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Paper Folding Device

1. 51 Potential Failure 3 Paddle seizing or unmoveable Operating mode when failure could occur Potential Failure Mode Folding and Feeding Ceased mobility of paddle Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 5 5 Potential Cause s Mechanism s of Failure 6 6 Probability of occurrence OCC Current Controls for Detection and Prevention 1 1 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 30 30 1 Include some discussion justification for the rating for severity SEV No danger but device will not function properly and will not complete the task 2 Include some discussion justification for the rating for probability of occurrence OCC As testing is completed and changes can be made this occurrence should be minimal but until prototype is made we ll assume it rather likely to happen eventually or initially 3 Include some discussion justification for the rating for probability of detection DET You will physically and visually be able to tell if the paddle is not moving as the handle will not turn 4 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for completing the actions and the completion date Ensure maintenance is pe
2. rue 12 4 1 Problem Clarifications hee dee 12 4 2 Patent 13 4 3 Concept SNE E 14 3 0 Concept Screening and Evaluation 22 6 0 Final 24 7 0 Prototype Design Development and Testing 26 E ME E He ExXDp erIments uu ENEE SEENEN 29 7 3 Prototype Construction 33 M 37 8 0 Final Design Design 39 Sch Do c 39 62 Design Refinement sesruro ii iien IER EE RAO TA 42 Eegen eg 43 O n 44 UE EE 45 M 46 EE EUN DRE RED A 46 A2 FEA Detalls dee gege EE EE EEN EE 55 A3 Cost e ET 61 DUE 66 A5 Assembly Part c 77 1 0 Introduction The basis of this report is founded on the general idea that many citizens throughout the world are disabled and are seeking employment assistance Being physically or mentally handicapped makes it difficult for individuals to perform tasks
3. Operating mode when failure could occur Potential Failure Mode During rotation of paddle Pins plates seize Rating Level 0 5 5 being the most severe Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 6 6 Potential Cause s Mechanism s of Failure 5 2 Probability of occurrence OCC Current Controls for Detection and Prevention 6 6 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 180 72 1 Include some discussion justification for the rating for severity SEV This is the main working mechanism in the design If it fails to move the paper cannot be folded although failure would be resolved with a simple fix 2 Include some discussion justification for the rating for probability of occurrence OCC There is bound to be dust and dirt build up and will require some lubrication otherwise this could potentially happen often 3 Include some discussion justification for the rating for probability of detection DET It s easy to detect because the plates will stop moving which would indicate failure This can be prevented with proper maintenance 4 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for completing the actions and the completion date Recommend
4. Using the initial customer needs list a more specific hierarchal customer needs list was created This list shows more specific needs to better define the customer requirements The information in this list was created using benchmarking research and the discussions with the workers at Mail Plus Table 2 2 Hierarchal Customer Needs List Flatten 1 1 5 8 thick Fold 2 1 Z Fold 2 2 Fold variability Stuff in Envelope Ease of Use 4 Manually driven Safety 5 No sharp corners 5 2 No pinch points 5 3 No additional safety equipment required Quality 6 1 Design life of machine 6 2 Finished product low failure rate Speed 7 1 Maintain productivity with someone with less than 100 functionality Staples 8 1 Fold with stables in paper 8 2 Flatten with staples in paper Size 9 1 Fit on table top 9 2 Store easily 10 Weight 10 1 Easy mobility 10 2 Storage 11 Appearance 2 1 Weighting of Customer Needs Table 2 3 was constructed to define the importance of each requirement for the customer These values were determined during team discussions and benchmarking The team rated the requirements one through five with one being the least important and five being the most important The ratings were based on the observations and discussions with the works at Mail Plus Table 2 3 Requirement Importance Flatten 5 2 2 Revised Needs Statement Create a low cost device for SW Resources to fold Wally s amp Wimpy
5. B REVISION HISTORY REV DESCRIPTION DATE APPROVED Lowe TE 080909 TEAM CATALYST Seen Qu Unversity Senior Design Team 2 SUE OWC NO UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 21 0 3 PL 0005 FILE NAME 005_BoxBottomipartnumSldft WEIGHT SHEET OF PIECE CUT FROM 1 2 STOCK MEDIUM DENSITY FIBER WOOD LA DETAIL E 500 d TT T T TT m r m c E 14 000 4250 5000 i 5 9 500 A 7750 5 3625 X 9 1 poso 8 REVISION HISTORY REV DESCRIPTION DATE APPROVED INTERIOR RADII 0 125 0 005 mm N DETAIL D COUNTER SUNK 10 SCREW HOLES 4 SETS TYPICAL d 06 09 09 DR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 250 14 20 UNC REVISION HISTORY REV DESCRIPTION DATE APPROVED ER SE TEAM CATALYST Ohio University Senior Design Team 2 Drive Shoft REV UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 SUE OWC NO 10 FILE NAME 007 DriveShaftlpartnum7ldft WEIGHT SHEET OF 2
6. Figure 8 3 Detailed view of the moveable plate and spring loaded feature Figure 8 3 also shows spring loaded feature for bottom moveable plate These springs allowed the plates to return to their original position so that the paper was oriented correctly The correct springs were chosen by determining the proper spring constant that would keep the plate in constant contact with the paddle at all times Tabs on the side of the box were also incorporated to make sure that the bottom plate does not block the slot where the newspaper is inserted The final feature of the design includes the rollers pulley system AC motor and a safety contact switch as seen in Figure 8 4 The rollers are made from a 2 diameter stock of PVC coated with a rubber film for extra friction when pulling the newspaper off of the paddle An AC motor with a built in gear box was used to drive the bottom roller A pulley system was then used to drive the top roller in the opposite direction of the bottom roller Pulleys were used instead of gears because they were cheaper and easier to install While gears would reliable we decided th fabricating our own gears which would have been necessa vould be too costly and time consuming A flexible coupling was used roller to compensate for the misalignment of shafts The main reason for the roller system is to provide the final crease in the z fold and flatten it to the required thickness There is also a contact sw
7. y Y 5250 10 750 15 000 X 438 190 Typical Y CA 138 x4 500 Typical 562 ID ep REVISION HISTORY REV DESCRIPTION DATE APPROVED B pir 1 000 U 28 5 4875 6 750 500 Note dimensions are to nearest edgeline of screw holes 080909 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES LES 3 PL 0005 975 r ek a 13 000 11 500 12 500 REVISION HISTORY REV DESCRIPTION DATE APPROVED PLATE CUT FROM 3 8 THICK STOCK PLATE OF HIGH DENSITY POLY ETHALENE ALL INTERIOR RADII 0 125 0 005 500 8906 7094 6 094 J _ 2 A D 4 500 cy 2 219 4344 K le DI 10 969 wa eh rt 12 750 c T50 Se DETAIL D SLOT CLEARANCE CUT FOR 1 4 DIA STOCK TYPICAL UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 2 0 2 PL 005 3 PL 0005 1 500 750 250 REVISION HISTORY REV DESCRIPTION DATE APPROVED 14 20 UNC CATALYST Ohio University Senior Design Team 2 UNLESS OTHERWISE SPECIFIED DIMENSI
