ME460 Presentation
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This document presents the preliminary design review for an automated seeding machine. It includes customer requirements, a functional decomposition, concept selection, and the final design. The final design uses a scissor lift for tray input and output, a conveyor to transport trays between stages, and a roller with slots to dispense seeds into tray holes. Timing, costs, and improvements are also discussed. The design aims to automatically seed plant trays with a cycle time of less than 90 seconds per tray.
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ME460 Presentation
- 1. Automated Seeding Preliminary Design Review Team Members: Peter Ishiguro Shireen Kheradpey Jeremy Lee Frank Lin Boston University Department of Mechanical Engineering Discussion Leader: E. Gutierrez Lecturer: A. Sharon
- 2. OUTLINE ● Customer Requirements ● Functional Decomposition ● Alternative Concepts ● Final Design ○ Input System ○ Seed Dispensing System ○ Output System ● Financial Justification ○ Bill of Materials ○ Cummulative Cash Flow ● User interface screen ● Areas for Improvements
- 3. Customer Requirements 1. Transfer tray from input stack to seed dispensing system a. Tray Dimensions: 120 cm x 60 cm x 5 cm b. Input must accommodate stack of 10 trays 1. Fill each tray hole with one seed (95% accuracy) a. 200 holes/tray (20 rows of 10 holes) b. Hole Diameter: 1 cm; Hole spacing: 5 cm ± 1 cm c. Seed Diameter: 0.1 cm 1. Stack seeded trays on output cart a. Minimum 5 cm overhead space for loaded cart 1. Cycle time = 90 sec per tray or less
- 4. Functional Decomposition Automated Seeding Machine Hold Tray Stack Move Single Tray to Conveyor Transport Trays: 1. Input to Dispenser 2. Dispenser to Output Dispense seeds Sense Finished Tray Adjust Tray Height Fill Trays Adjust Tray Height Transfer Tray to Cart
- 5. Morphological Chart Parameter Possible Solutions Tray Input / Output Linear Drive Scissors Lift Claw Transportation Linear Drive Conveyor Belt Move machinery to trays Seed Dispenser Vertical Tubes Air Suction Roller with Slots
- 6. Tray Input and Output Weight Factor Linear Drive Scissors Lift Claw Speed 1 0 0 +1 Cost 1 0 -1 -1 Weight Capacity 2 0 +1 -1 Stability 2 0 +1 -1 Ease of Assm 1 0 +1 -1 Controllability 2 0 -1 0 TOTAL 0 2 -5
- 7. Seed Dispensing Subsystem Weight Factor Vertical Feeder Tubes Air Suction Roller with Slots Reliability 2 0 +1 +1 Controllability 2 0 +1 +1 Cost 1 0 -1 0 Ease of Assm. 1 0 -1 0 TOTAL 0 2 4
- 9. Final Design Input System Seed Dispensing Output System
- 10. Input: System Overview Scissor Lift
- 11. Input: System Overview Scissor Lift Tray Stack
- 12. Input: System Overview Scissor Lift Pushing Arm Tray Stack
- 13. Input: System Overview Scissor Lift Pushing Arm Tray StackLimit Switch
- 14. Input: System Overview Inverted Linear Drive Scissor Lift Pushing Arm Tray StackLimit Switch
- 16. Input: Machine Requirements Load: 28.9 kg Distance Traveled: 1.2m Max Velocity = 0.3 m/s Acceleration = 0.075 m/s^2 Time = 8 sec Torque = 2.31 Nm
- 17. Sensors at Input Switch Open Switch Closed Carriage ● Switch closed by carriage returning to home position ● Closing switch raises input stack by 5 cm
- 18. Dispensing System: Overview Roller Seed Holes ● ⌀ 1.5 mm, 1.5 mm deep ● 4 equally spaced rows of 10 holes
