall below a certain level. This setting is a prime opportunity to implement an automated control system to allow these parameters to be met with upmost efficiency. With potential savings in excess of $20,000 per year and an estimated payback period of 8 weeks, the …

Automated Runout Measurement Tool, Ethan Tisch

Williams Honors College, Honors Research Projects

A new measurement process and tool is to be developed to improve the existing method for measuring runout on the commutators of brushed DC product.

After an armature is manufactured, the commutator is inspected by placing the completed rotor assembly in one of several non-standard measurement fixtures. An indicator is then positioned on the commutator. A trained operator proceeds to rotate the armature while taking runout and bar-to-bar measurement at various positions along the length of the commutator.

This existing process is slow, costly, and unreliable. For these reasons, there is substantial economic pressure to develop a superior method for …

The Business Case For Industrial Safety: Revealing The Comprehensive Value Of Ergonomic Investments For Manufacturing Enterprises In Industry 4.0, Shane Stan

Honors Theses

How can today’s manufacturing enterprises construct, implement, and optimize modern safety initiatives in a manner that will present maximum return on investment and facilitate enterprise growth? Furthermore, how can these manufacturers assure individual ergonomic investments become part of a larger strategy to facilitate organizational change in safety? This work addresses these questions by placing industrial ergonomics in a business improvement context which comprehensively presents the financial returns and growth opportunities poised by modern safety initiatives. Additionally, to further strengthen the business case for industrial safety, an ergonomic action planning framework is established to guide the creation of holistic safety programs …

Automated Machine Tender, Ryan A. Canfield, Samuel N. Adler, Louis S. Roseguo

Mechanical Engineering

The use of CNC (Computerized Numerical Control) machines automate production in factories through programs controlling manual operations such as milling or lathing. The manufacturing process can be automated beyond the use of CNC machines through the addition of a robotic tender capable of carrying out the same tasks as a human operator. A tender can be integrated into the CNC machine itself, or purchased separately and configured to autonomously operate a particular machine. Smaller companies making limited production runs may not find it economically feasible to purchase large scale integrated machine tenders, but would benefit from a versatile autonomous machine …

Fiber Glass Mat Splice Automation, Max Weinstein, Charles Scott Forbes, Max Kilpatrick

Mechanical Engineering

Currently, GAF has two operators manually splice together each roll of fiberglass mat. To save money and resources, GAF wants to automate this splicing process. Our team is responsible for stage 3 of 5 in this automation process. We are responsible for ensuring that the system is able to move autonomously to the necessary positions required for splicing together the rolls of fiberglass mat. We have determined the best solution for accomplishing this movement is to use linear slide actuators. This document will describe the process by which we arrived at our solution, the details of our solution, and a …

Economic Analysis And Justification For Automated Welding Systems, Roxanne Raye

Industrial and Manufacturing Engineering

This report looks at designing a new welding process for a company in the Oil & Gas industry, ensuring method consistency and performance quality of their steel drill bit while increasing overall production. The current product is welded manually with a flux core wire, resulting in high cycle times and numerous cases of required rework.

The use of automation systems will be analyzed for their increased consistency, quality, safety, and production estimates. Specifically robotic cell design will be considered, since it can work on more parts with fewer operators, adding efficiency and flexibility to the production floor. Other areas of …

Semi-Automated Glass Mat Splice Operation For Asphalt Shingle Line, Justin Bracci, Harry Zhao, Chad Linafelter

Mechanical Engineering

The following report details the senior project sponsored by GAF Materials Corporation, Shafter, CA in regards to semi-automating a glass-mat splicing table for asphalt roofing shingle production. Herein includes details, research, design, and analysis regarding the semi-automation of the gluing processes for the splicing table. A working prototype was manufactured and tested for the future implementation onto GAF’s production line or further senior project involvement.

Design Of An Automatic Wood Trimming Machine, Van Ho, Nicholas Maskal, Andrew Rutland

Mechanical Engineering

This final design report, prepared for Sunrise Arts by the Cal Poly design team Mahogany Automation, details the year-long process in which the team of three engineering students designed and built an automated wooden -plank edge trimming machine that incorporates anti-jamming and continuous loading features. The team has examined current woodworking machines and features available on the industrial and commercial market, and used these as guides along with device requirements set by the project sponsor, Bruce Palmer. The focus has been on designing the simplest and most cost effective device that allows operators to make production runs of wooden slats …

A Case Study For Financial Feasibility Of Automated Costing Support In A Small Machine Shop, Benito A. Gonzalez

Theses and Dissertations - UTB/UTPA

A knowledge-based cost estimating expert system is chosen by a Mexican machine shop. Differences between the traditional experience-based system employed and the automated system are studied. Data is gathered to analyze time effectiveness, accuracy and payback of the software. Data from seventy part models is recorded to study the time experiment, and data from fifty part models is used to study the accuracy and consistency. Data is analyzed by calculating mean, standard deviation, and test of hypothesis. The results indicate that the software is faster than the traditional quoting system; however, the payback point is high. Also, results show the …

Improving Manufacturing Processes Through Energy Monitoring, Andrew Grzelak

Purdue Polytechnic Masters Theses

Energy efficiency and sustainability are very popular topics in the current field of manufacturing. With the increase in use of automation technology as well as the recent growth in the area of energy management, there is much focus on the overall improvement of manufacturing processes. For this research a project was completed to create a system that could improve both process efficiency as well as decrease energy consumption. By taking a look at the machine level energy consumption of an automated piece of manufacturing equipment, by eliminating waste in process, both energy efficiency and operational efficiency can be improved.

Using …

Automating The Fret Slotting Process Using A Plc Controlled 1.5 Axis Mill, James Stratton

Purdue Polytechnic Masters Theses

Stratton, James A. M.S., Purdue University, August 2011. Automating the Fret Slotting Process Using a PLC Controlled 1.5 Axis CNC Mill. Major Professor: Richard Mark French.

Can automation assist small job shops and hobbyists in the production of stringed instruments? This research set out to answer the question using a quantitative approach to determine if an economical CNC machine could be produced in such a fashion as to seamlessly join the workshop as an affordable, yet precise instrument to aid in the production of stringed instruments. The key was to incorporate common industrial automation equipment into the operation of the …

Machine Vision Course For Manufacturing Engineering Undergraduate Students, Jose Macedo, Kurt Colvin, Daniel Waldorf

Industrial and Manufacturing Engineering

A 10-week course was designed with funding from the Society of Manufacturing Engineers (SME) and input from industry representatives, to offer upper division engineering students a course on advanced automation. The objective was to provide engineering students theoretical and hands-on practical experience with automation technologies that will be of prime importance over the next decade: data acquisition and instrumentation, machine vision and motion control. This paper describes the machine vision portion of that class. It describes important concepts, hands-on equipment, and labs developed for this course, as well as examples of student projects from Spring Quarter, 2004. The course and …

Running With The Pack: Jit & Automation For Small Manufacturers, Thomas E. Phillips, John R. Ledgerwood

Publications

While both just in time (JIT) concepts and automation programs have been widely implemented and highly successful in large manufacturing companies, many smaller manufacturing companies have wondered whether it would be economically feasible to utilize these same techniques and derive these same benefits. When JIT is adopted by small manufacturers, it provides them with advantages over traditional manufacturing systems, such as lower cost, quality improvements, higher productivity, and less working capital tied up in inventory. Small US manufacturers must understand the basic principles and philosophy of JIT and update their production equipment if they are to be competitive in today's …