8. Align coupling halves and tighten set screws Cut 4 stainless steel rod for guide pins to length per drawing 9 Insert guide pins into holes in bottom of box Slide springs over guide pins 11 12 Cut HDPE for movable plates per drawings 4 19 Using CNC mill cut slots and groove in movable plates per drawings 4 19 Place bottom movable plate over guide pins on top of springs Cut 2 diameter PVC to length for bushing per drawings 2 Use lathe to drill hole through bushing and groove in bushing per drawing 2 Drill hole for handle guide pin in bushing per drawing 2 Remove top front of outer box Place handle guide pin in bottom front of outer box Remove lever from handle Slide handle through bushing aligning groove in handle with hole in bushing for handle guide pin Insert bushing over handle guide pin and into bottom front of outer box Screw top front of box back in place Reinstall lever onto handle Place top movable plate on guide pins on top of paddle Put springs on guide pins Cut 1 1 2 wide by 1 8 thick aluminum bar stock to length for guide pin supports per drawings Cut holes in guide pin supports per drawing 3 36 28 Insert guide pin supports into mortises in left and right sides of box making sure guide pins go into holes in supports 7 4 Prototype Testing After the prototype was constructed team testing began During this testing several problems appeared The first problem arose with the loading of the pa
9. Box Moveable Plates Springs Step 2 Identify all potential failures and safety hazards for the system in each mode of operation A failure is any undesirable occurrence associated with the system If multiple failure modes have a common root cause please compile them together and identify the root cause Potential Failures e Pins plates seize o Lack of lubrication dirt dust build up improper tolerances spring failure e Springs fatigue fracture o Improper spring constant overuse e Plate wear o Friction from paddle on plate face guide pin hole wear e Paper loads incorrectly o Paddle interferes when paper is loaded friction causes paper to bunch improper tolerances plate and paddle don t sit flush e Doesn t fold paper correctly o Paper slips off paddle not enough weight spring constant not sufficient improper paddle position paddle edges not straight Safety Failures Pinch points o Springs rods plates paddle e Maintenance o While lubricating guide pins springs etc 46 Step 3 For all significant potential failure modes in step 2 complete an FMEA table to determine the type of action necessary to achieve acceptable risk level and the priority of the action compared to the other failure modes Potential Failure 1 lack of lubrication dirt dust build up improper tolerances spring failure causing the plates to seize and not allow for smooth movements up and down to apply constant pressure
10. Handle Bushing REV UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 SUE OWC NO 2 FILE NAME 002 HandleBushinglpartnum2ldft WEIGHT SHEET OF REVISION HISTORY REV DESCRIPTION DATE APPROVED 250 I lt X 1000 1 O Le 13 500 w 250 A TEAM CATALYST TEAM 2 Top Guidepin Support REV SUE DWG NO 3 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 12 0 2 PL 005 3 PL 0005 FILE NAME 003 GUIDEPINSUPPORTIpartnum3 dft WEIGHT SHEET OF Wa ool 12 750 3 844 5 594 6 594 2000 11 500 13 000 8 406 ER ej 10750 REVISION HISTORY DESCRIPTION DATE APPROVED PLATE CUT FROM 3 8 THICK STOCK PLATE OF HICH DENSITY POLY ETHALENE ALL INTERIOR RADII 0 125 0 005 DETAIL A SLOT CLEARANCE CUT FOR 1 4 DIA STOCK TYPICAL UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 12 0 2 PL 005 3 PL 0005 500 1 12 500 L 5 250 x4 typical 000 typical Ax 250 7375 Cut from 1 2 thick MDF 145 viooo Board A
11. Our goal was to create a design that would allow less functioning workers to be able to work in the mail room at the paper folding station After coming across the bowing issues and not having the groove cut into the paddle handle there are too many issues that make this product difficult to use Table 9 1 shows which specifications we achieved and which ones we failed to meet Table 9 1 Specifications Pass Fail table Customer Needs Success Failure Flatten lt 5 8 Thick x Z Fold x Fold Variability Stuff in Envelope Ease of Use Safety Quality Speed Accepts Staples Compact Size Low Weight Appearance gt gt X gt lt lt gt gt gt lt We were able to meet the flattening less than 5 8 thick specification but we also had some issues with the paper jamming in the rollers and bunching the newspaper that would need to be addressed before delivery The quality of the fold was a success but there are still some issues with the occasional wrinkling of the paper that occurs This could potentially be corrected by adding a spring mechanism into the rollers to prevent buckling in the paper The fold variability and stuffing into an envelope was not a big priority However safety was a big concern and we were able to succeed on this specification by enclosing all the components in a wooden box and included a safety switch on the hinged lid This allows a supervisor
12. P23 push button switch Radio Shack 2751566 52 99 1 24 8 32 3 8 machine screw Lowe s 57842 51 18 1 25 8 32 3 4 machine screw Lowe s 57844 51 18 1 26 2pk 2 Narrow Hinge Lowe s 196300 52 56 1 27 Snap Latch Lowe s 51960 55 04 2 28 10 1 5 Lowe s 68374 55 47 1 76 Paddle Outer Box Assembly Part Num Part Name 1 Handle 14 Lever 16 Paddle Blades P1 Knob Paddle Assembly Roller Assembly Roller Setup Parts List Quantity Part Number Discription 1 23 Right Side 1 24 Left Side 1 21 Top Brace 2 22 Top Bracket 2 25 Mounting Bracket 2 15 Roller 3 26 Roller Shaft 1 7 Dirve Shaft 1 20 Idler Shaft 3 P10 Pulleys 1 P9 Belt 4 P2 Bearings 12 P24 8 32 Machine Screws 500 10 005 500 FT eee 4 12 1000 1573 000 7 000 we 0005 B H 200 Tuma TE AWN Brad 109 09 A M CA TA LYST Ohio University Senior Design Team 2 Handle 1 000 129 2 000 500 290 Si 1 000 REVISION HISTORY REV DESCRIPTION DATE APPROVED Cut from 2 Round Stock PVC TEAM CATALYST Ohio University Senior Design Team 2
13. Since the surface area of the plates is small there would not be much time required to apply the coating Even with the extra time to apply the coating the material costs would still be lower since MDF is much cheaper than HDPE This would cause the cost with the material change to be the same or lower than for the prototype Another change from our prototype to the final design is to add springs to the roller assembly During testing we had problems with the paper getting jammed in between the rollers due to too small of a gap Adding springs to the top rollers would solve this problem When the paper is pushed through the rollers the force of the paper will push the rollers up while the rollers apply the necessary force to crease the paper This will prevent the paper from getting jammed in the rollers Another way to fix this problem is to use a motor with higher torque A higher torque motor would better drive the rollers and a paper jam would be less likely Another problem we encountered during testing was the loading of the paper into the side slot The frayed edges of the newspaper often got caught on the side of the box which caused the paper to load incorrectly or not at all A solution to this would be to add guides to the slot similar to guides for loading paper into a printer This would allow for easier loading of the paper and could be used as storage for a stack of papers waiting to be folded 42 8 3 Manufacturing CostssDFMA Si
