Virtual Commissioning of Small to Medium Scale Industry Using the Concepts of...
ARGS final report_revise_8
1. 1
FALL 2015 IE 5330
AUTOMATION & ADVANCED MANUFACTURING
SYSTEMS
TITLE: AUTONOMOUS GUM REMOVAL SYSTEM
(AGRS)
FINAL REPORT
DATE SUBMITTED – 12/9/2015
SUBMITTED BY:
PING HUNG FRANK TSE – 1001120631
MADHUR KALGUTKAR – 1001105047
ADNAN AMIRALI MAREDIA – 1001101262
RAJESH KUMAR SUGUMAR – 1001098724
SHENG-CHE LU (BRUCE) – 1001096042
Location: Outside of the entrance of Woolf Hall, UTA
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EXECUTIVE SUMMARY
This project is about designing an Autonomous Gum Removal system (AGRS). We started this
project with defining the stakeholder’s and their specific needs. Depending on the analysis of the
stakeholder needs we defined the system requirements in terms of dimensions, performance,
design and Eco friendliness and various other factors. Our entire system design and functionality
is centered on the stakeholder needs.
To understand Input, Output, Control and Mechanism we designed base SADT model for
processes and developed subsequent models for each major processes to identify the sub
processes and their controls. Using SADT model, we are able to explore the details and system
requirement systematically.
To get a better idea about the overall system we designed a conceptual model design by
identifying major components like power, program of instructions, control system and processes.
We then did an exhaustive study of type of control system that will be used in the project. This
included the introduction of highly sophisticated sensors available in the market and defined
their use in our design. We also introduced some of the actuators like motors for the operation of
scrubbing and pump. The heart of our control system is in the electronic circuit board consisting
of the Motorola Microprocessor which controls the overall system with the programs installed in
it.
We classified the entire system into subsystems and subcomponents and identified it into Gum
detection, filling water/cleaning solution, spray pressurized steam and cleaning solution, heating
water and cleaning solution and scrub & vacuum. For every subsystem we have clearly
mentioned the description, functions, diagrams, technical requirements, hardware, software/
controls , tests and their evaluations, series of system tests , potential failures and costing of the
entire subsystem and its associated subcomponents/sensors. A clear summary of the evolution of
the subsystem/ subcomponents is provided which is a comparison of practical subsystem
developed vs considered in the initial design phase. Any deviations with the Initial design phase
are observed and written for each subsystem.
We have also provided a costing analysis of the entire system and concluded that the cost is
within the initial developed budget. At the last we have given the Autocad drawing of the model
as a graphical representation of AGRS.
3. 3
CONTENT
I. Stake Holders ……………………………………………………………………4
II. System Requirements …………..…………..…………..…………..…………...7
III. SADT- 1 ………………………………………………………………………….8
IV. SADT- 2 ………………………………………………………………………….9
V. Conceptual System Design & Process Flow Diagram ……………………......10
VI. Sub-System Design Phase Evolution ……………………………………….….11
vi-1 Gum detection
vi-2 Filling Water/Cleaning solution
vi-3 Scrub & Vacuum
VII. Sub System/Sub Components …………………………………………………11
vii-1 Gum Detection
vii-2 Filling water/cleaning solution
vii-3 Spray Pressurized steam and cleaning solution
vii-4 Heating water and cleaning solution
vii-5 Scrub and Vacuum
VIII. Technical Descriptions ………………………………………………………...19
IX. Costing of AGRS ……………………………………………………………….20
X. CAD DIAGRAM ……………………………………………………………….21
XI. Appendix ………………………………………………………………………..22
XII. Reference ………………………………………………………………………..37
XIII. Work Distribution ……………………………………………………………...38
4. 4
I. STAKE HOLDERS
1) USER / OPERATOR:
For user/operator, they are the people operating the gum removal machine. Their needs
would be focusing the safety, ease of use, effectiveness and efficient during the operation.
2) MANUFACTURING ENGINEER:
For manufacturing engineer, they would focus on the production, reliability, quality and
the safety of the system.
3) SALES PERSON: Sales person concentrates on the positives of the product by which he
can convince the customer to buy the Gum removal Machine.
4) OWNER/MACHINE: Unit owner can be the user or a company which provide these
services. They mainly focus on the cleaning results and reliability of the machine.
5) PROPERTY OWNER: They are the one who own the property in which the
autonomous gum removal machine is to be used.
6) BYSTANDERS: They are the one who are the observers, spectators or the people
passing to and from within the property where the autonomous gum removal machine
will be used.