- 19. Dispensing System: Overview (Cont.) Roller Bearing Limit Switch Stepper Motor Tray Notches
- 21. Dispensing: Machine Requirements ωmax = 39.3 rev/s (2356 RPM) Time = 0.01 sec Torque = 0.063 Nm Seed Holes Row θ = 90 °
- 22. Sensors at Dispenser -Gated sides of trays complete limit switch to power stepper motor -Ensure seed dispense when holes in proper position. Limit Switch Off Limit Switch On
- 23. Output System: Overview Scissor Lift Linear Drive Pushing Arm Limit Switch Brushless Motor
- 25. Output: Machine Requirements Vmax = 0.3 m/s a = 0.15 m/s^2 Time = 4 s Torque = 2.28 Nm Load: 28.9 kg Travel Distance: 0.6m
- 26. Sensors at Output Completion of tray loading onto output hit limit switch signaling: -Input push arm to begin new cycle -Lift adjusts height to correct level of cart Open Switch Closed Switch
- 27. Lifts Control - Powered by Hydraulic System - Programmed controller with height variation cycle Courtesy of Presto Lifts
- 28. Timing Diagram Rise input stack of trays Push tray on to conveyor Dispense individual row of seeds Tray arrival at output lift Lower / raise tray to cart levels Conveyer Travel = 2.5s Raising = 1.5s (Occurs during previous cycle) Full Tray Dispensing = 19s Trigger: Gated tray side + Roller limit switch Conveyer Travel = 11.8s Trigger: Return of push arm to retracted position + limit switch Unloading = 8s Trigger: Loading of output lift + limit switch Loading completion triggers limit switch Max travel = 6.3s Ave travel = 4.4s Load tray on cart Return to “home” position Loading = 8s Max travel = 6.3s Ave travel = 4.4s Average Cycle Time = 54.1s Programmed Controller
- 29. Timing Diagram Rise input stack of trays Push tray on to conveyor Dispense individual row of seeds Tray arrival at output lift Lower / raise tray to cart levels Conveyer Travel = 2.5s Raising = 1.5s (Occurs during previous cycle) Trigger: Return of push arm to retracted position + limit switch Full Tray Dispensing = 19s Trigger: Gated tray side + Roller limit switch Conveyer Travel = 11.8s Unloading = 8s Trigger: Loading of output lift + limit switch Loading completion triggers limit switch Max travel = 6.3s Ave travel = 4.4s Load tray on cart Return to “home” position Loading = 4s Max travel = 6.3s Ave travel = 4.4s Average Cycle Time = 54.1s Programmed Controller
- 30. Timing Diagram Rise input stack of trays Push tray on to conveyor Dispense individual row of seeds Tray arrival at output lift Lower / raise tray to cart levels Conveyer Travel = 2.5s Raising = 1.5s (Occurs during previous cycle) Full Tray Dispensing = 19s Trigger: Gated tray side + Roller limit switch Conveyer Travel = 11.8s Trigger: Return of push arm to retracted position + limit switch Unloading = 8s Trigger: Loading of output lift + limit switch Loading completion triggers limit switch Max travel = 6.3s Ave travel = 4.4s Load tray on cart Return to “home” position Loading = 8s Max travel = 6.3s Ave travel = 4.4s Average Cycle Time = 54.1s Programmed Controller