14. each other and to said rollers 4 3 Concept Generation As a team we decided to each come up with at least 2 or more conceptual designs and not discuss our ideas until we held a meeting This would allow ourselves not to get stuck on one idea too early and roll with our first idea This allows for 14 conceptual designs to determine the best design to begin refining We then had a group meeting to collaborate our ideas As the group meeting progressed we agreed on several ideas to incorporate in our integrated designs Some of the initial designs that were used in integrated designs are shown below 14 173 200 Figure 4 2 Folding template amp modified paper shredder d compos Js fe Sie 9 P TTT LLLI LIA ses AA 112111 6 1 sr LL T ES rE ane ae Geer eri T a GR ia 11 _ at H 446 over oct LAD 2 CH C a ua SO Figure 4 3 Manual folding template 16 Side e eee to pop FA Line othe QP Ofer So WO ky Con 47 peP ei temple te tellers into envelope Sec odds Co p eSs on on Peper Figure 4 4 Rolling assembly line design Figure 4 5 Folding template
15. just a cheap easily available pin We also decided to ensure a material was selected that had low wear properties and low friction to keep wear minimal With this in mind we decided to use HDPE because it is strong and lightweight while still providing a smooth surface and good wear properties Its strength will be evaluated further through FEA analysis to confirm is it suitable for the paddle blades and will not fracture or deflect too much The roller assembly FMEA yielded a few possible additions to the design To avoid gear fracture and to keep costs down we elected to pursue a track belt pulley system This allows for easy replacement and is cheaper than gears This would also assist in avoiding motor failure and or overheating If a paper jam were to occur the motor would continue to run but not turn and could burn out the motor With a pulley systems if the torque were to get too high the belt may snap rather than a gear pulley or having the motor burn up A pulley system is yet to be selected but we could select one that would break at a certain force torque It is also being considered to cool the motor in order to prevent overheating In order to protect the motor from electrical hazards the motor will be encased and waterproofed but will have vent holes to avoid heat buildup A safety switch will also be implemented on the box to shut off the rollers when the top lid is opened to avoid any safety hazards This top lid will assist when
16. 250 7 6 REVISION HISTORY REV DESCRIPTION DATE APPROVED Al 9 Ohio University Senior Design Team 2 Guide Pins CATALYST SUE OWC NO UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 9 E NAME 009 GuidePin Part Nurn WEIGHT SHEET OF REV Cut from 1 thick MDF Board 2 125 7250 14 000 R 1 000 4 190 71 000 250 x4 typical m R 750 2500 B dr d 3875 000 x4 typical 1 x Lowe TET DATE 09 09 REVISION HISTORY REV DESCRIPTION DATE APPROVED ek CUT FROM 3 4 STOCK MEDIUM mir DENSITY FIBER WOOD YT E LI H 500 7250 7 i 1000 B DETAIL A COUNTER SUNK 10 SCREW HOLES 4 TYPICAL v Ke 3875 L 14000 0050 C d 06 09 09 DR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 21 0 2 PL 0 05 3 PL 0050 4875 5 000 3250 3 125 REVISION HISTORY DESCRIPTION DATE APPROVED CATAL
17. Connection Handle von Blades von Mises Stress Mises Stress Displacement Aspect Mesh Size in Nodes DOF psi psi in Ratio 0 063 33998 101994 3242 6 3212 0 0018 8 032 with 025 refine pts 251710 755130 4240 8 821 8 0 0018 13 Load Case 1 of 1 Maximum Value 4240 77 Ibf in 2 ges 0 608 in 1218 1 825 Minimum Value 19 3666 Ibf in 2 Figure A2 2 Handle Tab Stress 57 Table A2 2 FEA results for handle ran nodes 2715 2685 3808 13108 Stress von Mises 2 2227 507 2004 757 1782 006 1559 255 1336 504 1113 754 891 0031 668 2524 445 5017 222 751 0 0002952562 Time 15 Time Step 20 0720 Maximum value 2227 51 Ibf in 2 Gen Se E in Al Minimum value 0 000295256 Figure A2 6 Max stress for handle 58 Stress von Mises 242 Ibf in 2 2000 4 4 4 4 aoe 400 06 0 5 0 4 01 8 Figure 2 7 Stress vs time for handle non linear analysis Figure A2 8 Loads and constraints on top plate 59 Table A2 5 Results for FEA on top plate Elemen Max Stress Max difference Mesh in ts Nodes psi Displacement in stress 0 5 636 690 2070 579 05 0 0363 N A 0 25 2357 2454 7362 667 48 0 0421 14 19 0 1 13659 13854 41562 67
18. Paddle Testing Data Figure 7 4 shows the force recorded during the experiment This force represents the input force of the user to rotate the paddle 180 degrees Through 20 rotations the max force recorded was about 23 N which converts to 5 17 pounds force This was much less than what was expected which was designed for 10 pounds This concludes our design will not cause problems with user fatigue 7 3 Prototype Construction The prototype paper folding device was constructed using four sub assemblies These consisted of the roller setup paddle electrical system and outer box Creating these sub assemblies allowed for easy changes to be made to these specific sub assemblies without affecting the others Drawings of manufactured parts are located in the appendix The outer box subassembly consists of 7 parts the bottom left side right side back top front bottom front and top These are made from 1 2 medium density fiberboard MDF The two front pieces are 1 thick which requires that two 1 2 pieces be glued together The outer box is held together with 10 wood screws 112 long See Appendix AS Outer Box Assembly Procedure 1 Rough cut four pieces of Lo MDF 1 larger than specified in drawing for the top front and bottom front 2 Glue two of these pieces together to create two 1 thick pieces 33 Cut 1 thick pieces for front per drawings 10 11 Cut MDF for right side of box per drawing 17 Cut slot in righ
19. completing the actions and the completion date Test to ensure it folds properly Possibly selecting clear materials to visually allow folding process 5 Notes on Completed Actions N A 53 Potential Failure 5 Excess deflection or fracture of paddle Operating mode when failure could occur Potential Failure Mode Folding Excess Deflection fracture of paddle Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 9 9 Potential Cause s Mechanism s of Failure 6 6 Probability of occurrence OCC Current Controls for Detection and Prevention 7 7 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 378 378 1 Include some discussion justification for the rating for severity SEV Inoperable completely and possibly risk of safety hazard with sharp edges and debris 2 Include some discussion justification for the rating for probability of occurrence OCC May be possible to break but material selection and further testing should reduce this 3 Include some discussion justification for the rating for probability of detection DET Some detection may be visually audibly or physically possible but if it is minor and inside of box it will be hard to detect 4 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of
20. of Failure 7 7 Probability of occurrence OCC Current Controls for Detection and Prevention 3 3 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 105 105 1 Include some discussion justification for the rating for severity SEV No danger but mechanism won t complete task properly Inoperable 2 Include some discussion justification for the rating for probability of occurrence OCC Testing hasn t been complete so to be conservative we are assuming it will likely be somewhat of a problem 3 Include some discussion justification for the rating for probability of detection DET The box is designed so that the paper will fit perfectly in the box and be aligned Therefore it will be visually detectable if the paper isn t loaded properly 4 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for completing the actions and the completion date Smooth surfaces along with proper design should allow this problem to be minimal Testing will dictate any changes that must be made 5 Notes on Completed Actions Design of box paddle and plates all are generated in order to reduce this risk but until further testing no other changes can be made 50 Potential Failure 2 Paper crinkling during f
