Objective: Students will learn how to design an integrated manufacturing system by selecting and building a complete integrated system from beginning to end.
Method: The basic steps are outlined below,
2. Students (individuals or groups) will submit a proposal for a project within the first three weeks.
3. The instructor will review the proposal, and suggest changes as necessary.
4. During the term students will design, build and test their proposed projects.
5. In the last week of classes the final project will be demonstrated and formally presented.
• The following topics are some possible topics, in priority,
a) Develop a computer program for scheduling.
b) Design and build a material handling station for the lab.
c) Develop a product information database
d) Develop a quality monitoring systems
e) Write a workcell control program (either C or Java)
2. Select a problem from a local company
3. Select a project based on your interests
a) Build a CMM that uses an arm with measured joint angles.
c) Develop an idea of your own.
d) Design and build an NC machine.
“GVSU Workcell” (Jenny Agnello, Tom Johnson, Colin Moore, Lisa Nahin, Jeremy Scott) The material handling system at GVSU was designed to produce puzzles. The heart of the system was an Allen Bradley SoftPLC and Devicenet. It controlled a material handling system supplid by Worksmart Systems. The system included a robot for loading/unloading the mill. A CNC mill for cutting the parts. A vision system for inspecting the final parts. Various feeder and fixtures were designed and build by students in EGR450.
“Hole in Sphere Project” (Alex Wong, Robert Krygier, Andre Cargnelli, Ahmed Nensey) A mechanism will be designed and built for orienting spherical balls with small through holes. This will be done with a mechanism that uses three rollers for orientation, and an optical pair to detect the hole. An electromechanical control system will be used.
“Automated Robot Arm” (Lev Mordichaev, Karl Fung, Dennis Ngo, Nikko Chan, Edwin Wen, Elaine Rodrigues) A robot arm will be designed and built that can move up/down, left/right, and has a gripper that will open/close. The robot will be controlled via a computer program, and electrical connections to the robot.
“A Manually Controlled Robot” (Keith Lou, Sue Lee, Richard Dankworth, Phat N. Huynh, Howie Lam, Tarius Makmur) To build a manually controlled robot to perform a certain task using a joystick for control. This small scale robot will be capable of picking up an object, and positioning it in another location. And, for proof of concept, a set of fixtures, jigs or feeders will be constructed for a simple robotic task. Note: This project has too many people for construction of a robot only.
“A Box Sorting System” (Joey Aprile, Don Christie, Gabe Fusco, Mike Poczo) A conveyor based system will be designed and built for sorting boxes by a switched conveyor path. This will include construction of the conveyor, sensors, actuators, and control system.
“Automated Drink Dispenser” (Keith German, Dave Van Den Beld, Jeff Kempson, Brent Rubeli, Michael Staples) Glasses on a conveyor belt will be transported to/from a dispensing station where they will be filled by an automated mechanism. The system will be designed and built, possibly using a PLC, or a PC for control.
“Self Leveling Platform” (Gerard Biasutto, Mario Borsella, Dino Farronato, Marco Gaetano, John Yuem) An actuated system will be designed and built to level a platform under tilting conditions. This will involve actuators positioned at four corners. A control system will be constructed to drive the actuating cylinders.
“Raytracing and Animation” (Greg Squires, Ed Hoskins, Marie Malyj, Allan Zander, Tara Hillebrandt) POVray was used to animate a sequence of images to illustrate a pipe layout
“NC Machining with SmartCAM” (Neil Babcock) A fishing reel was designed. The reel was cut on an NC machine using Smartcam software for programming.
“A graphical computer program for flow analysis on PC’s” (James Barr) A computer program was written to do an analysis of a sphere moving through a fluid.
“Manufacturing Database” (K. Beute, M. Mead) A manufacturing database will be developed that allows operators to call up machine configurations based on part numbers. This system uses an HMI to allow easy operator access.
“Construction and control of Stiquito Robot” (T. Cowan and J. Cummings) A kit for a stiquito robot will be purchased and assembled. The appropriate interface electronics and software will be written to control the robot.
“Virtual Reality Modeling” (N. Dunklin) VRML will be explored and used to implement a 3D model of a complex part. This will allow a user to explore the 3D world using a simple internet browser.
“Automatic Generation of CNC Programs” (K. Gehrke) A computer program will be written in C/C++ to automatically generate computer programs in C or C++ to cut initials in keytags.
“Java Programming” (N. Kaye) The Java language will be learned, and a program will be written to cover some aspect of integration or automation.
“Computer Based Analysis of Battery Discharge Data” (R. Sietsema) A computer application will be developed using Excel, and a scripting language, to allow a user to do an analysis of battery discharge data.
“Force Feedback Joystick” (R. Serebryakov) A force feedback joystick will be designed and built. It will be interfaced to a PC and controlled with Labview.
“Design and Construction of Robot” (S. Williams) A robot will be designed and built. The robot will be interfaced to a computer for control.