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Laser Extinction Measurement System (LEMS) Group Members: Jack Copenhaver Kara Griffin Billy Holland Tiruneh Haile Faculty Advisor: Dr. Jie Chen Sponsor: Dr. Siva S. Krishnan Capstone Design Project, SP 2006 Slide 2 Overview Introduction Planning the Project Customer Requirements & Project Objectives Benchmarks Concept Development & Design Final Design Design Validation Overall Product Design Evaluation Recommendations Acknowledgements Summary Slide 3 Customers Dr. Siva S. Krishnan, Professor Manish K. Saini, Research Assistant Slide 4 Laser Extinction Device Laser Horizontal Knob Vertical Knob Burner Slide 5 Planning the Project Gantt Chart Slide 6 Customer Requirements & Project Objectives Align the Laser to the Burner Improve Safety Improve Accuracy More Ergonomic Cost Effective Decrease Experiment Time Slide 7 Problems with Benchmark Slide 8 Concept Development & Design 1. Design Concepts Motorized Vertical & Horizontal Travel Motorized Vertical Travel with Manual Horizontal Travel Manual Extension on Vertical Travel 2. Alignment Procedure Slide 9 Concept #1 Slide 10 Concept #2 Slide 11 Concept #3 Slide 12 Alignment Procedure Alignment Target Normalize the laser to the burner surface Put the goggles on to view laser beam Use the LabView program to move the burner until the laser is aligned on the target Move the burner in the positive vertical direction 76.2 millimeters. Open COSMOS program provided by Velmex and set the zero position Zero Position Slide 13 Final Design Concept Cost MANUAL TO MOTORIZED CONVERSION KIT MMC-23-0050 $95.00 MANUAL TO MOTORIZED CONVERSION KIT MMC-23-0100 $95.00 VEXTA PK266-03A STEP MOTOR 5-0982 $155.00 VEXTA PK266-03B STEP MOTOR 5-0983 $165.00 D6CL DAMPER FOR TYPE 23 STEPPER MOTORS $88.00 VXM-2 PROGRAMMABLE STEP MTR CNTRL,2 AXIS $785.00 Total Cost$1,383 Slide 14 Design Validation BenefitsPer Experiment Fuel Savings $25 - $50 Oxygen O 2 Savings $50 - $75 Improved Time 45 min 1hr Improved AccuracyFrom 0.1 mm *********************************************************** More Ergonomic Enhanced Safety Cost Effective Slide 15 Overall Product Design Evaluation Slide 16 Summary Concept #1 Overall Benefits Best Overall Concept Improved Safety Improved Accuracy More Ergonomic Decreased Experiment Time Added Benefits Fuel Savings Cost Effective - Return on Investment ($$$) Slide 17 Recommendations Motorize Laser Closed Loop Feedback System Slide 18 Acknowledgments Dr. Jie Chen, Faculty Advisor Dr. Siva S. Krishnan, Sponsor and IUPUI Professor Mr. Rudy Earlson, Manufacturing Consultant Mr. Eric Docteur, Velmex Inc. Mr. Manish K. Saini, Graduate Research Assistant Mr. Mitch Evans, Velmex Inc. Slide 19 Questions? Slide 20 Design Validation Target Values Old LEMS Design New LEMS Design Laser Alignment Time (min.) 120.5 Burner Alignment Time (min.) 2.550.5 Laser Alignment Process Easability (steps) 363 Burner Alignment Process Easability (steps) 362 Time to Move Burner (min.) 2.550.833 Number Of Steps to Move Burner (steps) 242 Knob Position (Distance from Operator) (m) 01.10 Slide 21 Failure Modes OperationalCharacteristics Mode of Failure No.ObjectPotential Failure Potential Causes of Failure Potential Effects of Failure 1X-axis MotorBurn OutOverworked, old Research Delay, Delays Use of Bislides 2Y-axis MotorBurn OutOverworked, old Research Delay, Delays Use of Bislides 3ControllerCircuit FailureOverworked, old Complete Shut Down of System 4 Lead Screw Vertical Worn Out Vertical Limit Switch Failure Complete Shut Down of Vertical Slide. Horizontal would Still be Operational 5 Lead Screw horizontal Worn Out Horizontal Limit Switch Failure Complete Shut Down of Horizontal Slide. Vertical Slide would Still be Operational 6 Lab View Program Burn Out Motors and Damage to Limit Switches Improper Input Data for Motor Specifications Complete Shut Down of System Slide 22 Slide 23