21. pushed against static wall 17 Figure 4 6 Moveable folding wall 18 lys fence be freer Cac A 15 ths dig tence Cag 6 4 x des IS pape nf Peper chip holdes N Next part of Aes grr Figure 4 7 Paper Clip Holder By taking elements from various conceptual designs we were able to come up with some integrated designs shown below The first integrated concept shown in Figure 4 8 includes the folding template idea with a stationary wall The paper is held down with a wire fork and then the plates are pushed together Once folded the compressed paper could be passed through the rollers directly into an envelope One problem that has been discussed is the ability of the rollers to successfully grab the paper out from the folded template This has been seen as a difficult issue to overcome as the plates will need to be tight to assure creased edges 19 Figure 4 8 Integrated design concept 1 The second integrated concept shown in Figure 4 9 involves roller system that is all driven by one wheel It is folded in the template on tracks and is carried to the roller system and then fed to an envelope at the end of the roller The advantage here is that all the steps are done by one control the wheel One problem that has been identified is difficulties in linking everything together on the same drive train 20 Figure 4 9 Integrated design concept 2 Th
22. s newspapers and pack them in an envelope focusing on ease of use to allow people with a broad range of disabilities to perform the task safely 3 0 Benchmarking Standards and Target Specifications 3 1 Benchmarking The entire group was given the task of searching for current solutions Each member was responsible for finding four current solutions or ideas Our search took place primarily on Google scholar The research turned up many reports and patents on automated machines While these didn t provide any direct aid to the project many ideas spawned from this research in some way or another In resource 1 the device was a complex system of cams and deflectors This system though was limited to only a letter sized piece of paper 2 Input Defirctert n d Cz D Con 2 Resource 1 Resource 2 was layout of different fold types we looking into possibly making the fold operations more diverse within our own device it will be important to know the different folds E Single Half V fold Letter C fold 7 Accordion fold Half Accordion Double Parallel Cross Fold fold French Right fold Fold out Engineering fold Gate fold Resource 2 Resource 3 involves a device where the paper is folded between plates that come together and compress the paper into the appropriate fold This d
23. that supervisor cleans and lubes the guide pins 5 Notes on Completed Actions Materials were selected HDPE Plates amp SS Guide pins which will not require lubrication but may require cleaning for dust dirt purposes 47 Potential Failure 2 paper fails to load into the paddle correctly due to friction in the plates or improper tolerances allowing the paddle to sit flush in between the two plates Operating mode when failure could occur Potential Failure Mode When loading the paper into the device Paper loads incorrectly Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 6 6 Potential Cause s Mechanism s of Failure 4 2 Probability of occurrence OCC Current Controls for Detection and Prevention 6 4 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 144 48 6 Include some discussion justification for the rating for severity SEV If the paper doesn t load correctly then it cannot be folded or could ruin the paper It is not a 10 or near 10 because the paper could possibly be removed and loaded again 7 Include some discussion justification for the rating for probability of occurrence OCC If the plates are made correctly with the right tolerances and width between them then this shouldn t occur very often It was rated a 2 because if the plates do not seat correctly
24. the alternatives that were considered the person s responsible for completing the actions and the completion date Conduct thorough analysis to ensure material selection and sizes will reduce the chance of this happening 5 Notes on Completed Actions N A 54 A2 FEA Details Paddle Blade Figure A2 1 Loads and Constraints on Paddle Blades Table A2 1 Results for FEA on Paddle Blades Max Stress Max difference Elements DOF psi Displacement in stress 0 0787 33992 22779 68337 427 86 1 48E 03 N A 0 0591 66005 51562 154686 513 43 1 49E 03 18 18 0 0394 176226 146505 439515 638 17 1 50E 03 21 66 0 0295 210856 198201 594603 684 58 1 50E 03 7 02 Table A2 2 Mechanical Properties for HDPE http www k mac plastics net data 20sheets hdpe htm Density 0 0338 0 0348 Ib in UTS 3480 6530 psi Yield Strength 2180 4350 psi 55 Displacement Magnitude mm 0 03817894 0 03436104 0 03054315 0 02672525 0 02290736 0 01908947 0 01527 157 0 01145368 0 007635787 0 003817894 D Load Case 1 of 1 Y Maximum Value 0 0381789 mm 0 000 31 103 82207 93 310 Minimum Value 0 mm Figure A2 1 Displacement Locations in Blades Displacement factor of 5 Fatigue in handle tab paddle blades connection Figure A2 4 Loads and constraints on handle tab paddle blades connection 56 Table A2 1 FEA Results for Blade Handle
25. then this could cause failure which should be detected during testing 8 Include some discussion justification for the rating for probability of detection DET It will be hard to determine if the paper is crinkled up inside but should be prevented by the design on the box dimensions because they are the same width as the newspaper 9 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for completing the actions and the completion date Testing will determine how well the paper loads and any adjustments that may be needed Alternatives include different ways to load the paper Possible plexi glass wall opposite of loading side to improve visibility to identify problems loading 10 Notes on Completed Actions Paddle was chamfered steeper and gap between paddle and plates is reduced to avoid the potential of the newspaper sliding under or over the paddle 48 Subsystem 2 Paddle Assembly Failure Modes and Effects Analysis for Safe Reliable Effective Designs Step 1 Provide a description of the full system including all subsystems and accessories in all modes of operation including storage setup transportation operation cleaning maintenance etc If possible please include sketches with users in operating positions for the main operating modes This information can b
26. to be able to clear a paper jam or perform maintenance on the machine but disengages the roller system so that fingers and or clothing do not get caught Also there are not any sharp corners or pinch points that the user could get injured on Overall we succeeded by meeting most of our specifications but the failure in the ease of use specification is too important to overlook If we had more money and time this problem could potentially be solved by adding the groove into the paddle handle and using a stronger material for the moveable plates to solve the bowing issue However this still may not be the 44 solution and the risk is too large to continue with the design As the project stands now it is not user friendly the overall cost is too high to move forward into production References US Census Bureau 2005 2007 http factfinder census gov servlet STTable bm y amp geo_id 01000US amp qr_name ACS_2007_3YR_G00_S1801 amp ds_name ACS_2007_3YR_G00 Resource 1 http www personal umich edu awtar MS paper fold htm Walczyk Prof Daniel Paper Folding Mechanism October 21 2008 http www personal umich edu awtar MS paper fold htm Resource 2 http www officezone com folding guide htm folds Office Zone What are the different kinds of paper folds October 21 2008 http www officezone com folding_guide htm folds Resource 3 http www google com patents id D9MwAAAAEBAJ amp pg PA 1 amp dq 22paper f