7) DEVELOPMENT ENGINEER: Development engineers are the one who are
responsible for conceptual design and ergonomics of the machine. They are also
responsible to design the machine within the budgetary/financial constraint and at the
same time ensure financial viability.
8) EPA: Environmental Protection Agency is the one which was created to protect human
Health and Environment by writing and enforcing regulations. Hence, we need to
consider EPA as the stakeholder because we need to follow certain regulations while
designing the AGRS.
9) OSHA: Occupational Safety & Health Administration says to keep the working
environment to be safe and healthy. Hence, we have to consider OSHA as the stakeholder
because we need to follow certain regulations while designing the AGRS.
5. 5
II. SYSTEM REQUIREMENTS
Customers need a handy machine, so the dimensions of system should be restricted within 36”L
x 27”W x 36”H and weigh less than 50 lbs.
In terms of continuing to operate system perfectly, the system requires long battery life of up to 4
hours of continuous performance and 22 hours of standby.
For the design of machine system, 5 liter stainless steel cylinder should be installed in the gum
removal machine in order to enhance performance and durability. In additional, machine with
ergonomic design can avoid personnel injury.
To achieve the feature of low supervision, system should be designed to have manual
intervention by operator or user less than 60%
For performance of removing gums, machine has a limit of warm up time up to 3 min. The
system should be able to remove 95% of the gum at the rate of removing12 gums per min. To
ensure machine reliability, the average break down of system cannot over once in six months.
Moreover, this machine system should be sprayed wide enough to make sure this machine is
practical machine. Generally, the spray range of the system is recommended to be 1 ft by 2 ft.
For safety and eco-friendly, system can only consume up to 1.33 L of bio-degradable chemical
per hour. Also, the system is able to provide emergency stop button and electric shock proof.
GRAPH SHOWING IMPACT OF STAKEHOLDERS NEEDS ON SYSTEM
REQUIREMENTS:
System requirements are driven by most of the stake holders needs. Analysis of stake holder
needs and system requirement has been done. Around 12 out of 23 stakeholder needs impact
the system requirement and out of the entire stake holders user, development engineer impact
the most on the system requirement. Below table indicates the percentage impact of stake
holders on system requirement.
Note: Equal weightage is assigned to all the stakeholders needs.
7. Stakeholder
Customer Need
System
Requirement
User/operator
Manufacturing
Engineer
Salesman Owner/Machine Property owner Bystander
Development
Engineer
EPA OSHA
Ease of use,
effectively,
efficient, and
safety
Production,
reliability, Safety
and Quality.
Sales
Cleaning Results,
Reliability
Cleaning
Results
Cleaning
Results
Design,
Financial
Environm
ental
Protectio
n
Safety
Easy to move around
Large spray area of 1'x2'
Cost effective and affordable price of around $3400
Eco Friendly, consuming 1.33L of bio-degradable chemical/hr
User Friendly
Work Effectively 95%
Hygenic
Average breakdown once in 6 months
Efficient/Quickly removes gum of approx. 12 gums per min.
Unit Comes with a 3 years of physical warranty and 5 years of
functional warranty
5 litre Stainless steel cylinder for enhanced performance and
durability
Ergonomic
Unit is Multifunctional which can be used
on hard floors and carpets
Low Supervision, Semi automated (reduced manual intervention by
60%)
Warm up time of upto 3 minutes
Dimensions 36"L X 27"W X 36"H and weighs less than 50lbs.
Cheap and easily available Replaceable Parts costing 15% - 35% of
the total cost
Long Battery Life of upto 4 hours of continuous performance and 22
hours of standby
50% less damage to the floor compared to manual removal
Able to detect any anamolies of greater than 1"
Noise Level of less than 70 dB
Safety - Electric shock proof, Emergency stop button
Technical Support Service, 95% postive feedback
Stakeholder Preference
Summary of System Requirements
7
8. NODE: NO.:TITLE:
A0
Operate an
Autonomous Gum
Removal System
Clean Floor
Gum Removal
Machine
Operator
AGR system Operation
Manual
Instructions from
property owner
Cleaning Solution
Clean Water
Dirty Floor
Purpose: Understand the tasks involved in operating an autonomous
chewing gum removal system from sidewalks in an urban environment
properly and effectively.
