The document describes the design of an automatic mill cutter insert replacement system comprised of three subsystems: a linear actuator, carousel, and screwdriver. It outlines the objectives, previous work, iterations, and final products for each subsystem. The overall system aims to automate the removal and replacement of 85 cutting inserts used to cut titanium. Key achievements include programming the subsystems to work independently and together, redesigning components for improved functionality, and overhauling the electronics and wiring. Future work focuses on increasing mechanical precision and reliability.

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

10. Combined PLC Wiring Diagram

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

12. Bill of Materials

13. A.M.C.I.R. -
Screwdriver Subsystem
Members:
Trevor Douglas
Aaron Thonney
Nicholas Wood
Scott Olivares

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

17. Bill of Materials

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

20. A.M.C.I.R. -
Linear Actuator Subsystem
Members:
Kisa Brostrom
Joseph McKenna
Andrew Clements
Connor McBride

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

25. A.M.C.I.R. -
Carousel Subsystem
Members:
Kisa Brostrom
Joseph McKenna
Andrew Clements
Connor McBride

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

34. Final Product