Using NX in Project-Based        Design & Build Courses           Kevin DevineAssociate Professor/ET Coordinator       Ill...
Overview• Background   •Engineering Technology at ISU   •Design-Build Collaboration Opportunities• Sample Project   •Robot...
Engineering Technology at         Illinois State University• ATMAE accredited• Prepare technically-oriented management  pr...
Engineering Technology Facilities• Facilities support hands-on instruction  •   Plastics manufacturing  •   Metals machini...
Caterpillar  IntegratedManufacturing      Lab     (IML)
IML provides   numerousopportunities for  design-build    projects
Sample Student ProjectDesign and build devices that allow the   robots in the IML to use purchasedtooling components in ma...
Purchased                ToolingVacuum cup:              Components                      Gripper:                         ...
IML Student Project Requirements• Must meet predetermined functional requirements   – ISU was the customer• Students in tw...
Overview of Design Process• Design students worked in groups of 4• Gathered background information   – Downloaded document...
Overview of Design Process• NX assembly models of “best”  design concepts were created• Models were exported to  RobotStud...
Prototyping•Prototypes were created using Rapid Prototyping machine (FDM)•Prototypes were assembled and attached to the ph...
Designs Were Finalized in NX     2-Jaw Gripper & Vacuum Cup         in Tool Changer Plate               http://plmworld.or...
Manufacturing Tasks• Manufacturing plan was developed as a group in the  machining course.• Class was divided into product...
2-Jaw Gripper                           Student                          Machining                             Task   http...
Milling Fixture                                 Part BlankTool Changer    PlateBored Hole                                 ...
Machining Gripper Attach Plate   and Tool Changer Plate            http://plmworld.org/   17
Machining Side Holes                                           Gripper                                         Attach Plat...
Machining Vacuum Adaptor                      Custom Vise                         Jaws        Stage 1 Setup         http:/...
Machining Vacuum Adaptor        Stage 2 Setup          http://plmworld.org/   20
Machining Vacuum Adaptor        Stage 3 Setup          http://plmworld.org/   21
Finished ProductGrippers In Tool                          Robot Holding Changer Rack                             3-Jaw Gri...
Challenges in Design-Build Projects• Projects require careful planning  – Project scope must be “doable”  – Time managemen...
Benefits of Design-Build Projects• Students experience design and manufacturing  challenges in the classroom• Completed pr...
Siemens Software Tools Used• Part design was completed using NX  – Modeling  – Assemblies  – Drafting• Fixture design was ...
Other Projects• Robot Held Drill• Thermoformed tray insert for robot assembly  project• Overall IML layout and workstation...
Robot-Held Drill      NX ModelRobotStudio Simulation                    Real Robot   & Programming                        ...
Thermoformed Tray Insert                           28
Initial IML Layout     http://plmworld.org/   29
Workstation Design                                          Detailed                                         WorkstationIn...
Questions?                  Kevin Devine            Illinois State University                kldevin@ilstu.eduSiemens PLM ...
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Using NX in Project-Based Design & Build Courses

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Kevin Devine, associate professor at Illinois State University, presented at PLM Connection 2012. See related blog post.

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Using NX in Project-Based Design & Build Courses

