Insulation Measuring and Cutting Module

The goal of the project is to design and build a module that scans a work order, determines a desired length, measures insulation to that length, and cuts it without any human input required.

=Project Definition=

The purpose of this project is to create an automated process that accurately measures and cuts insulation to desired tolerances, while minimizing cost and time.

Background
A large amount of energy is spent on heating the fluids that run throughout airplanes. Insulation is used to reduce this cost and decrease the chance of component failure due to unwanted heat transfer. In order ensure that all components function properly this insulation must fall within a certain tolerance. Currently in the Boeing Tubing, Duct, and Reservoir Center there is not an automated process for cutting expensive insulation to a desired length, which leaves the task open to inconsistencies and human error. Our client would like to minimize

Deliverables
Design a system which can accept a barcode input to automatically set length of tube insulation cut. The system will pull the insulation through the measuring system free of human intervention, then cut the insulation to size. Module will then fully eject cut insulation from system.

Functional Requirements
Module will be encased and safe for all human operators. Module will cut insulation to a tolerance of +/- 0.3" of desired length. The operator should not have to physically cut or measure any insulation throughout this process. This system should take less time than the current method of cutting. Intake insulation smoothly and not get caught or stuck. Keep insulation loaded once a new box has been placed inside of it. Measure and cut insulation to a desired length. Fully eject insulation from contraption. The system should know when there is no insulation in the system and act accordingly i.e. stop and notify the operator. Able to make angled cuts based on the bends in the tube.

Cutter Requirements
The cutter must be able to cut straight through the insulation without debris. The cutter may not alter the insulation’s integrity. The cutter must be able to cut through insulation that is 2.5”-3” OD. Cutter must be reusable for 100,000 cuts and easy to replace. Optional: Must adjust the angle cut based on the bend in tube.

Scanner Requirements
The scanner should be the standard model used by The Boeing Company (provided by Sponsor). Scanner must connect to system through a USB. Scanner must be able to differentiate barcodes and input length measurements to system correctly. 3 numbers, a letter, 4 numbers, a – and anywhere between 1 number and 4 numbers.

Measuring Requirements
Measure the insulation within +/- 0.270” tolerance. Measure insulation at maximum 118”. Measure insulation at minimum 3.5”. The systematic error should be no more than 1%.

Electrical Requirements
Wiring will be grounded and insulated properly. All wiring will be soldered into a circuit board. Circuit(s) will be put into a case to protect them from environmental and human factors. Contraption will be able to plug into a 120V AC socket.

Software Requirements
Interface touchpad with measurement system to allow length input. Interface scanner with measurement system to allow length input. The software should use the information from the touchpad/scanner to control measuring/cutting systems. Program has a consistent output for a given input. Must be able to be constantly and easily updated with new barcodes.

Spatial Requirements
Module length will not exceed 6’. Module width will not exceed 2’. Module height/width ratio will not exceed 1/3. Measuring and Cutting mechanisms will be visible from outside the unit. The module will have easy access to the circuitry and mechanical components for maintenance.

Safety Requirements
Pinch Points will be marked. All sharp edges will be covered or marked. Emergency Shutoff button will be functional. Mechanism will not run or initiate unless all casing is in the correct place.

Cost Requirements
All costs will fall within the budget provided (See budget for cost specifics). The time spent by each individual on this project will not affect the livelihood of said individual. Team members will not spend personal funds on this project.

Schedule Requirements
GANTT Chart will be a live document and updated bi-weekly at a minimum (See GANTT Chart for schedule specifics). The project will be turned into The Boeing Company by May 2020. Work will not be done over Thanksgiving, Christmas, or Spring Breaks unless agreed upon by team members.

=Design Considerations=

Team Insulation Station decided to split our project into four main systems: Programming, Intake, Measuring, and Cutting. The initial thought was to create a system with a hinged wheel intake that used gravity as pressure for holding insulation down, and cutting the insulation with a guillotine contraption.



It was determined that a linear actuator would be better at opening and closing a guillotine contraption.

This shows our design idea with a hinged wheel and a heated wire as the cutting method attached to a linear actuator.

=Project Learning= In the early months of our project, we learned a lot about project management and design setup. We learned how to properly set up a budget, a GANTT chart, a Product Requirements Document, and a Design Validation plan.

On September 30th, 2019, Team Insulation Station took a trip to the Tubing, Duct, and Reservoir Center (TDRC) at the Boeing Factory, and fully learned about their problem and what they needed to do. They developed professional communication skills with real-world engineers.

From their research, they have learned that the insulation they are cutting is non-toxic when cut with a heated wire, and have honed in on their CAD modeling skills.

=Final Design=

=Validation=

=Team Members=

=Additional Documentation=

Project Schedule



Meeting Minutes

Presentations



Client Interview