Electronic Module Extraction Tool - PowerPoint PPT Presentation

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Electronic Module Extraction Tool

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Electronic Module Extraction Tool – PowerPoint PPT presentation

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Title: Electronic Module Extraction Tool


1
Electronic Module Extraction Tool
  • Final Review
  • University of Delaware
  • December 12, 2003
  • Team 7 Allison Bruton, John Fitzgibbons Rich
    Herseim, Greg Spalding
  • Sponsors John Dean Ann Rickle

2
Outline
  • Project Background
  • Benchmarking Summary
  • Project Scope
  • Preliminary Concepts
  • Design Recommendations
  • Extraction Tool
  • Testing and Analysis
  • Project Management
  • Transition Plan
  • Questions

3
Project Background
  • Northrop Grumman
  • Worldwide leader in global defense electronic
    systems
  • No handheld tools exist for extraction of
    electronic modules in horizontal configuration
  • Purpose of tool
  • Extract electronic modules within tight tolerance
    for repair

Cap Board
Ceramic Base
Ring Frame
Electronic Module
Module size relative to half dollar
4
Critical Issues
  • Tight Spacing
  • Fragile Parts
  • Module is composed of metallic non-metallic
    layers

Cap Board Non-Metallic
Ring Frame Metallic
Ceramic Base Non-Metallic
Side View of Electronic Module
5
Constraints
  • Minimize damage to cap board module
  • Maintain tight position tolerance
  • Meet OSHA regulations

6
Mission Statement
  • To design a handheld extraction tool for
    electronic modules

7
Lessons Learned from Benchmarking
  • Phase One
  • Variety of Integrated Circuit (IC) extractor
    devices on the market

Dual In-Line Package IC Extractor Tool
Advanced Tweezer Extractor
Basic IC Extractor
Self-Contained Vacuum Pickup Tool
8
Lessons Learned from Benchmarking (continued)
  • Phase Two
  • Gained greater understanding of
  • Material properties of each layer within
    electronic module
  • Electromagnets
  • Magnetic analysis
  • Phase Three
  • Gained greater understanding of
  • Ergonomic design - OSHA
  • Magnet pull force
  • Plate analysis

Rare Earth Magnet
Electromagnet
9
Customers, Wants Metrics
Wants
Target Value
Extraction force (lb)
gt3.6 Stress on ring frame (psi)
lt50,000 Bending force on pins/tubes (lb)
lt0.17 Tolerance fit check Yes
Metrics
10
Project Scope
Repair System
Design recommendations for new electronic module
Repair Operation
Operation Manual
Ergonomics
Extract Module
Extractor
Interface
Force Application
Simple Superstructure
11
4 Preliminary Concepts
2 Concept Finalists
  • Clamping Device
  • Physical testing proved required extraction force
    (3.6 lbs) was not met
  • Hook Device
  • Analysis predicted tool interface would deform
  • Suction Device
  • Interaction between
  • suction cap board could damage module
  • Magnetic Device
  • Needed further investigation
  • After further development

12
Design recommendations for electronic module
  • Ceramic Board
  • Two chamfered corners
  • Allows pin placement
  • Capboard
  • Cutouts
  • Accommodates magnetic interface
  • Capacitors and Fuses
  • Realignment
  • Optimizes capboard cutouts

Capacitors Fuses
Cap Board
Ring Frame
Ceramic Base
Revised Electronic Module
13
Extraction Tool Prototype
  • Force Application
  • Human powered
  • Push rod and knob
  • Superstructure
  • Linear ball bearing
  • Linear guides
  • Support pins
  • Magnetic Interface
  • Rare earth magnets

14
Extraction Tool - Operation
3 Simple Steps
  • Obtain proper extraction position
  • 2) Compress knob until contact is made with the
    exposed ring frame
  • 3)Pull knob up extracting the module

15
Extraction Tool - Operation
16
Testing and Analysis
  • Magnetic Interface Test
  • Finite Element Analysis on Ring Frame
  • Bending Analysis
  • Tolerance Fit Check

17
Magnetic Interface Test
  • Purpose
  • Prove that the magnetic interface can withstand
    the required extraction force

F
Load Cell
Magnet Holder
Ring Frame
Tested Magnet Sample .25 Dia x .75
Test Fixture
18
Magnetic Interface Test
Required 3.6 lbs
Metric Target Value Satisfied
5.4 lbs
  • Extraction
  • force gt 3.6 lbs
  • Conclusion
  • Extraction force of 5.4 lbs achieved
  • Safety factor of 1.5 provided

19
FEA Ring Frame
  • Purpose
  • Prove that the maximum stress in the ring frame
    is below its yield strength

Metric Target Value Satisfied
  • Max stress in
  • the ring frame
  • lt 50,000 psi