Viewpoint: Operator
NODE: NO.: PFT001AGR/A-0 TITLE: Operate an autonomous gum removal system
Waste Drum
8
SADT – A-0 Diagram
9. NODE: NO.: PFT002AGR/A0 TITLE: Operate an autonomous gum removal system
1
A1
Communicate with
the property owner
A2
Setup the AGR
system
A3
Execute the tasks
A4
Inspect the
floor
A5
Shut down the
AGR system
O1 Clean floor
I2 Clean Water
M2 Operator M1 AGR System
C2 AGR system Operation
Manual
Operation Plan
Ready to use
AGR system
Finished or
unfinished job
Rework
Finished job
A6
Drain waste
Waste
O2
Waste
drum
C1 Instruction from
property owner
I3 Cleaning Solution
I1 Dirty Floor
9
SADT – A0 Diagram
10. 10
V. CONCEPTUAL SYSTEM DESIGN
Process flow diagram
Power Sensors/ Actuators
Set up Execute task Finish job Color Sensor
Volume/Float Sensor
Thermocouple
Pressure sensor
Actuator- Motor
Actuator- High pressure gun
Gum detection sensor
Recharcheable
Battery
Program of Instructions
-Fill the cleaning solution.
- Fill water
-Turn on machine.
-Set desired pressure
-Set desired temperature
-Warm up the machine
-Allow the machine to warm up
for 3 min
-Gum spot detection
-Spray cleaning solution
-Spray pressurized
steam
-Scrub and vacuum
-Set pressure level to 0 psi
-Turn off the heating
system
-Turn off the machine
-Discard the waste
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VI. SUB-SYSTEM DESIGN PHASE EVOLUTION
In the process of designing the AGRS, we have made adjustment and modification to our design
to turn it more practical and realistic.
1. Gum detection
Color sensor is changed to dirt detector to detect the gum on floor. Color sensor uses camera
to detect the color of the gum, while dirt detector uses LED to detect the gum, and followed
by a color analyzer. Dirt detector gives a more robust result of detection as LED light bulb is
implemented. Hence dirt detector provides the states that the system is operating.
2. Filling Water/Cleaning solution
The tank size is changed from 5 L each side to 2.2 gal each side (equiv to 8.3 L). Larger
tanks are needed to avoid refilling water and cleaning solution during the operation of gum
removal. Hence, the tank material is changed from using stainless steel to polyethylene due
to cost justification.
3. Scrub & Vacuum
In original design, one rotary motor is used to brush and vacuum. However, an individual
motor should be used for task of brush and vacuum. The motor taking care vacuum is unable
to incorporate the task of providing the scrub and brush. Another issue is to avoid the
moisture from wastewater damaging the general motor. Float sensor is incorporated in the
wastewater tank to prevent from overfilling.
VII. SUB SYSTEM/SUB COMPONENTS:
1. Gum Detection
Specification
Gum detection is a major subsystem in AGRS, generally, the gum detection device was
installed at the bottom of machine to detect dirt spots on the ground. For detecting dirt spots on
the ground, the following sub-components can be used and comprised:
a) dirt deck
b) Color Analyzer
A piezoelectric sensor has been used as the dirt deck. When a dirt spot hits the sensor, they
generate tiny electric impulses and, presumably, an excessive number of these impulses trigger
the microcontroller of Color Analyzer and generate the tiny current from battery. Once the
current pass through the current limiting resistor, RGB LED will be activated and the standard
red LED then light up which means AGRS has detected the black spots and ready to operate.
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Function: Dirt deck & Color Analyzer
Dirt deck provides a piezoelectric sensor which is capable of instantaneously sensing and
responding to the dirty area with proper types of ground surface where is indoor or outdoor, and
thus immediately responsive to dirt spots on a floor to be cleaned. Color Analyzer shows up the
status of AGRS, once it received signal from dirt deck, red LED will light up which means
AGRS is available to operate. Otherwise, it will keep off.
Component Test
Component test for the gum detection can be done with physical inspection and electrical
inspection which can be recorded by these two ways:
Perform sensitivity test and surface test to piezoelectric sensor
Perform current test to Color Analyzer
Evaluating the potential performance of the SS/SC
For evaluating performance of piezoelectric sensor, we can determine the different
thickness of gum which were stick in different surface. For example, 3 levels thickness
of chewing gum have been prepared for detecting, simultaneously, preparing 3 kinds of
surface which can be used as ground, as result, we can get 9 combinations of
performance.
For evaluating performance of Color Analyzer, we can use different current resistors to
generate a range of current that the red LED light will work.
Potential failures
Failure to detect gum spots on the ground.
o Failure of forcing piezoelectric sensor because of the thickness of gum spots, the
electric impulses will not be generated.
o The rough surface increases difficulty of sensor detecting, for instance, the tiny
crushed stone will break sensor down while machine is operating on the street.
Failure to light up the red LED signal.
o Inappropriate current resistor to be used of the color sensor, and lead extra current
pass through the circuit. It may cause damage of all detection system.
