Rexnord Automatic Deburring Machine Final Design Corp 9 Project Group Paul Cofield Frank Orona Steven Rich Spencer Reynolds Dr Beale Comprehensive Design One MECH 4240 Spring 2010 MISSION OBJECTIVE Our mission is to Create an automated deburring and transport system while Reducing production time Improving overall quality of the finished product Improving the efficiency of the waste removal process System Requirements Deburr all sizes and shapes of the specified parts Leave the necessary finish on the part surface Fully automated from beginning requiring no aid from an operator Automatic collection and removal of dust No sparks must be generated during deburring process Must deburr the bottom and sides of each part Must be free to quickly move to other cells Deburring system must meet all OSHA safety and environmental standards for operations Subsystem Level Requirements Entrance conveyor must be adjustable Magnetic conveyor must be stable Magnetic conveyor must release part onto exit ramp Exit ramp must be able to support two parts of any size Radial deburring brushes must remove burs without damaging part No sparks Active dust collection system to remove all dust and store in a hopper for later removal Machine Architecture Technical Resource Budget Tracking Volume 2 feet wide 4 feet long 5 feet tall 40 cubic feet Weight The cart being used to hold the entire system has a capacity of 500 lbs Item Weight lbs Cart 40 Motor 52 Hopper 10 Brushes 9 Exit Ramp 20 T tubing 146 Total 277 Power 120VAC 60 Hz source will power all motors conveyors sensors and the relay The brush motors are horsepower and operate at 1725 rpm Product Hierarchy Structure and Safety Shield Magnetic Conveyor Deburring Brush Deburring Brushes sides Dust Collector and Exit Ramp Wiring Diagram and Controller Insert locgic controller Wiring diagram Bill of Materials Quantity Part Part Company Price 2 Light Sensor 65845K56 McMaster 65845K57 McMaster 284 22 1 1 Timed Relay E Stop 2809T41 McMaster Idec HW1X Wolf Automation 60 83 32 50 1 1 or 3 1 1 1 Bearing and Mount Brush Motor Motor Control Door Switch Magnetic Conveyor 6244K56 McMaster 3K771 Grainger FA206 Keenzo 65665K13 McMaster Custom Bunting Magnetics 38 65 74 00 ea 28 97 80 03 4 011 00 1 Duct System Custom American HVAC Parts 50 00 1 Exit Ramp Custom Metals Depot 38 24 1 Cart WES101 Hand Trucks 103 98 1 or 3 Deburring Brush Custom Industrial Brush 362 25 ea Structural Parts 80 20 Parts 1873 74 Total Cost 6 487 09 Burden Rate burden rate 35 hr 0 58 min 33 3 min x 0 58 min 19 425 day 389 dollars will be saved per month Cost 6514 97 389 16 77 months machine payback Medical Implications More Ergonomic Less work for operator No sparks or handling part at all Less steps traveled by operator Less Stress for operator more productive Increase in Productivity 2500 parts per month 125 parts per day deburr one part is 16 seconds 33 3 min day 33 3 min 4 min cycle time 8 3 parts 47 dollars per part x 8 3 376 dollars per day 20 work days month 7520 revenue month 20 30 profit margin 1504 to 2256 month profit The Deburrer pays for itself in 2 4 Months Brush Analysis 4 18 x 10 16 Stress in Bristles psi 14 12 10 8 6 4 2 0 0 0 5 1 1 5 Distance Into Brush in 2 2 5 Risk Assessment Rank Risk Title Risk Exp Action Risk Type Status 1 Part not deburred sufficiently Likelihood Low Consequence Hi Research Watch Technical Program Speed adjustment on conveyor and brush motors 2 Cost Effectiveness Likelihood Low Consequence Mod Research Organization The machine has been analyzed and determined to have a satisfactory payback period 3 Brush wear Likelihood Low Consequence Low Watch Organization Brushes will need checking and replacement on scheduled intervals 4 Dust collector blocked Likelihood Mod Consequence Low Watch Organization Hopper will need to be emptied on a timely basis for proper maintenance 5 Timing Issue Likelihood Low Consequence Low Research Watch Technical Program The machine has been timed effectively to maintain pace with the operator and supporting machines Estimated Timeline CONCLUSION Keep It Simple The refined system meets all standards and requirements Lighter Cheaper Smaller Continuously running Simple maintenance No sparks Minimize dust Questions