Magnet Locations
Stress Distribution
  • Conclusion
  • Maximum stress present in the ring frame 14,000
    psi
  • Safety Factor of 3.57 provided

20
Bending Analysis
  • Purpose
  • Prove that the ceramic base deflection will not
    plastically yield the module pins

Metric Target Value Satisfied
  • Force on
  • pins lt
  • 0.17 lbs
  • Conclusion
  • Worst ceramic deflection 1.82 E-4 in.
  • Resultant force on pins 0.00025 lbs
  • Provides a safety factor gtgt10

21
Tolerance Fit Check
  • Purpose
  • Prove that the support pins of the extraction
    tool fit in the four corners of the rapid
    prototype module

Rapid Prototype Module
Support Pins
  • Conclusion
  • Passed tolerance fit check

Tool Fit Check
22
Device Ergonomics
Tool Design
Knob
2.0
Proper neutral wrist position
Horizontal work surface
  • 2.0 diameter fell within acceptable diameter
    range for power grip use
  • Met OSHA regulations
  • Appropriately designed hand tool so wrist can
    remain straight
  • Met OSHA recommendations

23
Project Completed in a Team Effort
Development
Analysis
Testing Prototyping
24
Project Management Cost Summary
Quantity Description Total Price ()
2 Push Rods 12
20 Neodymium Magnets 66
1 Linear Ball Bearing 43
2 Miniature Guide Block 110
2 Rail for Mini Guide Block 42
58 Screws Washers 16
2 Knob 6
8 Support Pins 23
2 Handles 6
10 parts Northrop Grumman Machining 5,000
Actual Cost 5,324
800 hrs Team 7 Labor Costs _at_ 20/hr 16,000
Theoretical Cost 21,324
25
Transition Plan
  • Operation Manual
  • Ergonomic issues
  • Improved handle design
  • Tool Alterations
  • Improved support pins
  • Reduced tool weight
  • Limited linear motion
  • Module Recommendations
  • Ceramic chamfers
  • Cap board redesign

Capacitors Fuses
Cap Board
Ring Frame
Ceramic Base
26
Summary
  • Reviewed Project Background
  • Explored Benchmarking
  • Presented Project Scope
  • Explored Preliminary Concepts
  • Provided Design Recommendations
  • Discussed Extraction Tool
  • Demonstrated Analysis Testing
  • Discussed Project Management
  • Presented Transition Plan

27
Acknowledgements
  • Northrop Grumman Sponsors
  • John Dean Ann Rickle
  • Advisor Dr. Wilkins
  • Senior Design Staff
  • Dr. Glancey
  • Dr. Keefe
  • Mr. Cloud
  • Steve Beard
  • Roger Stahl

28
Questions???
29
Extraction Force Calculation
Extraction Force 0.11 lbs
Connector Type Total Required Extraction Force (lbs) Total Required Extraction Force (lbs)
RF 5 0.5 2.5
Pin 10 0.11 1.10

Total -- -- 3.6
30
Temperature Consideration
  • Maximum required operating temperature of
    extraction tool
  • Neodymium Iron Boron rare earth magnets maximum
    operating temperature

60oC
80oC
31
Extraction Tool Fabricated Parts
Before
After
Top
Push Rod
Side
Coupler
Bottom
Magnet Holder
32
Clamping Interface Test
Max Extraction Force 3.5 lbs lt 3.6 lbs
Required 3.6lbs
33
FEA Clamping Force
Compressive Forces on Ring Frame
Stress Distribution
Max stress 4000 psi ltlt 50000 psi (ring frame)
34
Ring Frame Used in Clamping Test
Actual Ring Frame
Tested Ring Frame
35
Extraction vs. Insertion
  • Insertion is considered a small hand operation
  • Easier to insert correctly than extract
  • Northrop Grumman main focus is extraction

36
Magnet Interface Testing
¼ the Required Extraction Force
1.6 lbs
37
Tolerance Analysis
  • Purpose
  • Prove that the support pins of the extraction
    tool fit in the four corners of the 0.017 in2
    area tolerance

Metric Target Value Satisfied
  • Tool support pins fit in the 0.017 in2 area
    tolerance

Support Pin Tolerances
38
Linear Motion Test
  • Purpose
  • Ensure magnets move in a linear fashion
  • Results
  • Max deflection at magnet holder 0.0035
  • Conclusion
  • Tool will extract in a linear fashion

Dial Indicator
Magnet Holder
Test Set Up
39
Cost Perspective
40
Basic Design Features
  • Grip/Handle-User Interface
  • Extraction Structure
  • Module-Tool Interface

41
Extraction Tool - Prototype
Knob
Linear Bearing
Handle
Magnets
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