2. Filling water/cleaning solution:
Description
Filling water/cleaning solution is the primary sub system of AGRS and it comprises following
components:
1. Two compartment tank
2. Volume float sensor
3. Flow meters
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Functions of the sub system
One of the task in this sub system is to fill the water and solution in to the tank at the beginning
of the operation. At beginning each of the liquid is filled equally. The float sensors are installed
in the tank to give the warning of high level and low level in the tank.
I. Two compartment tank:
Description: This component stores the water & cleaning solution which will be used by the
system during the Gum removal operation.
Component Testing:
Component testing can be performed by connecting the pipes from tank in to the pump at desired
volume (gallons) with the help of flow meters & timing sensors.
Evaluation:
With the knowledge of desired volume we will evaluate the desired flow rate necessary for pump
suction. In any case we need to be sure that the pump doesn’t run dry.
Potential Failures:
Blockage at the tank outlet because of the sand particles accumulation at the tank bottom.
Material corrosion can cause the tank leakage.
II. Volume / Float sensors:
Description: This sensor is used to detect the level of liquid in tank. For AGRS the right
proportion of volume of water will be 2 gallons & proportion of cleaning solution will be 0.5
gallon.
Technical Description:
Dimensions: 12” Length & 1/8” NPT mount
Material of construction: Poly-propylene
Component Testing: Testing for this component is done by maintaining the liquid level very
low in the tank and the response time of the sensor to the MCU is noted, if the response time is
very high than the sensor is rejected.
Potential Failures: Failures can occur at this component at the sensing part which will not sense
the level of liquid and communicate properly with the MCU which in turn will cause the system
to dry run or over filling the tank with liquids which is not desirable.
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III. Flow meters:
Description: Flow meters are used to supply the accurate amount of liquid to the pump ratio of
1:2.
Component Testing:
Flow meters can be tested by allowing the liquids to flow from it different flows and then
checking at the discharge side of the pipe manually the actual flow received and flow meter
readings are checked if its same or not.
Potential Failures: Sometimes the flow meters might not work properly because of the loose
connection in wirings which might cause the inaccurate mixture of the liquids and hence
resulting in less cleaning efficiency of the system.
3. Spray Pressurized steam and cleaning solution
Description
Pump is located at the center of the AGRS system. It performs it task throughout the operation of
the system. Input to the Pump is the mixture of water and cleaning solution and a motor is used
to drive the pump. Output (Pressurized solution) from the pump is connected to the boiler
(heating filament).The high pressure pump works with the principle of centrifugal pump, it is
connected to the electric motor which drives the shaft of the impeller. Because of the rotation of
the impeller a suction is induced at the one end of the pump which draws water from the water
tank. The water rotates along with the impeller which leads to an increase in pressure and kinetic
energy. A pressure gauge is attached to the delivery frame which helps in controlling the
pressure level with regards to the use.
Function of the subsystem:
The major function of centrifugal pump is to take in the water and cleaning solution from the
tanks and to increase its pressure before sending it out through the nozzle.
Component Testing:
The component testing can be performed just by connecting the pump with the motor. Then
a tachometer is used to check whether the impeller is rotating at a desired RPM level.
Rotation direction can also be checked by changing the knob on the motor. Tachometer
shows both the RPM and the rotational direction.
Hydrostatic Tests
Shop running tests
Thermodynamic testing
15. 15
Evaluation of potential performance of the Component Test:
System tests at full capacity of the allowable pressure.
To prove the mechanical integrity of the pump, vibrations and verify performance.
Used to measure heat generated, power consumed and pressure difference using pressure
sensors.
Potential Failures:
Connection cut out between the impeller and the output shaft form the electric motor.
Connection break between the water tank and the suction frame.
Bearing failure due to wear
Part wear
Pump locked up
Excessive heat
Coupling problem
Sub Component of Centrifugal pump
3.1. Electric Motor:
Description
A standard electric motor is used to run the centrifugal pump, the motor driven by supplying
electric current from battery. The output shaft of this motor is connected to the shaft of the
impeller. Below figure shows the various parts of the electric motor. Rotation of this electric
motor can be controlled to either clockwise or anti clockwise direction.
Function of the subsystem
The electric motor is used to drive the centrifugal pump, the rotational movement from the
motor is transferred using an output shaft which is in turn connected to the impeller.
http://www.northerntool.com/images/downloads/manuals/16154.pdf
Sub Component Testing:
Component testing for an induction motor is done either by physical inspection or electrical
inspection. Following are the ways for checking our motor.
Check the windings for short circuiting to the frame.
