John Bailey

1
Airbag Automaton

• John Bailey
• Hattie Hiatt
• Chun Hau Low
• Jason Harwood
• Wayne Gallup
• Jason Canaday

2
Presentation Outline

• Problem Definition
• Customer Needs Summary
• Project Breakdown
• ME Subteam Designs
• ECE Subteam Designs
• How They Fit Together
• Deliverables
• Budget
• Work Plan

3
Problem Definition

• Problem Statement
• Autoliv uses a variety of machines to fold and
  package their airbag. These machines take up
  space, capital, and require a new machine design
  for each new folding process.

4
Project Breakdown

• Customer Needs
• Plug and play machine that supports airbag
  folding processes
• 1) SMED tool interface
• 2) Move interface and tooling
• 3) Central Hub that supports all operations of
  folding process

5
Tool Interface Concepts

• Decision Criteria
• Ease of use
• In-house manufacturability
• Cheaper alternative to existing robotic
  interfaces
• Important Design Aspects
• Auto connect/disconnect pneumatic connection
• Rocking docking
• Lock down mechanism

Design Inspiration
Top to Bottom Switch Step in Snowboard
Bindings Walther Tool Master Robotic Tool
Changer Techno-Sommer Robotic Tool
Changer Robotic Accessories Robotic Tool Changer
Applied Robotics in Use at Autoliv
6
Tool Interface Concepts

• Functional Requirements
• Docks tool to machine
• User Locks/Unlocks tool manually
• Hands-free connection of utilities
• Senses secure connection
• Design Criteria
• Usability
• Cost
• SMED
• Two Step Connection Procedure
• Put on
• Lock in

7
Slider Support Concept

• Alternatives for Slider Support
• Roller/Ball Bearings
• Dovetail ways
• Triangular ways
• Closed cylindrical bushings

Slider support using open cylindrical bushings on
precision ground shafts
8
Hub Concept

• Conceptual Design
• Actuator attached to 12 Oclock arm
• Pivot connection depends on arm design
• Tilt connection mounted to Bobcat (base)

9
ME Budget
Item Cost
Linear Guides
Linear Bushings 200
Precision Shafts 500
Aluminum for brackets 50
Tool Interface
Manufacturing Materials 150
Power/Data/Pneumatic Connections (Male/Female) 500
Stainless Steel Rods 50
Hub
Pivot bushings 150
Steel for Pivot Axles 50
Various Fasteners 150
TOTAL COST 1800
10
Tool Positioning System
Requirements Control position of tool within
1/8th inch resolution Move tool to minimize
cycle time but stay within hardware
specifications
11
Hardware Components

• Drive
• Position Sensor
• Controllers

12
Drive
13
Position Sensor

• Requirements
• Minimum velocity of 15 in/s (0.4 m/s)
• Maximum 1/8th inch (3 mm) resolution
• Measurement range of 600mm

Sensor Options
14
Controller
Currently researching -Programmable Logic
Controller -Microcontrollers
15
Tool Controller

• Controls tool movements
• Tool identification
• Computer requests tool ID or
• Tool sends ID at interface connect

16
ECE Budget
Drive 1200 Motor 1000 Controllers 15
0 Position Sensor 500 Cables 300 Other
Discrete Electronics 100___ Total 3250
17
Putting it all Together
18
Team Design Deliverables

• SMED tool interface
• Single arm assembly
• Hub System
• Accommodates 3 arms, Linak tilt system and
  routes utility cables
• Tool identification system
• Proof Of Concept tool recognition and automatic
  program download
• Tool positioning control

19
Team Documentation Deliverables

• Complete set of engineering drawings of custom
  parts and product information for manufactured
  parts
• Repeatability testing
• Failure and Fatigue analysis with predicted
  machine lifetime
• Electrical circuit diagrams control models

20
AIRBAG AUTOMATON Design Schedule
21
AIRBAG AUTOMATONOverall Budget
ME Budget 1800
ECE Budget 3250
Miscellaneous Costs 400
Total Cost 5450