1. Automatic Mill Cutter Insert
Replacement
Members:
Kisa Brostrom
Joseph McKenna
Andrew Clements
Connor McBride
Josiah Wai
Nicholas Wood
Trevor Douglas
Aaron Thonney
Conor Moloney
Scott Olivares
2. OBJECTIVE
● End mills use 10,000+ inserts per week
used to cut titanium
● Boeing workers spend too much time and
effort preparing end mills
● System that automates the removal and
replacement of 85 cutter inserts
3. DESIGN APPROACH
● Split whole team into three
subsections
a. Screwdriver
b. Carousel
c. Programming
● Set high but realistic time/design
goals
● Transition into a complete integration
● Transition to programming
4. A.M.C.I.R. -
Programming and Electronics
Programming:
Josiah Wai
Conor Moloney
Integration:
Andrew Clements
Nicholas Wood
Connor McBride
Scott Olivares
Trevor Douglas
Joseph McKenna
Aaron Thonney
Kisa Brostrom
5. Objectives
● Learn the programming languages
○ TIA portal and FCT
● Program all the subsystems
○ Must work independently
○ Linear Actuator
■ Move tool
■ Rotate tool
○ Carousel
■ Rotate carousel
■ Actuate pneumatic arm
○ Screwdriver
■ Actuate screwdriver
■ Insert/remove screw
6. Previous Work
● Programming
o Linear actuator and carousel
basic TIA programming
● Untested
basic/plan
Only actuator configured
o screwdriver
No code
● Electronics
o Two PLCs
Wired separately
o Grounded to bolts
o No sensors
o No HMI
7. Final Product
● Programming
o All systems home and position
correctly
o Linear Actuator
both motors move tool
● rotational motor
underpowered
o Carousel
Calibrated to rotate 1 cutting
insert per increment
Jerkiness of movement
eliminated with higher power
motor.
o Screwdriver
linear and rotational calibrated
requires an I/O module to obtain
sufficient activation of all signal
commands (screw & unscrew)
8. Final Product ● Pneumatic Piston and Vacuum Generator
piston and vacuum by solenoids through PLC
2 pneumatic valves
● with 4 actuators
Vacuum system improved by higher pressure
inlet supply
Piston position improved by ordering FESTO
module for PID dynamic control. (Currently
operates with position control.)
● Electronics
o Overhauled electronics board
PLCs interconnected and to HMI
All components fused for safety
Cleaned and organized wiring with
grounding/terminal blocks
Grounded with aluminum plate
o Sensors for subsystems
9. Electronics Layout
● Components
o 24 VDC power supplies
o carousel, linear rail, and worm gear
motor controllers
o 2 PLCs
o HMI
o Communication module
o Distributed 16 signals I/O module
o ethernet cabling for
HMI/communication module/PLC
connections and (test phase only)
motor controller PC diagnostics.
o Wiring connection to all sensor and
actuators
11. Future Work
● Programming
o Functionality and control-via-PLC/HMI demonstrated for every
system.