Use an ohmmeter to check resistance value (below 0.35 MegaOhm)
Check that the windings are not open or blown.
Full Load and No load testing on the motor to find the overall performance
Potential Failures:
Failure to ensure the wiring connections as provided in manual
Leakage of water from the tank into the motor components.
Improper mounting to the body frame.
16. 16
Failure due to windings in the motor
Failure due to motor rotor issues
4. Heating water and cleaning solution
Description
Boiler is located at the bottom of the system besides the pump.
Input to the boiler is pressurized solution and is connected to the pump.
Output of the boiler is heated vaporized solution and is connected to the pressure gun.
Function of the subsystem
The boiler tank consists of a steel tank where copper pipes are coiled inside. The high pressure
water pumped out is fed inside. Coil is heated using electricity, which in turn heats up the water
molecules through conduction. The temperature inside the boiler can be controlled by using a
temperature sensor. Heating temperature of the coil and go up to 185 degree Celsius.
4.1. Thermostat:
Component Testing:
Thermostat is attached outside the machine which measures the temperature inside the
coils.
TDS(Total dissolved solids) meter to measure boiler water TDS, feed water TDS, make up
water TDS
Evaluation of potential performance of the Component Test:
Thermostat attached outside the machine can measure the temperature inside the coils
which measures and maintains temperature at desired point
TDS meter is used to indicate the total dissolved solids in the solution which measure the
conductivity of the solution.
Series of System level test:
Test the combustion efficiency of the working fluid in several intervals of time during
operation.
Test the reliability of Thermostat while the water is getting heated in the boiler when the
system is working.
Potential Failures:
Use of dirty water can lead to corrosion of the copper coil.
Overheating
Mechanical failures
17. 17
Corrosion
Thermal Fatigue
Failure of the safety valve
5. Scrub and Vacuum:
Description
This subsystem which includes a brushless motor and vacuum motor, is located at the bottom
part of the system. It performs at the end of each individual task; however, it operates
continuously throughout the whole project. It works similar to a carpet cleaner.
Function of the subsystem
Scrub and brush
One of tasks in this subsystem is to scrub the floor to remove the remaining gum sticking
on the floor. A series of spinning scrub brush can be used in this task to enhance the
scrub effect.
Vacuum
Vacuum is another task of this this subsystem. It is performed after scrubbing and
brushing to suck up the dirty solution and remaining gum left on the floor. The removal
of the liquid and gum completes the procedure of gum removal; hence, it also helps the
gum detecting sensor for further detection for any miss gum.
Component Testing:
Component testing for an induction motor is done either by physical inspection or electrical
inspection. Following are the ways for checking our motor.
Perform a mechanical test to motor
Perform a suction test to the vacuum motor[14]
Perform a sensitivity level test to the float sensor
Evaluation of potential performance of the Component Test:
With knowing the torque of the motor, we are able to determine the sticking strength of
gum we can remove with the motor. The torque of motor can be measured with a torque
sensor, and the output of torque sensor can be analyzed by computer.[11]
With knowing the suction power and the air flow amount, we are able to determine the
limit of weight of gum and wastewater that the vacuum motor can be lifted. Using
barometer, we can determine the pressure which can be converted to suction power.
With knowing the sensitivity of the flow sensor, we can determine the tolerance of the
wastewater bin before overfilling and spilling. In order to test sensor, we can place the float
sensor at a fix location and set up a series of experiment to increase the volume in the
wastewater tank to test the sensitivity and reliability of the sensor to trigger the respected
command.
18. 18
Series of System level test:
Test the scrubbing and brushing with gum at different conditions
o Dry gum
o Gum is wetted with steam
o Gum is wetted with steam and cleaning solution
o Gum residual
Test the vacuum power with wastewater and gum at different condition
o Pure wastewater
o Pure gum residual
o Mix of wastewater and gum
Test the reliability of float sensor to stop the operation of scrub and vacuum when the
wastewater tank is getting full
Potential Failures:
Failure to scrub and brush the remaining gum on the floor
o This can happen if area is very narrow that prevents the machine from entering or
not flat or has too many obstacles
Failure to vacuum the wastewater and gum residual on the floor.
o The wastewater and gum residual may be too dirty to the vacuum motor, and air
flow could be reduced overtime if the too much gum residual were blocked or even
stuck on the wall of the vacuum motor. The vacuum motor would be dysfunctional
eventually due to the excess of gum residual
o Any leak from the hose from the vacuum motor to the wastewater tank could result
of electric shock
Failure to stop the operation of scrub and vacuum when the wastewater tank is full.