- 31. Timing Diagram Rise input stack of trays Push tray on to conveyor Dispense individual row of seeds Tray arrival at output lift Lower / raise tray to cart levels Conveyer Travel = 2.5s Raising = 1.5s (Occurs during previous cycle) Full Tray Dispensing = 19s Trigger: Gated tray side + Roller limit switch Conveyer Travel = 11.8s Trigger: Return of push arm to retracted position + limit switch Unloading = 8s Trigger: Loading of output lift + limit switch Loading completion triggers limit switch Max travel = 6.3s Ave travel = 4.4s Load tray on cart Return to “home” position Loading = 8s Max travel = 6.3s Ave travel = 4.4s Average Cycle Time = 54.1s Programmed Controller
- 32. Timing Diagram Rise input stack of trays Push tray on to conveyor Dispense individual row of seeds Tray arrival at output lift Lower / raise tray to cart levels Conveyer Travel = 2.5s Raising = 1.5s (Occurs during previous cycle) Full Tray Dispensing = 19s Trigger: Gated tray side + Roller limit switch Conveyer Travel = 11.8s Trigger: Return of push arm to retracted position + limit switch Unloading = 8s Trigger: Loading of output lift + limit switch Loading completion triggers limit switch Load tray on cart Return to “home” position Loading = 8s Max total= 20.6 s Avg totall = 16..4s Average Cycle Time = 54.1s Programmed Controller
- 33. User Interface -Power On / Off -Emergency Shut off -Master Reset -Returns all lifts, push arms, etc to “home” position - Manual/Auto - Switch to manually control output scissor lift. POWER AUTO MANUAL RESET 1 0 8 9 4 5 6 2 3 EMERGENCY SHUTOFF 0)Home 1)Level 1 2)Level 2 3)Level 3 4)Level 4 5)Level 5 6)Level 6 7)Level 7 7 ENTE R CNCL
- 34. Components Company Part Number Qty Unit Price Total Cost Cart Wheels Misumi CLGK65-G 4 $98.52 $394.08 Linear Drive (1.2m stroke) Thomson WM06S050-01200-01630AS-0000 1 $3,077.00 $3,077.00 Linear Drive (0.6 m stroke) Thomson WM06S050-00600-00990AS-0000 1 $2,477.00 $2,477.00 Stepper Motor Lin Engineering 4018X-07 1 $40.00 $40.00 DC Brushless Motor Aerotech BM500 1 $1,195.40 $1,195.40 Scissors Lift Presto Lift DXS60-20 2 $7,837.76 $15,675.52 Conveyor Misumi CVSX-500-2000-90-TA115-IM-75-H 1 $2,842.00 $2,842.00 Compact Limit Switch McMaster Carr 7988K2 1 $28.87 $28.87 Snap-Acting Limit Switch McMaster Carr 7510T12 2 $5.57 $11.14 Polyethylene Rod (3 ft) McMaster Carr 8754K76 1 $40.48 $40.48 Stainless Steel Sheet (100"x48") McMaster Carr 8983K358 15 $606.31 $9,094.65 Stainless Steel Bar (1" Thick, 2' long) McMaster Carr 8992K167 2 $78.91 $157.82 Stainless Steel Rod (d=3", l = 6ft) McMaster Carr 89535K75 4 $490.02 $1,960.08 Fasteners (Nuts, Bolts) McMaster Carr Multiple 110 $160 $160.00 Trough: 16875 in^3 SS McMaster Carr 8992K908 31 279.3 $8,658.30 Extraneous Costs Estimate - - 1 30000 $30,000.00 Total $78,202.34 Bill of Materials
- 35. Financial Justification: Bill of Materials Total Development Cost = $462,200 4 Engineers working at 40 hours/wk for 6 months Assumptions made: ● 2 months Preliminary Design ● 2 months Final Design & Testing ● 2 months Assembly & Integration Extraneous Costs Include ● Milling cost for cart, trough, and input output stands
- 36. Financial Justification Development Cost: $462,200 Annual Maintenance: $7,820 Operation Costs: $50,000 Payback Time: 1.48 yrs NPV (5yrs): $1.094M Annual Tray Production: 138,410 Annual Savings: $319,094.270 1 2 3 4 5 Year Cummulative Cash Flow
- 37. Concluding Points Improvements to the system: Trough Shaker Prevents seed clogging Tray Centering Account for disruptions along conveyor Output Arm Design Allow for flexibility of cart placement
- 39. Questions?