27. x5 6 x12 5 10 500 sheets hr Fold variability Figure 3 2 Left to Right 10560 Dahle amp FD 305 Paper Folder Officezone com 2008 10 3 2 Target Specifications Constraints and Design Criteria We have set target specifications based on customer specified desires for which our device must meet The first set by SW Resources is that it must be capable of completing the task at a rate of 125 hour This specification is set on the idea that this machine could account for one person on a four person team working at a rate of completing 500 in a single hour It must fold the papers in a z fold a specification set by the newspaper publishing company which contracts SW Resources to perform this task The final product newspaper and envelope must be less than 5 8 thick in order for the post office to mail the product SW Resources also set the specification that it must be able to handle staples Their current machine can t support the folding of papers with staples because the staples jam the machine and destroy the roller components A maximum of 1 of the newspapers put through the machine are allowed to fail Modes of failure include an improper fold the final product not being within specification the paper not being inserted into the envelope correctly or at all or the news paper could rip Other modes of failure are to be determined There are also criteria which our team would like to keep our design within These includ
28. 0420 0 430 ol 0290 0395 0 440 ol 0300 0400 0 510 AVG 0 0 307 0 399 0 481 Table 7 2 is used to test for convergence for the thickness of the paper after folding to the specific criteria needed This table shows that all gaps tested crease the paper under our upper specification limit of 625 We will be using the 1 8 thickness to provide the optimum amount of thickness possible without paper jamming The main objective of the force experiment is to measure the amount of force that is required by the customer to turn the handle 180 degrees The purpose of this experiment is to find the ease of use necessary to rotate the paddle and to minimize the opposing force of the springs The easier it is to turn the handle the broader a range of customers can use the device This experiment will show if different springs are required or a longer lever are needed to reduce the force necessary to rotate the paddle The Vernier Lab Pro was used to measure the force applied to the handle to turn it The procedure for testing the maximum force on the paddle handle is as follows 1 Attach a force gauge to the end of the paddle handle using welding wire 2 Pull the force gauge perpendicular with respect to the handle and blades at a 90 degree angle 3 Record results using the digital force gauge program 4 Make note of any elastic deformation cracking and or complete failure 32 lt o o Time Figure 7 4
29. 6 77 0 0468 1 38 0 075 24214 2441 73233 681 32 0 0473 0 670 Figure 2 9 Deflection of top plate 60 A3 Cost Worksheets Table A3 1 Cost details for electrical system Electrical System and Final Operation 1 Operation 2 Operation 3 Assembly Assemble Assemble Insp amp Clean Up electrical entire system system and safety switch a total time to complete 1 0 1666 0 25 operation s in hours b labor rate for the operation 12 12 12 hr c Labor cost axb 12 2 3 d basic overhead factor 1 1 1 e Equipment factor 0 5 0 5 0 5 f Special operation tolerance 0 0 0 factor g labor overhead equipment cost 30 5 8 cx I d e f h purchased 32 0 0 materials components cost Total Cost 574 61 Table A3 2 Cost details for outer MDF box Outer MDF Box Operati Operati Operati Operati Operation Operati Operation 7 Operati 1 2 3 on 4 5 on 6 on 8 Cutting Cut out Knotchi Drilling Assembly Cutting Turning Dril Insp amp to size slots ng PVC ling on Lathe Clean Up a total time to 1 0 5 1 0 5 0 5 0 25 complete 0 1666 operation s in hours 67 0 2 b labor rate for the 12 12 12 12 12 12 15 12 operation hr c Labor cost axb 12 6 12 6 6 2 3 3 d basic overhead 1 1 1 1 1 1 1 1 factor e Equipment factor 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 f Sp
30. OF 344 333 X 9 18 REVISION HISTORY REV DESCRIPTION DATE APPROVED Cut from 3 8 thick plate stock of High Density Poly Ethalene 500 DETAIL B D 1 De l i 594 406 2250 2150 4 500 3625 4167 en CCC 3X 1134 Y Tm TEAM CATALYST nc hr Ohio University Senior Design Team 2 a me aood 22 24 AL El emp B asin Mee D 16 f 000 Ke Ed FILE NAME 0 6 Padd 3625 250 Sus 4125 lt 1000 LL KM 250 eg 500 DETAIL A 145 Typical 16 000 493 95g ZE 714 2808 4803 6678 NS 6678 x2 500 Typical S I IERI 190 Typical 15 000 138 REVISION HISTORY REV DESCRIPTION DATE APPROVED 2 wide x 0 125 Y slots Note Dimensions are to nearest edgeline of screw hole C Lowe TE 080909 UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES LES 3 PL 0005 12 000 15 000 16 000 CH 1
31. ONS ARE IN INCHES ANGLES 310 3 PL 0005 Idler Shaft 9 900 6 000 REVISION HISTORY REV DESCRIPTION DATE APPROVED 00 4X 216 J25 Use Standard 1 5 125 Aluminum Stock as Width and Thickness C Lowe TE id 9 CATALYST Ohio University Senior Design Team 2 Top Support Roller Assembly UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES REV jm dft REVISION HISTORY REV DESCRIPTION DATE APPROVED 2X 410 32 UNF 2X 0 216 000 TEAM CATALYST Ohio University Senior Design Team 2 L MGR APPR UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 Top Angle Roller Assembly DWG NO 22 Use Standard II X I X 125 Aluminum Angle Stock 12214 REVISION HISTORY REV DESCRIPTION DATE APPROVED Luo us pero 4X 10 32 UNF 2X 05 2X 625 002 v 188 4500 Zo Q Q 500 P B 375 250 Le 750 1 125 e TEAM CATALYST Ohio University Senior Design Team 2 Righ
32. Paper Folding Device Team Catalyst Team Members Alex Berger Adam Deel JD Litten Mike Mulroy Robbie Gildenblatt Brad Delaney Jared Rich Wednesday June 10 2009 Paper Folding Device for the Handicapped Team Catalyst has taken it upon themselves to design and manufacture a device to assist in the task of z folding a Wally s amp Wimpy s Football Digest to less than 5 8 thick for a broad range of handicapped employees at SW Resources in Parkersburg WV We researched designed prototyped tested and refined a manually operated folding device that incorporates an automated roller all inside a safe transportable unit Based on team testing the device is capable of increasing production from 170 papers hr to 240 papers hr while also allowing workers with more severe disabilities to complete the task due to the simple operation of the machine Table of Contents Ba Page uuu EE 3 1 1 Initial Needs 4 0 0 esses esses 3 20 Customer Needs 4 2 1 Weighting of Customer Needs oe Renee eege ege e 5 2 2 Revised N eds ET EE 6 3 0 Benchmarking Standards and Target Specifications 6 Sek 3s 6 3 2 Target Specifications Constraints and Design 1 11 20 Concept Generation
33. YST Ohio University Senior Design Team 2 Tm D L SUE No UNLESS OTHERWISE SPECIFIED 2 DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 Motor Housing REV OI MotorHousinglpartnumi 21dft WEIGHT SHEET OF T DETAIL REVISION HISTORY DESCRIPTION APPROVED L we m I J e m _ Kurusa UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 1 0 3 PL 0 005 TEAM CATALYST Ohio University Senior Design TITLE Box Lid SIZE NO A2 13 FILE NAME 013 Lidlpartnum3ldft SCALE WEIGHT SHEET 1 OF 1 REVISION HISTORY REV DESCRIPTION DATE APPROVED 375 CUT FROM 3 8 DIA ALUMINUM STOCK SS e 000 DETAIL A THREADED END TYPICAL 080909 6109 0 UNLESS OTHERWISE SPECIFIED D DIMENSIONS ARE IN INCHES ANGLES 10 3 PL 0050 2000 14 20 UNCY 1 000 Typical REVISION HISTORY REV DESCRIPTION DATE APPROVED 1 000 4 7 50 CATALYST Ohio University Senior Design Team 2 REV UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 SUE OWC NO FILE NAME 015 51 WEIGHT SHEET