o Failure of triggering the system to stop the operation of continuous vacuum make
the wastewater tank overfill and cause spill
o Electric shock may be resulted if the wastewater was overfill and got into contact
with the internal part of the system
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Hardware, Sensor, Software:
VIII. TECHNICAL DESCRIPTION:
Filling
Compartment tank Float sensors Flow Meter
21.5”L x 13.75”W x 10” H 12” Length 1” Female NPT
2.2 Gallons capacity 1/8” NPT mount Kynar
2 x 2” Diameter inlet ports Polyethylene
Polyethylene
Pressurizing
Centrifugal pump Induction Motor
Horsepower: 3 hp Horsepower: 5 hp
Voltage: 230 V Voltage: 230 V
110 gpm Rotation speed: 1740 rpm
Suc x Dis: 1 ½” x 1 ¼” Rotation direction: CCW
Dimension: 12" x 12" x 11"
Heating
Boiler
Voltage: 220 V
7.5 KV
Current: 34A
0.05 Mpa to 0.6Mpa
Temp: 89-190 C
Dimensions: 30x30x30 cm
Subsystem Gum Detection Filling Pressurizing Heating Brushing and vacuum
Hardware RGB
Compartment
Tank
Vane Blades,
frame, Impeller,
Induction Motor
Pressure sensor, Spill
sesnor, Extraction fan,
igniter, heating
filament
General motor,
vacuum motor, brush
head, wastewater
tank
Sensor
Piezoelectric
sensor, color
detector
Float Sensor,
Flow Meter
Pressure sensor,
pressure gauge Thermostat
Float sensor,
potentiometer
Software/Control MCU programmed software
Piezoelectric sensor Color detector
Voltage sensitivity: 0.1 mV Size: 1” x 2” x 1”
Current consumption: 0.5 mA Current sensitivity: 3 mA
ColorDetection
Capacitance: 220pF
Weight: 3.5 oz
Detection: 0.05 cm – 0.2cm
Angle: 180◦
20. 20
ScrubandVacuum
General Motor Vacuum Motor Float Sensor Potentiometer
Horsepower: 1/4 Voltage: 120V Fitting type: 1/8”
NPT pipe thread
Resistance: 50kΩ
Voltage: 115V Air flow: 112 cfm Power: 200mW
Height: 9.25 in Avg Life: 500 hr Switch Rating:
30 W, 240V max
Taper: Linear
Body Dia: 5.6 in Height: 7 in Diameter: 6mm
Body Diar: 5.7 in Length: 20 mm
IX. COSTING OF AGRS
SUB-SYSTEM COMPONENT
COST
($)
Gum Detection
Dirt Deck 45
Color Analyzer 40
Filling Water/Cleaning
solution
Two compartment
tank
30
Connection Pipes 3
T-Joint 5
Filters 65
Volume Float
Sensors
15
Flow Meters 30
Spray Pressurized steam &
cleaning solution
Centrifugal Pump 350
Electric Motor 400
Heating Water & Cleaning
Solution
Boiler 100
Scrub & Vacuum
General Motor[8]
235
Brush Heads[9]
23.9
Vacuum Motor[10]
91.9
Float Sensor [12]
12.4
Potentiometer [13]
1.33
TOTAL COST 1447.53
22. 22
XI. APPENDIX
STAKE HOLDERS - NEED
1) USER / OPERATOR:
For user/operator, they are the people operating the gum removal machine. Their needs
would be focusing the safety, ease of use, effectiveness and efficient during the operation.
NEED: In terms of safety, the system cannot be too big or heavy to carry, the system
should weigh less than 50 lbs and constrained within 36” L x 27” W x 36” H. The
chemical cannot be hazardous, the noise level should be under the acceptance level,
approximately 70 dB and the system should have safety features like shock proof and
emergency stop button.
For ease of use, wheels should be taken into consideration for feature of easy to move
around. The customer needs include low setup time, like3 min. Low supervision is
another crucial feature. Semi-automated system can help reduce supervision from
operators, reducing the manual intervention by 60% should be one of the major features.
For effectiveness and efficiency, the gum removal system should be able to detect
anomalies with greater than 1” height, and remove 95% of the gum in every 1’ x 2’ area,
approximately 12 gums per min. It should be able to operate up to 4 hours continuously
at performance level and 22 hours of standby. Reliability is an important quality
criterion. Every machine has its limit, and this gum removal system should not be broken
down in average every 6 months. The system cannot damage the concrete or floor more
than 50% comparing to manually removing gum.
2) MANUFACTURING ENGINEER:
For manufacturing engineer, they would focus on the production, reliability, quality and
the safety of the system.
