Automated Surface Grinder "Slicer"

Abstract

Mr. Bernn Hitch, President of Island Ceramic Grinding, tasked team 16 to automate a manual Chevalier FSG-618M Surface Grinder so that it can run a simple, repetitive program for slicing ceramic pieces with minimal operator interaction besides the initial setup of the program. To accomplish this goal, we were given requirements by our sponsor that include automation of the three axes of the surface grinder through one cohesive interface that allows for editing of the program while it is in use and no measurable increase in tolerance of the parts being manufactured for under $5000. Alumina is to be used for all testing, as it will ensure any product that Island Ceramic Grinding currently uses on their grinders will not present any problems for the automation. Engineering specifications were generated according to the requirements such as the tolerance of motion accuracy and precision. After performing a functional decomposition and brainstorming, several of concepts were generated to meet the requirement of our sponsor and the corresponding engineering specifications. Five Pugh Charts were created for different functionalities that need to be realized, with weighting between one and five for each criterion. The five Pugh Charts decided that the transmission would be timing belts, stepper motors would be used for in-out direction and up-down direction, a DC motor would be used for left-right direction, a sealed keypad would be used for interface; the microcontroller would be a PLC, a Hall Effect sensor would be used to control the motion of the grinder. Engineering analysis was implemented to determine the required specifications for motors and transmissions. Theoretical modeling and empirical testing were implemented to find out the maximum torque when turning the hand wheels during normal operation. The component selection was narrowed down using the specifications from this analysis, and CAD models of mountings for each axis were generated. A detailed plan for the control system is also described. FMEA and risk analyses were done to discover, evaluate, and minimize potential problems. Design verification testing was then performed to verify that the individual components performed as expected and would allow the machine to function as intended. Precision of the Y and Z-axes were confirmed to outperform expectations, and the speed of the X-axis was also deemed acceptable. Verification was unable to be performed on the system as a whole due to additional components that were needed and delays in assembling the electrical system.