34. acement parts manufactured Part Part name number 2 Handle bushing 4 Bottom plate 6 Box back 8 Guide pin and motor support 10 Box front top 12 Motor housing 14 Lever 16 Top paddle blade 18 Slotted box side 20 Top plate 22 Roller Asm Top 24 Roller Asm Right 26 Roller Asm Bottom 75 Table 2 Replacement parts list bill of materials purchased knob Mcmaster 61095K45 51 39 1 P2 Ball Bearings Mcmaster 6455K2 514 87 4 Motor Mcmaster 6142K48 548 48 1 4 1 4 Coupling Mcmaster 6408K111 52 33 1 5 5 16 Coupling Mcmaster 6408K112 S2 33 1 P6 Flex Spider Mcmaster 6408K84 51 52 1 7 1 4 Aluminum Bar Stock 36 Length Mcmaster 8975K563 511 09 1 P8 Springs celal N A 6 05 8 P9 Track Belt 0 5 x 36 Mcmaster 7891K5 17 26 1 P10 Pulleys 1 25 dia Acetal Mcmaster 57105K16 7 61 3 P11 PVC 2 x 24 round stock Mcmaster 8745K26 15 54 1 12 Rubber Film 18 x12 x1 32 Mcmaster 8622K41 533 92 1 P13 HDPE 24 x48 x3 8 Mcmaster 8671K34 546 51 1 14 Stainless Steel 72 x1 4 barstock Mcmaster 89535K21 57 76 1 15 Aluminum 36 x1 barstock Mcmaster 6750K193 33 02 1 P16 10pk small wire clips Radio Shack 2781668 2 99 1 P17 10pk Wire Connectors Radio Shack 6403133 2 19 1 P18 H18 gauge wire Radio Shack 2781226 6 99 1 P19 Power Cord Radio Shack 6102876 7 99 1 P20 Rocker Switch Radio Shack 2750694 2 99 1 21 Inline Fuse Holder Radio Shack 2701281 52 69 1 22 fuse Radio Shack 2701025 2 99 1
35. aft The shaft goes into the box to join with the blades It may become difficult to move and if so simply lubricate the shaft and the groove with dry graphite lubricant to ease the movements tem4 Blades The two blades may over time become warped or bent if this occurs remove the three screws and remove them They will need to be replaced with new paddle blades 73 3 4 Movable Plates The movable plate assembly consists of an upper plate and a lower plate the guide rods and eight springs The trouble shooting process is summarized below Refer to Tables 1 and 2 for each individual part number 1 Guide Rods There are four guide rods that keep the plates moving in the proper direction if one of these should become bent or broken it will need to be replaced Item 2 Plates If a plate should happen to become warped bent or broken it will need to be replaced to maintain the ability to create an acceptable fold If the fold starts to become undesirable or if the paper starts to become difficult to load check the plates for this occurrence Item 3 Springs The springs support the bottom plate allowing it to maintain contact with the paddle blades If the paper starts to become difficult to load look to see if the bottom plate is sagging and not contacting the blade while in the rest position if so the springs have fatigued and will need to be replaced 74 4 0 Replacement Parts List Table 1 Repl
36. ally The whole device could be manually cranked which would reduce any hazards of electricity cords etc Manually operating the device could cause fatigue in the user and slow down productivity If some type of motor was used it would have to be safe and be able to run throughout the day possibly continuously 4 2 Patent Searching There were several patents researched and discovered relating to the design of our paper folding device Several patents pertain to the actual method of folding while others pertain subjected parts used within the system The first patent discovered is for a folding machine that uses rollers attached by gears and is powered by a single motor This patent can be found at http www freepatentsonline com 4573672 html Another patent that was discovered through research was a creasing folding machine used to fold paper and bookbinding articles It has a feed unit feed path a creasing unit and a folding unit This patent can be found at http www freepatentsonline com 5905935 html A patent for another folding method can be found at http www freepatentsonline com 20060089246 html There are two paper stop drive assemblies of similar construction each providing for the automatic positioning of the respective paper stops In both paper stop drive assemblies a potentiometer provides an electronic feedback to a microprocessor on the current position of a belt with the paper stop The microprocessor then activates a motor
37. ated for each concept The design with the lowest number theoretically has the best potential of satisfying the customers and our needs The three feasibility charts are shown below 22 Table 5 1 Feasibility Chart for Integrated Design 1 Flatten 5 4 Fold 2 1 Variability Stuff in 5 1 Staples 4 5 Ease of 5 4 Size 2 4 Use Fold Failure Table 5 2 Feasibility Chart for Integrated Design 2 Flatten Fold 2 1 Variability Stuff in Env Staples 4 5 Fold Failure 1 4 23 Table 5 3 Feasibility Chart for Integrated Design 3 Flatten 5 4 Fold 2 3 Variability Stuff in 5 1 Staples 4 5 Env Safety 5 1 Weight 3 3 Fold 5 4 Appearance 10 Failure TOTAL 132 As one can see Integrated Design 3 had the lowest total score resulting in the most feasible design to proceed with Easeof Use 5 2 2 4 6 0 Final Design Concept Figures 6 1 6 2 and 6 3 show Solid Edge images of the final design concept Instead of using a fork a paddle was made using rapid prototyping software which allowed for a sturdier holding device To make sure that the paddle is aligned correctly every time the handle of the paddle is fixed inside the front wall and only allowed to rotate and move in and out due to a fixed pin and guide The guide is a groove cut into the handle of the paddle which allows the fixed pin to travel in The box is cut to exact dimensions in order to fit the paper squarely on the
38. deal with people of severe disabilities in the employment environment The design or task at hand must be orientated towards helping current employees improve their work skills or helping someone who is currently unemployed become employable As the class is divided into 8 design teams it was decided that our team Team Catalyst would work with a non profit organization called SW Resources They are located in Parkersburg WV and hire a broad range of disabled employees in order to complete certain jobs Many of their workers deal with packaging mailing sign making and various assemblies After continuous communication and follow up trips to SW we decided to work with their mail department employees to formulate our project Once the problem is clearly defined and a solution is required the design process will begin Not only will our team help define the problem and design a solution but we will prototype the project and deliver it to the customer for testing and feedback Proper changes will be made accordingly and the revisions will be made in order to give SW a working prototype that they can use for their employees 1 1 Initial Needs Statement Society has a demanding need for assistance in the employment environment for those of the physically and mentally handicapped nature In order to maintain or engage in active employment those with disabilities require assistive technologies devices or processes These technologies will allow them t