NEED: For production, manufacturing engineers also need to produce the system in a
dimension and weight feasible for users to carry. The system should weigh less than 50
lbs and constrained within 36” L x 27” W x 36” H.
For the perspective of reliability and quality, the system should be very reliable as
manufacturers are liable to warrant their products with service and repair. In order to gain
clients confidence about the gum removal system, a reliable system is needed. In details,
it should not break down less than 6 months in average. Hence, the manufacturers give 3
years of physical warranty and 5 years of functional warranty. The replacement parts
should be easily accessible and should not cost more than 35% of total cost. They also
23. 23
need to ensure the long lasting battery life to meet their client’s need. It should be able to
operate up to 4 hours continuously at performance level and 22 hours of standby. The
technical product support service should receive minimum 95% positive feedback.
For safety, manufacturing engineers are liable to make products meet the safety standards
from OSHA. The system should have safety features like shock proof and emergency
stop button.
3) SALES PERSON: Sales person concentrates on the positives of the product by which he
can convince the customer to buy the Gum removal Machine.
NEED: First and foremost thing of selling this product is its price, and comes at an
affordable price of. It is user friendly and easy to operate. The system works effectively
with output results of 95%.In order to win the customer enhanced performance and
durability are achieved. The unit is multifunctional and also required less supervision.
Damage to floor is reduced compared to manual removal. Low noise level and safety
features to make it comfortable for the user.
4) OWNER/MACHINE: Unit owner can be the user or a company which provide these
services. They mainly focus on the cleaning results and reliability of the machine.
NEED: The price range should be less than $3400 to make it affordable and must have a
working efficiency of 95%. The unit must possess a good life cycle and a breakdown
cycle of once in six months. Unit should have a 3 years of physical warranty and 5 years
of functional warranty to make it more reliable. A good product support system should be
provided or easy serviceability. Replaceable parts must be easily available at a low cost
of 15% - 35% of the total cost. Damage to floor must be reduced compared to manual
removal.
5) PROPERTY OWNER: They are the one who own the property in which the
autonomous gum removal machine is to be used.
NEED: Being the property owners they expect that the machine should be Eco-friendly,
hygienic, should not damage/least damage to the floor where is used, less noisy and
should be safe i.e. should not injuries or fatalities on the site.
6) BYSTANDERS: They are the one who are the observers, spectators or the people
passing to and from within the property where the autonomous gum removal machine
will be used.
NEED: Since by-standers do not come in direct contact with the machine, there are least
number of factors which they need. They need the machine to be green i.e. it should be
eco-friendly, hygienic, less noisy and safe i.e. should not cause any shock or mechanical
hazards to the people passing nearby.
24. 24
7) DEVELOPMENT ENGINEER: Development engineers are the one who are
responsible for conceptual design and ergonomics of the machine. They are also
responsible to design the machine within the budgetary/financial constraint and at the
same time ensure financial viability.
NEED: Since they play a major role in the design and ergonomics all the
constraints/needs imposed on the machine and system requirements will be a function of
their scope of work. They should design an autonomous gum removal machine which is
portable and easy to move around, nozzle has large spray area, user friendly, eco-
friendly, work effectively, removes gum at the rate of approx. 12 gums per minute, less
breakdown of the machine, durable, ergonomic, multifunctional unit which is capable to
be used on hard floor and carpet both, low supervision i.e. is semi-automatic, less warm
up time, long battery life, less damage caused by machine to the floor, able to detect other
anomalies greater than 1”, less noisy and mechanically and electrically safe to use. Apart
from these needs they will also make sure that the machine is cost effective and
affordable.
8) EPA: Environmental Protection Agency is the one which was created to protect human
Health and Environment by writing and enforcing regulations. Hence, we need to
consider EPA as the stakeholder because we need to follow certain regulations while
designing the AGRS.
NEED:
EPA has put some regulations which any manufacturer needs to follow. The first and
foremost thing they expect from our AGRS system is that it should have minimum Noise
level in order to reduce the noise pollution. EPA regulates that the equipment should have
Noise level of less than 70 Decibels. Secondly, the safety of customer is of high priority
so, the AGRS should be Safety - Shock proof in using it also there should be Emergency
shut of switch in case of any kind of Emergency.
EPA also regulates the equipment to be Eco friendly, so ideally our AGRS system should
consume approximately 1.33L of bio-degradable chemical/hr. Also, the equipment should
maintain the work area to be hygienic after and before the use.
9) OSHA: Occupational Safety & Health Administration says to keep the working
environment to be safe and healthy. Hence, we have to consider OSHA as the stakeholder
because we need to follow certain regulations while designing the AGRS.
