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AutomaticMeshWeldingMachine-FinalReport

AutomaticMeshWeldingMachine-FinalReport - EML 4905 Senior...

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EML 4905 Senior Design Project A SENIOR DESIGN PROJECT PREPARED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING AUTOMATIC MESH WELDING MACHINE Final Draft Luisa Forero (MME) Juan Villar (MME) Luis Millan (EE) Advisor: Dr. Sabri Tosunoglu This report is written in partial fulfillment of the requirements in EML 4905. The contents represent the opinion of the authors and not the Department of Mechanical and Materials Engineering.
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2 Ethical Statement This team hereby certifies that each member has reviewed the NSPE (National Society of Professional Engineers) Code of Ethics and that the following proposed design has been thoroughly evaluated and selected in accordance with its fundamental canons, rules of practice, and professional obligations. As future members of this profession, we affirm that the fit, form and function of this proposed design exhibit the highest standards of honesty, integrity, and impact on the quality of life for all people, directly or indirectly. Considering the future implementation of this project, extreme considerations have been given to safety, health, and welfare of the public and sustainability of the design. Juan Villar Panther ID: Luisa Forero Panther ID: Luis Millan Panther ID:
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3 Table of Contents Ethical Statement ............................................................................................................................ 1 Table of Contents ............................................................................................................................ 3 List of Figures ................................................................................................................................. 6 List of Tables .................................................................................................................................. 9 1. Introduction ........................................................................................................................... 10 1.1 Problem Statement ......................................................................................................... 10 1.2 Background .................................................................................................................... 11 1.3 Literature Survey ............................................................................................................ 12 2. Project Formulation ............................................................................................................... 21 2.1 Overview ............................................................................................................................. 21 2.2 Program Objective .......................................................................................................... 23 2.3 Design Specifications ..................................................................................................... 23 2.4 Constraints ...................................................................................................................... 23 2.5 Assumptions and Limitations ......................................................................................... 24 2.6 Operating Environment .................................................................................................. 25 2.7 Intended Users and Intended Uses ................................................................................. 25 2.8 Standards Considerations ............................................................................................... 26 2.9 Health and Safety Considerations .................................................................................. 28
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4 2.10 Ethical Considerations and Social Impact .................................................................. 31 3. Design Alternatives ............................................................................................................... 33 3.1 Overview of Conceptual Designs Developed ................................................................ 33 3.2 Feasibility Analysis ........................................................................................................ 37 3.3 Sustainability Considerations ......................................................................................... 39 4. Project Management .............................................................................................................. 41 4.1 Overview ........................................................................................................................ 41 4.2 Work Breakdown Structure ............................................................................................ 43 4.3 Multidisciplinary Aspects .............................................................................................. 48 4.4 End Product Description ................................................................................................ 50 5. Engineering Design and Analysis .......................................................................................... 54 5.1 Budget ............................................................................................................................ 54 5.2 Stress, Deflection, Analysis ........................................................................................... 55 5.3 End Pin Analysis ............................................................................................................ 63 5.4 Component Design/Selection ......................................................................................... 67 6. Prototype Construction .......................................................................................................... 70 6.1 Description of Prototype ................................................................................................ 70 6.2 Construction ................................................................................................................... 73 6.3 Manufacturability ........................................................................................................... 82
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5 7. Design Considerations ........................................................................................................... 85 7.1 Environmental Impact .................................................................................................... 85 7.2 Risk Assessment ............................................................................................................. 86 7.3 Testing Methods ............................................................................................................. 87 8. Conclusion ............................................................................................................................. 90 8.1 Results Evaluation .......................................................................................................... 90 8.2 Life Long Learning ........................................................................................................ 90 8.3 Conclusion ...................................................................................................................... 90 9. References ............................................................................................................................. 92 Appendix A: Detailed Engineering Drawings of All P ................................................................ 94 Appendix B: Machine Elements ................................................................................................... 97 Appendix C: PLC ........................................................................................................................ 111 Appendix D: TBasic Code .......................................................................................................... 112 Appendix E: CosmoWorks Static Test Results on Structure ...................................................... 114 Appendix F: CosmoWorks Static Test Results on Structure and Components .......................... 119 Appendix G: Standards ............................................................................................................... 125 Appendix H: Transformer ........................................................................................................... 138 Appendix I: Stepper Motor ......................................................................................................... 139 Appendix J: Transformer Catalog ............................................................................................... 140
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6 Appendix H: Mesh Wire Use ...................................................................................................... 143 List of Figures Figure 1 Drawing 1. Patent 5416288 ............................................................................................ 13 Figure 2 Wire Straightening and Cut-Off Machine ...................................................................... 14 Figure 3 Drive roller for wire feeding mechanism, United States Patent 4,021,634 .................... 16
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