Multi-function Vector Bar

Transcription

1 Multi-function Vector Bar December 15, :00-9:30 AM Kristen Domboski Andrea Liem Ray McCauley Mike Morton

2 SURVICE Engineering Specialist in combat system survivability, weapon system effectiveness, and system safety. SURVICE Metrology division is expanding upon the companies use and expertise with high-end laser-based dimensional inspection equipment, and has established a substantial R&D capability, and is currently working a number of US Department of Defense research grants.

3 Design Goal/ Objective: To improve the set-up and use of the igps laser-based metrology system vector bar. The intent is to develop a next-generation system that automatically recognizes and reconfigures itself based upon extensions and tools selected for use to support streamlined maintenance of next-generation composite aircraft. 3

4 Design Process

5 Current Vector Metrology Bar

6 Design Guidelines/ Requirements Enhance the existing Metris metrology-grade vector bar (small version) to: Support removable/reconfigurable tips To include ultrasonic sensor with quick disconnect Relocate igps sensors Limit operator hand/arm from blocking line-of-sight to transmitters while maintaining smaller profile/design. Must have 2 sensors 6

7 Design Guidelines/ Requirements Integrate multi-color LED indicators Integrate multi-button operation (using USB connection to PC) Provide ergonomic packaging/grip Consolidate wiring Aesthetics (including logos and theme colors) Rigid and User-friendly

8 Concepts A, B, and C Concept A: Vector Bar with Pistol Grip Concept B: Interchangeable Vector Bar With Pistol Grip and Trigger Concept C: Vector Bar With Raised Area for Buttons

9 Three concept ideas were identified. Concept Selection Metrics, costs and benchmarking were considered for each concept and were compared to and given a numerical rating. From these ratings, an overall score was given

10 Vector Bar Prototype Drawings Here the vector bar is shown with a UT sensor tip. Here the vector bar is shown with a pointed sensor tip. 10

11 Overview of Sub-systems There are FOUR Subsystems: I. Ergonomic Handle explained by Kristen II. Main Hollow Cylinder explained by Mike III.Sensor Tip explained by Ray IV.Sensors explained by Andrea Subsystem IV Subsystem I Subsystem II Subsystem III 11

12 Ergonomic Handle 2 nd Iteration 1 st Iteration 3 rd Iteration Final Prototype 12

13 Ergonomic Handle 1 st Iteration Handle Clay Modeling Trail and Error modeling Team SURVICE opinions used for analysis 2 nd Iteration Handle Finger grips sizes Button placement Made by 3D printing University of Delaware Biomechanical Engineers department consulted to analyze design 13

14 Ergonomic Handle 3 rd Iteration Reflects changes made by anthropometrics research and biomechanical engineering recommendations Made by 3D printing Ring and Pinkie finger space merged to allow for a variety of hand sizes Grip size changed to increase grip strength Grip expanded and grip angle changed to increase stability during use 14

15 Ergonomic Handle Prototype Handle Reflects changes made after speaking with SURVICE Engineers Made in ABS plastic Trigger button changed Wire placement changed to reflect product availability 15

16 Inside Handle Grip USB I/O interface located in the center of the handle This will incorporate the igps sensors, LEDs, buttons, and tip recognition into one wire. White USB wire and black UT cable will exit through the bottom of the handle into plastic tubing.

17 Main Bar Sub-System The main bar connects all of the major components: Threads on the front of the main bar allow a sleeve screw to connect the multiple tips. Two screws go through the top of the bar into the handle grip to secure the bar in place. A screw coming out of the back of the main bar connects the igps sensors.

18 Sensor Tips Tip Sensors Three sensors Eight possible tip configurations Uses USB Conductive Contacts Quick Interchangeable Tips Nylon Tip Ultrasound Transducer - Effective area of ¼ inch UT Sensor Nylon Tip

19 Sensors Mini-Vector Bar Sensor Bought from Metris Part Number: # Cost: $ 4,950? Why did we buy this particular sensor? Ideal Size Ideal Shape Ideal Weight 19

20 Sensors Drawing from Metris

21 Mini Vector Bar Sensor Fastening 21

22 Prototype Design

23 Prototype Design 23

24 Test Results: Dimensions & Weight Length of Vector Target Value: less than or equal to 12 Actual Value: 12 Diameter of Vector Bar Target Value: less than 1.5 Actual Value: 1 Weight of Vector Bar Target Value: less than or equal to 3 lbs. Actual Value: lbs. 24

25 Test Results: Center of Gravity 25

26 Test Results Number of Wire Ports Target Value: 1 wire port Actual Value: 1 wire port Number of Mouse Buttons Target Value: 2 buttons Actual Value: 2 buttons Complexity of Device Target Value: less than 5 subsystems Actual Value: 4 subsystems Cost of Prototype Target Value: less than $10,000 Actual Value: The projected hardware unit cost is roughly $7,000. from David J. Turner of SURVICE 26

27 Design Criteria Met Ultrasonic Sensor 2 Sensors Multi-color LED lights Ergonomic Handle Grip Aesthetics (logo and colors) 27

28 Expense Costs Items Actual Cost Prototype Cost igps Sensor Transducer Rapid Prototyping Hardware Aesthetics Total $ 5882 $

29 Future Path Forward Left-hand users Accuracy & Tolerance of Metal Tip Sensors Calibration & Testing of the Vector Bar Programming the USB I/O interface Software Programming Ultrasonic Tip Sensor with wire coming straight out of the back igps mini-vector bar sensors with wire coming straight out of the back

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31 Additional Pictures

32 Additional Pictures

33 Detailed Expense Costs Part Actual Cost Prototype Cost igps sensor UT Sensor UT holder Handle LED Lights Buttons Engraving Sleving Screws Screws More Screws USB Random parts Sub totals AL Bar 20 0 Student Meetings Shipping Total