Rexnord Automatic Deburring MachineFinal DesignCorp 9 Project GroupPaul CofieldFrank OronaSteven RichSpencer ReynoldsDr. Beale – Comprehensive Design One – MECH 4240 – Spring 2010MISSION OBJECTIVEOur 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 processSystem 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 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 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 ArchitectureItem Weight (lbs)Cart 40Motor 52Hopper 10Brushes 9Exit Ramp 20T-tubing 146Technical 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 Total 277entire system has a capacity of 500 lbs.  Power – 120VAC 60 Hz source will power all motors, conveyors, sensors, and the relay.  The brush motors are ¼ horsepower and operate at 1725 rpm.Product HierarchyStructure and Safety ShieldMagnetic ConveyorDeburring BrushDeburring Brushes (sides)Dust Collector and Exit RampWiring Diagram and Controller Insert locgic controller Wiring diagramBill of MaterialsQuantity Part Part #/Company Price ($)2 Light Sensor 65845K56 / McMaster 65845K57 / McMaster 284.221 Timed Relay 2809T41/ McMaster 60.831 E-Stop Idec HW1X / Wolf Automation 32.501 Bearing and Mount 6244K56 / McMaster 38.651 or 3Brush Motor3K771 / Grainger74.00 ea1 or 3Brush Motor3K771 / Grainger74.00 ea1 Motor Control FA206 / Keenzo 28.971 Door Switch 65665K13 / McMaster 80.031 Magnetic Conveyor Custom / Bunting Magnetics 4,011.001 Duct System Custom / American HVAC Parts 50.001 Exit Ramp Custom / Metals Depot 38.241 Cart WES101 / Hand Trucks 103.981 or 3 Deburring Brush Custom / Industrial Brush 362.25 eaStructural Parts 80/20 Parts 1873.74Total Cost 6,487.09Medical Implications 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. Burden RateMedical ImplicationsMore ErgonomicLess work for operatorNo sparks, or handling part at allLess steps traveled by operatorLess Stress for operator=more productiveIncrease 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 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!!1012141618x 104Stress in Bristles (psi)Brush Analysis0 0.5 1 1.5 2 2.50246810Distance Into Brush (in)Stress in Bristles (psi)Risk AssessmentRank Risk Title Risk Exp Action Risk Type Status1 Part not deburred sufficientlyLikelihood: LowConsequence: HiResearch/Watch Technical/ProgramSpeed adjustment on conveyor and brush motors2 Cost Effectiveness Likelihood: LowConsequence: ModResearch Organization The machine has been analyzed and determined to have a satisfactory pay-to have a satisfactory pay-back period3 Brush wear Likelihood: LowConsequence: LowWatch Organization Brushes will need checking and replacement on scheduled intervals4 Dust collector blocked Likelihood: ModConsequence: LowWatch Organization Hopper will need to be emptied on a timely basis for proper maintenance5 Timing Issue Likelihood: LowConsequence: LowResearch/Watch Technical/ProgramThe machine has been timed effectively to maintain pace with the operator and supporting machines.Estimated TimelineCONCLUSION “Keep It Simple” The refined system meets all standards and requirements:Lighter Lighter  Cheaper  Smaller  Continuously running Simple maintenance No sparks Minimize