39. e a 3 x 3 footprint such that the device can sit easily on a tabletop or other type of stand The device can be no heavier than 15 lbs This will enable easy transport and storage of the device The design cost will be more expensive but the manufacturing cost should be less than 150 00 This means that the labor and materials to make another device if they so choose is less than 150 00 Also the device should be adaptable specifically the folding section The device will hopefully be able to support multiple folds including but not limited to half folds C folds and others which are too be determined later Table 3 2 Customer requirements and target specifications Customer Requirements Target Specifications Flatten papers 500 hr crease rate Ability to handle staples Z fold Ability to handle various 5 8 max final product thicknesses thickness Increase efficiency Handle standard staples General safety 1 failure rate 11 4 0 Concept Generation Folding eZ fold eAutomatically eLoaded into machine eby hand automatically Holding Flatten paper to 5 8 thick envelope Variable folding One step By hand Flattening 4 1 Problem Clarification The Flow chart above shows the four tasks that the device must complete The first is how the paper is going to be held There are several possibilities but the most likely are to manually load the machine or to have some kind of fe
40. e correct roller gap and apparatus was constructed that can allow the thickness of the rollers to be adjusted multiple times until something works In Figure 7 3 below a device is shown with a fixed base that has the motor mounted on it The fixed supports have a hole through them to allow for a fixed bottom roller There will also be a slot in the supports above the fixed roller to allow the top roller to be adjusted up and down Figure 7 3 Roller testing apparatus The following procedure was used to find the optimal roller gap 1 Set the fixed bottom on the table and attach to the table if needed with c clamps Set the adjustable top roller at initial height from the bottom roller 3 Push paper through by hand and record thickness of paper and distance from the center of both rollers 4 Adjust rollers accordingly and repeat measurement until a constant thickness of less than 5 8 thick is achieved for at least ten or more tests Once the thickness is achieved calculate the required gear ratio needed Mount gears on both rollers and motor 7 Test the thickness produced with the motor and record results x Adjust if needed and repeat 5 7 31 Table 7 2 Roller testing data Roller Gap 0 0625 0 125 0 25 0 375 ol 0310 0385 0 442 0 0332 0322 0462 0 0280 0 485 0 553 ol 0 305 0385 0 525 0 0 295 0 375 0 475 O 0315 0440 0462 ol 0 325 0380 0 510 ol 0 313
41. e included here or as an attachment to this document The paddle assembly consists of the top and bottom blade the handle with tab the screws and lastly the lever arm that is attached to the handle Different modes of operation consist of inserting paper rotating handle and assembly and transition or pushing of the paddle towards the roller assembly Step 2 Identify all potential failures and safety hazards for the system in each mode of operation A failure is any undesirable occurrence associated with the system If multiple failure modes have a common root cause please compile them together and identify the root cause e Improper insertion of paper into paddle e Paper crinkling during folding process Paddle ceasing or un moveable e Material wear of assembly components e Improper fold of the paper Excess deflection or fracture of paddle Step 3 For all significant potential failure modes in step 2 complete an FMEA table to determine the type of action necessary to achieve acceptable risk level and the priority of the action compared to the other failure modes 49 Potential Failure 1 improper insertion of paper into paddle causing device to be inoperable Operating mode when failure could occur Potential Failure Mode Paper Loading Improper insertion of paper Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 5 5 Potential Cause s Mechanism s
42. e third idea shown in Figure 4 10 uses a fork that is the width of the fold to grip the paper in the center There is a spring loaded top that presses down on the fork so that when it is rotated 180 degrees it will fold the top and bottom portions of the z fold One problem we have discussed is being able to turn the fork while still applying enough pressure from the top to successfully compress the paper 21 Ss B 7_ f L CH CS 1 Z NS 4 _ PH UE d LZ C ap UV Ve Y e 09 m np Folt K AE Vm i Y e VAM i tot W Figure 4 10 Integrated design concept 3 Box and fork 5 0 Concept Screening and Evaluation To determine the best conceptual design we created feasibility charts for each of the three integrated designs The variables that were rated were how well it would flatten fold and stuff in the envelope ease of use safety fold failure fold variability speed staples size weight and appearance Each variable was rated with a number being least important and 5 being critical to our customer These numbers were based by unanimous agreement during a group meeting These numbers were then multiplied by a number from zero to five in red below zero meaning doesn t satisfy the requirements and five meaning exceeds requirements This number was voted on by each member of the group and averaged The total was then calcul
43. ecial 0 0 0 0 0 operation tolerance factor 0 0 0 5 530 15 30 15 15 5 8 8 labor overhead equi pment cost c x 1 d e f h purchased 31 0 0 so 37 3 50 50 materials component s cost Total Cost 156 62 Table A3 3 Cost details for moveable plates guide pins Moveable Operatio Operatio Operatio Operation Operatio Operation Operatio Plates Guide Pins nd n ne S n5 6 GEI Rough Set Up Milling Cut Drill Cut stock Insp amp cutinto CNC Mil Aluminu holes in into 4 Clean two 1 m for guide pieces for Up pieces guide pin pin guide pins frame frame a total time to complete 0 083 0 25 0 75 0 0833 0 0833 0 083 0 25 operation s in hours b labor rate for the 12 12 20 12 12 12 12 operation hr c Labor cost axb 1 3 15 1 1 1 3 d basic overhead factor 1 1 1 1 1 1 1 e Equipment factor 0 5 0 0 5 0 5 0 5 0 0 f Special 0 0 25 0 25 0 0 0 25 0 25 operation tolerance factor g 3 7 41 2 2 2 7 labor overhead equipme nt cost c x I d e f h purchased 40 0 0 11 0 6 0 materials components cost Total Cost 121 63 Table A3 4 Cost details for paddle assembly Paddle Assembly Operat Operat Operat Operat Operat Operat Operati Operat Operat Operat ion 1 ion 2 ion 3 ion 4 ion 5 ion 6 on 7 ion 8 ion9 ion 10 Set Mill cut Set Up mil
44. ed system The feed system could be belt driven or possibly spring fed such as a magazine for a firearm Next is folding the paper There is a required z fold to meet the requirements but if there is the ability to fold in different configurations it could open of the range of uses The z fold requires two main folds in opposite directions If this could be accomplished in one step with a simple motion it could simplify the folding task for the user The third step is flattening the folded paper until it meets the required 5 8 thickness There are several possibilities including a manual crank automatic rollers or some type of press It is important to remember that if the paper is not flattened while in the envelop it needs to be flattened enough to include the envelope thickness in the overall 5 8 requirement The last major task of the project is the envelope The paper must be folded and placed into an envelope and still be under 5 8 thick It is possible to fold the paper and flatten it before putting it into the envelope or it could be folded put into the envelope then flattened There is consideration of manually putting the folded paper into the envelope after flattening but it is undetermined whether it will be done by hand or automatically 12 e Safe Could cause fatigue Faster Some safety issues Motor edurance Complex Electrical Figure 4 1 Required Energy There will be some type of energy to operate the device continu