- 40. Appendix
- 41. Input & Output Motor Specifications * Motors from Aerotech
- 42. Motor Sizing Calculations Tray F F_friction FBD: Component Mass (kg) Carriage 0.36 Pusher 4.49 Tray 24.1 Total 28.95 INPUT (x = 1.2m, t = 8 sec) τ linear (Nm) 2.30 τ rotary (Nm) 0.01 τ min (Nm) 2.31 OUTPUT (x = 0.6m t = 4 sec) τ linear (Nm) 2.28 τ rotary (Nm) 0.0015 τ min (Nm) 2.28
- 43. Dispenser Motor Specifications *From Lin Engineering
- 44. Stepper Motor Sizing Roller θ(°) 90 Time (sec) 0.01 J motor (kgm^2) 1.39E-04 τ min (Nm) 0.063 Seeding Hole
- 45. Scissors Lift Specifications Courtesy of Presto Lifts
- 46. Output Lift Program Pseudocode >Move lift to desired level >Hold lift position >Trigger linear drive >Return drive carriage to home >Lower lift level to home
- 47. Linear Drive Specifications Input (Model No. WM06S050_01200): Stroke Length: 1.2 m Lead: 50 mm Screw Diameter: 20 mm J Screw: 0.0021 kgm^2 Output (Model No. WM06S050_00600): Stroke Length: 0.6 m Lead: 50 mm Screw Diameter: 20 mm J Screw: 0.0020 kgm^2 From Thomson Linear
- 49. Timing Diagram Extras Function Time (s) Raise Input tray 0.5 Transfer tray to conveyor 8 Dispense Seeds 40 Raise output lift 6.3 Transfer tray to cart 4 Max Cycle Time (1 Tray) 58.8 Cycle Time (10 Trays) 561.5 Shelf No. Time(s) 10 (Top) 6.3 9 5 8 3.8 7 2.5 6 (Start) 0 5 1.3 4 2.5 3 3.8 2 5 1 (Bottom) 6.3 Raise Input Cart Transfer to Conveyor Dispense Seeds & Transfer to Lift Raise Output Lift Raise Output Lift
Editor's Notes
- We will begin our presentation by talking about the different parameters and requirements we were given on how they influenced our design process Then we will break down and explain the details of our final design choice And finish off with the expected financial impact of our automated seeding machine.
- To begin designing we first looked at our customer requirements The overall task was to take a tray from a stack of ten, fill each planter tray with a single seed in each hole, then stack the tray on an output cart with a cycle time no greater than 90s. The customer also included details such as the dimensions and geometry of the tray and size of each seed. An additional piece of information we acquired from the customer was that the output cart should have an ovrhead space of 5cm above each tray
- Jeremy Focus on tray input and output functions.
- Operator puts stack into place Input system holds stack PICTURES INSTEAD OF WORDS Dispenser Sensing-sense that tray is there Transport to seed deispenser
- Jeremy
- Jeremy Prelimiary;s
- jEremy
- Frank
- Frank
- Frank
- Frank
- Frank
- Event chart postition to position. Velocity profile chart --with velocity or timing values. Torque. Place numbers and calculations in the appendix.
- -Forward motion of push arm begins when signaled received from output lift -Input lift raises a level upon push arm returning to retracted position
- PEte
- Peter
- same notes
- 1.7 cm gaps. circuit is completed when switch in gap TOP VIEW snapshots: when in and switch is completed, when roller out
- Jeremy
- position profile velocity profile loads Torque needed, motor choice
- This timing diagram maps out the the one complete cycle of a tray, beginning at the input stack and ending on its respective level of the output cart. The average cycle time for a single tray with our machine would be 54.1 seconds. (54.1 for first tray and 41.3s for every tray after that)
- At the input, the raising of the tray to the level of the conveyor will be triggered by the pusharm returning to its contracted postition. This process will take 1.5s but because it occurs during the previous cycle, it does not contribute to the overall cycle time. After recieving a signal from the output system, the pusharm will proceed to transfer the tray on to the conveyor taking 8 seconds.
- The tray will then travel for 2.5 seconds before it reaches the seed dispenser. The tray will then take 19 seconds to be completely loaded with seeds truggered by the gated stray side and the roller limit switch peter previouly spoke about.
- After loading is completed the tray will travel for another 11.8 seconds as it is transferred off the conveyor onto the output lift. When the tray is fully loaded, it will his a limit switch which tells the pusharm to unload another tray at the input, and the limit switch also enables our programmed controller to take over.
- The programmed controller tells the output lift what height to travel to, when the linear drive should unload the tray onto the cart. This will take a maximum of a6.6 seconds for the highest and lowest levels, or an average time of 12.8 seconds.
- Our automated seed dispenser will also feature a user interface that includes a power on/off switch, and emergency shut off button, and a master reset button which will return all lifts to the height of the conveyour belt and the pusharm to its retracted position.
- calculating maintenance. ook at harsh environments conveyor = 6% of cost bearing life for roller- good. estimating engineering hours = our own time construction, software, testing validation, break it down time of construction-
- Shireen
- Coefficient of friction steel on steel: 0.8
- take away charts and below each steps do time, different slide to highlight step of interest what makes it start (trigger) -> next step any important info can be placed underneath