  1. 1. Using NX in Project-Based Design & Build Courses Kevin DevineAssociate Professor/ET Coordinator Illinois State University http://plmworld.org/ 1
  2. 2. Overview• Background •Engineering Technology at ISU •Design-Build Collaboration Opportunities• Sample Project •Robot End of Arm Tooling• Challenges and Benefits of Design-Build Projects• Brief Look at Other Projects #PLMCONX 2
  3. 3. Engineering Technology at Illinois State University• ATMAE accredited• Prepare technically-oriented management professionals for work in a variety of manufacturing-related careers• Focus is on application of existing technology• Emphasis on hands-on learning #PLMCONX 3
  4. 4. Engineering Technology Facilities• Facilities support hands-on instruction • Plastics manufacturing • Metals machining/CNC • Material testing • CAD • Industrial automation • Caterpillar Integrated Manufacturing Lab (IML) #PLMCONX 4
  5. 5. Caterpillar IntegratedManufacturing Lab (IML)
  6. 6. IML provides numerousopportunities for design-build projects
  7. 7. Sample Student ProjectDesign and build devices that allow the robots in the IML to use purchasedtooling components in material handling applications. http://plmworld.org/ 7
  8. 8. Purchased ToolingVacuum cup: Components Gripper: Schunk PGN+64SMC ZPT16 Gripper: Tool Changer: Schunk PZN+64 Schunk SWS-011 http://plmworld.org/ 8
  9. 9. IML Student Project Requirements• Must meet predetermined functional requirements – ISU was the customer• Students in two courses will collaborate to design and build the required devices• Must have a high degree of confidence in design – Digital simulations – Physical prototypes• Solution had to function in the end! http://plmworld.org/ 9
  10. 10. Overview of Design Process• Design students worked in groups of 4• Gathered background information – Downloaded documentation and CAD models of purchased components – Investigated work-holding principles – Researched existing industry applications• Brainstormed to create several conceptual designs http://plmworld.org/ 10
  11. 11. Overview of Design Process• NX assembly models of “best” design concepts were created• Models were exported to RobotStudio robot simulation and programming software – Tools were digitally attached to the robots – Basic reach studies were 3-Jaw Gripper completed Attached to Robot in RobotStudio http://plmworld.org/ 11
  12. 12. Prototyping•Prototypes were created using Rapid Prototyping machine (FDM)•Prototypes were assembled and attached to the physical robots 2-Jaw Gripper & Vacuum FDM Prototypes Cup Attached to Robot http://plmworld.org/ 12
  13. 13. Designs Were Finalized in NX 2-Jaw Gripper & Vacuum Cup in Tool Changer Plate http://plmworld.org/ 13
  14. 14. Manufacturing Tasks• Manufacturing plan was developed as a group in the machining course.• Class was divided into product teams• Each team created manufacturing plans including: – Stock requirements – Process plans – Cutting tool requirements – Work holding methods• Fixture designs and CNC programs were created using NX http://plmworld.org/ 14
  15. 15. 2-Jaw Gripper Student Machining Task http://plmworld.org/ 15
  16. 16. Milling Fixture Part BlankTool Changer PlateBored Hole Gripper for MCS Attach Plate Location Clamps were moved during the machining process 16
  17. 17. Machining Gripper Attach Plate and Tool Changer Plate http://plmworld.org/ 17
  18. 18. Machining Side Holes Gripper Attach Plate Custom- Machined Vise Jaw Face 1Custom Indexing Fixture http://plmworld.org/ Face 2 18
  19. 19. Machining Vacuum Adaptor Custom Vise Jaws Stage 1 Setup http://plmworld.org/ 19
  20. 20. Machining Vacuum Adaptor Stage 2 Setup http://plmworld.org/ 20
  21. 21. Machining Vacuum Adaptor Stage 3 Setup http://plmworld.org/ 21
  22. 22. Finished ProductGrippers In Tool Robot Holding Changer Rack 3-Jaw Gripper http://plmworld.org/ 22
  23. 23. Challenges in Design-Build Projects• Projects require careful planning – Project scope must be “doable” – Time management • Big concern.. especially for manufacturing tasks – Designs must be within capabilities of manufacturing students and school equipment• Students need varying degrees of support and encouragement• Faculty time http://plmworld.org/ 23
  24. 24. Benefits of Design-Build Projects• Students experience design and manufacturing challenges in the classroom• Completed project can be useful in the future• Incoming students are motivated and excited about future classes• Results can be very gratifying for both students and teacher• Everyone learns http://plmworld.org/ 24
  25. 25. Siemens Software Tools Used• Part design was completed using NX – Modeling – Assemblies – Drafting• Fixture design was completed using NX – Modeling – Assemblies• CNC programs were created and verified using NX – Manufacturing Module http://plmworld.org/ 25
  26. 26. Other Projects• Robot Held Drill• Thermoformed tray insert for robot assembly project• Overall IML layout and workstation design http://plmworld.org/ 26
  27. 27. Robot-Held Drill NX ModelRobotStudio Simulation Real Robot & Programming Doing Work http://plmworld.org/ 27
  28. 28. Thermoformed Tray Insert 28
  29. 29. Initial IML Layout http://plmworld.org/ 29
  30. 30. Workstation Design Detailed WorkstationInitial Concept Workstation http://plmworld.org/ 30
  31. 31. Questions? Kevin Devine Illinois State University kldevin@ilstu.eduSiemens PLM Connection 2012 Las Vegas, NV May 7-10 #PLMCONX http://plmworld.org/ 31

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