requirements for full, independent automation:
● increase mechanical soundness w/ higher power
motors
● time in order to program
proves mechanical soundness
o Full PLC-PLC communication
Currently only a finite number of binary data can be
transferred. Requirements for full communication:
● time to learn Siemens communication protocol
● either I/O module or communication module
● Electronics
o Mount HMI and E-Stop
Machine or water jet aluminum plate
o cover the electronics board
Protect with a full non-metal housing
14. Objective
● Loosen and fasten Torx screws in a cutter body
● Torque screws to 35 in-lbs without cross
threading errors
● No time constraints related to performance
● Integrate with carousel and cutter body linear
actuator
15. Previous Work
● Built a stand to support two Festo servo motors
a. One to drive a ball screw to raise/lower an actuator
b. One mounted at end of beam to be used as a screwdriver
● Poor motor selection - Incorrect torques
a. Linear - Too Much
b. Screwdriver - Too Little
● Intended to remove screws and place them into a hopper
● No wiring or programming completed
16. Final Product
● Redesign frame
○ New mounting brackets with ample adjustability
○ New Minitec linear actuator components
○ Couplers and adapters bought and manufactured
○ Adjustable feet added to new framing system
● Swap motors
○ Large servo motor - screwdriver
○ Small servo motor - linear actuator
● Flexible shaft to reduce load on cantilever beam
● Wired both servos to PLC, power, limit switch, and serial
ports
● Mounted limit switch for homing purposes
18. Problems
● Motors
○ Unable to read torque values
○ Lack of error detection
● Flexible shaft did not perform as
expected
● Linear actuator is imprecise
19. Future Recommendations
● Replace large servo motor with adequate stepper
motor and separate motor controller
○ Usable torque readings
○ Less weight
○ Direct drive
● More stability and repeatability
○ Gantry style frame
○ Purpose built linear actuator
21. ITERATIONS
● Collaboration with all three subsections
● Create stability and support
o Add brackets which allow for no
movement
o Create a stand which aligns with
carousel and screwdriver
o Levels the linear actuator
● Troubleshoot system so system can be
programmed correctly
22. ITERATIONS
● Limit switches were
incorporated to home the
linear and rotational position of
the mill head mount
o solenoid
o touch
● Worm Gear Reinforced
o Mounts and shaft
remanufactured
o Addition of Bearing for
support
23. FINAL PRODUCT
● Rotational and Linear Motion
achieved
o Gear Box Added to Linear
● Integrated with HMI controls
● New Motor Mounts and Bearings
manufactured
● Design for Angle Stand and
Subsystem Connections finalized
24. FUTURE
● Addition of Vertical Actuator
● Worm Gear Refinement
o Stronger Material of Shaft
o Addition of Second Bearing
● Better Bearings
● Stronger Motors
26. OBJECTIVE
● Remove inserts after screw
removal
● Catalog inserts for inspection
● Design easily removable insert
cataloging system
● Removal system must also be able
to replace inserts
27. OBJECTIVE
● Ease of ring removal
● Redesign air system for better suction
● Be dynamic enough to handle 85 inserts
● Able to adapt to more or less inserts easily
● Allow for flawless integration with other
systems
28. PREVIOUS WORK
● System designed and manufactured which
o Spins carousel to store inserts
o Ejects screws through magazine
o Pneumatic actuator pushes inserts to and
from carousel and mill
● Plastic ring designed to hold 80 inserts
● System contained on Bosch frame as tabletop
● Little to no wiring or programming complete
29. ITERATIONS
● Top mounted components for easy access
● Components on top are hinged for ring replacement
● Redesigned ring with larger diameter to accommodate 85
inserts
● Designed suction head which conforms to insert perfectly
● Designed new pneumatic system for actuator
● Homing system designed
30. ITERATIONS
● Brackets for motors, carousel and homing
● Pneumatic valve system added
● Suction head casted
● Ring 3D printed
● Insert guide milled
● Bosch frame assembled
● Legs machined so system is level
● Feet added for stability
31. FINAL PRODUCT
● Top mounted components
● Best location of pneumatic actuator
● Hard resin casted suction head with soft silicone
surface
● Reed switch on actuator
● Dynamic mounts for ease of modification
● Stepper gear and track are compatible
● Hinge stops so system is in position
32. BILL OF MATERIALS
Part Quantity Unit Price per Unit Total Price
Carousel Ring 10 sections $5 $50
Suction head mold 3 sets $1 $3
Stepper gear 1 unit $1 $1
Hinges 2 sets 24.53 49.06
Waterjet brackets 10 brackets 4.00 40.00
Gussets 5 gussets 5.05 25.25
Bosch Tubing 6000 mm .01849 113.80
Total 282.11
33. FUTURE WORK
● Reliability of suction system
● Print/machine ring as one solid
part for complete accuracy
● Redesign of top mounting hinges
for repeatability
● Heavy duty bearing for carousel
track
● Accuracy of ring rotation