NEED:
OSHA has put some regulations for Occupational Safety & Health condition for the
people working with our AGRS system. First requirement is to reduce the Noise Level to
25. 25
less than 70 Decibels so that there is certainly less stress on the person who is operating
the equipment as well as the people who walk besides the equipment while the equipment
is in use. Secondly, since OSHA regulates the safety to for people working, the AGRS
should have safety and shock proof arrangements plus there should be an Emergency shut
off switch.
OSHA also wants the working environment to be less hazardous so ideally system should
consume 1.33L of bio-degradable chemical/hr.
26. 1
Overview the
cleaning Project
2
Identify the dirty
floor
3
Identify the power
source,water
C1 Instruction from
property owner
M1 Operator
O1 Operation Plan
NODE: NO.: PFT003AGR/A1 TITLE: Communicate with theproperty owner
Project Overview
Dirty floor plan
26
SADT – CHILDREN DIAGRAM A1
27. 1
Fill the cleaning
solution
2
Connect water and
power source
3
Turn on AGR
system and set
desired pressure
level
C2 AGR system Operation
Manual
M1 Operator
4
Warm up the AGR
system
M2 AGR System
O1 Ready to use AGR
System
I1 Clean Water
I2 Cleaning Solution
C1 Operation Plan
NODE: NO.: PFT004AGR/A2 TITLE: Setup theAGR System
AGR system with
loaded cleaning
solution
AGR system with
water and power
connected
AGR system at
desire pressure
level
27
SADT – CHILDREN DIAGRAM A2
28. 1
Detect the Gum
2
Spray the cleaning
solution onto the
gum
3
Spray Pressurized
steam onto the
gum
C1 Instruction from
property owner
M1 Operator
4
Scrub and vacuum
the floor
M2 AGR System
O1 Finished or Unfinished
job
I1 Ready to use AGR
System
C2 AGR system Operation
Manual
NODE: NO.: PFT005AGR/A3 TITLE: Excutethe tasks
I2 Dirty Floor
Targeted gum
on the dirty
floor
Cleaning solution reacted
with gum on the dirty
floor
Speed up the
chemical
reaction on the
gum
I3 Rework
NODE: NO.: PFT005AGR/A3 TITLE: Execute thetasks
28
SADT – CHILDREN DIAGRAM A3
29. NODE: NO.: PFT006AGR/A4 TITLE: Inspect the floor
1
Inspect the floor
visually
2
Compare the
standard from
property owner
C1 Instruction from
property owner
M1 Operator
O2 Finished Job
3
Schedule rework
Inspected floor
Unfinished job
O3 Rework
O1 Clean Floor
I1 Finished or unfinished
job
29
SADT – CHILDREN DIAGRAM A4
30. 1
Set pressure level
to 0 Psi
2
Cut off the Power
3
Disconnect the
water
M1 Operator
M2 AGR System
O1 Waste Water
C2 AGR system Operation
Manual
NODE: NO.: PFT007AGR/A5 TITLE: Shut down the AGR System
C1 Finished Job
4
Discard waste
AGR System at 0 Psi
AGR System with power
disconnection
AGR System
with water
disconnection
30
SADT – CHILDREN DIAGRAM A5
31. 1
Open the waste
compartment
2
Drain the waste
3
Collect waste in the
waste drum
M1 Operator
O1 Waste drum
C1 AGR system Operation
Manual
NODE: NO.: PFT007AGR/A5 TITLE: Shut down the AGR System
Waste leaving
compartment
Waste going to waste
drum
I1 waste
NODE: NO.: PFT008AGR/A6 TITLE: Drain waste
31
SADT – CHILDREN DIAGRAM A6
32. 32
1. Gum Detection
A. Diagram
Diagram and Schematic diagram of Dirt Detection [1, 2, 3, 4, 5]
2. Filling water/cleaning solution:
Labled Diagrams of Sub-Components
33. 33
Diagram of float sensor [15]
Diagram of flow meter [16]
3. Centrifugal pump:
Schematic diagram of centrifugal pump [18]
Delivery frame
38. 38
Work Distribution
We all work together and equally on the whole report. However, for specific subsystem, each
team member work individually.
Gum Detection By Sheng-Che Lu (Bruce)
Filling Water/Cleaning Solution By Adnan Amirali Maredia
Spray Pressurized Steam And Cleaning Solution By Rajesh Kumar Sugumar
Heating Water And Cleaning Solution By Madhur Kalgutkar
Scrub And Vacuum By Ping Hung Frank Tse
Subsystem Work Distribution