45. eplacement The motor will also turn off stopping the rollers if the lid is open This is achieved by a safety switch under the lid Rollers and Pulleys Motor Housing Safety Switch 5 Once the paper is extracted out of the back of the device the paper the required z fold for packaging and is ready to be placed into an envelope 71 3 0 Maintenance 3 1 Electrical System All the electrical components are constructed in a closed loop system and are regulated by a 3 Amp fuse each individual part number The trouble shooting process for the electrical system is summarized below Refer to Tables 1 and 2 F Item 1 3 Amp fuse This fuse regulates the current through the electrical system and will break the circuit connection in the instance of a power surge to protect the motor and the rest of the electrical system It is located in the bottom corner of the box next to the roller system encased in a black connector If the system does not turn on make sure the fuse has not been blown by removing it from the black encasing Item 2 Power switch This switch turns the system on allowing it to draw power from the wall outlet It is located on the outside of the motor encasement next to the power cord If the system does not turn on make sure the device is plugged into the wall and that the power switch is switched on Item 3 Safety switch This contact switch is a safety feature located in the top corner of the bo
46. evice is also fully encased which will satisfy a concern of safety and size It also has a slot where the paper exits this provides a good location for an envelope loading jig of some sort Resource 3 Resource 4 is a device that looks as though it s for folding long continuous strips but it seems that it may be modifiable such that it could work with inputting something to be folded Though it only shows it happening on one side this may be able to be modified to do both sides Another possibility is after its run through once the user could grab it flip it over and run it through again for the other side to get the z fold It also appears to already incorporate compressive rollers to get a good crease Resource 4 Resource 5 15 an older paper folding machine found on Wikipedia It may hold some manual devices systems and or operations to aid our final design in the aspect of manual operation Folder p 82 Resource 5 After looking at the different resources and different automated machines we have picked four of them to get an idea of their relative sizes weight cost speed fold variability and if their design had the ability to handle staples or not With comparing these specifications we could determine a comparable size cost and functionality needed for our project design Table 3 1 Benchmarking of Existing Paper Folding Machines Martin Yale i 1 20 9 x40 5 x19 5 20 13 10 12 x22 x16 12
47. ing the paper from the paddle If it begins to wrinkle or tear away from the roller it will need to be replaced First remove the current layer and wet the roller with acetone to remove left over adhesive Wipe it down and sand it lightly to remove any leftover adhesive Once all the adhesive is removed and the roller is dry roll on a new piece of rubber and let set for 30 minutes to ensure proper bonding with the adhesive Item 3 Pulleys If the pulleys break they will need to be replaced See Tables 1 and 2 for replacement part information tem4 Track Belt If the track belt breaks or the connection begins to slip due to stretching new belt will need to be made See Tables 1 and 2 for replacement part information Cut the belt to 14 inches Then glue the ends together with super glue and let set for 20 minutes to ensure proper bonding with the glue 3 3 Paddle The paddle is made of five parts the knob the handle the shaft and the two blades The trouble shooting process is summarized below Refer to Tables 1 and 2 for each individual part number Item 1 Knob This knob screw onto the end of the handle for grip if it becomes loose or off screw it back on if unable to it may require being replaced 2 Handle The handle acts as a lever arm and screws into the shaft If it becomes loose or removed then screw it back into the shaft if you are able if not then it may require being replaced Item 3 Sh
48. ink the design changes will benefit the overall design and improve performance safety reliability and ease of use We only selected a few of the potential failures as we decided these would be the most significant and be of our highest concerns as the design and prototype progress All other potential failures and analyses may be found in the appendix under FMEA Worksheets 28 Table 7 1 FMEA Overview Paddle Improper Paper Jam Motor Fracture Loading Failure Initial Design Refinements Severity Probability Of Occurrence a Prob failure is det amp prevented a 2 2 32 2 5 Risk priority number 7 2 Mock ups and Experiments To validate the final design several mock ups and experiments were conducted These included a rapid prototype paddle mock up of movable plates roller gap testing apparatus and a force test on the handle The rapid prototype paddle was used to validate the overall concept of the paper folding device Could a paper be folded with the paddle To test this a paper was placed between the two blades of the paddle The paddle was placed flat against a table and a book was placed on top of the paddle The paddle was rotated while keeping it against the table and the book The results from this test showed that the paddle did indeed fold the paper in a z fold 29 Figure 7 1 Initial paddle prototype To test the design feature of the movable plates moving up and down along four guide pins with
49. is lightweight and is smooth Smoothness was necessary to allow the paper to slide easily off the paddle The opening on the side of the paddle is chamfered to allow the newspaper to slide through easily without jamming up The width of the paddle was designed so that the z fold was uniform with an overall width of 4 5 The overall length of the paddle blade was made 1 shorter than the newspaper to provide an overhang for the rollers to easily grab and pull the paper off the paddle Figure 8 2 Front view of the z fold process roller sub assembly removed Figure 8 3 shows a detailed view of one of the moveable plates The main function of the moveable plate is to provide constant pressure on the newspaper when the paddle is rotated This gives the newspaper the initial z fold prior to entering the rollers There is a long recess in the plate which was made to align the paddle correctly It also was made to ensure that the paper does not catch on the lip of the paddle where the chamfers are located This keeps the newspaper from jamming during loading 40 The next feature of the moveable plate is the slotted holes where the guide pins are inserted Guide pins are used to restrict the travel for the moveable plates in any other direction other than vertical Slotted holes were used to prevent the plates from seizing during operation This allows the plates to have some side to side motion which eliminates any chance of seizing 117
50. itch located at the top of the box where the top hinged lid closes This switch was used so that if the roller system is in operation it will automatically shut off if the lid is opened This will prevent anyone from getting their limbs or articles of clothing caught in the rollers 41 Figure 8 4 Pulley system drive shaft coupling safety switch and AC motor 8 2 Design Refinement There a few changes that we thought we could make to our design to improve its performance Due to time and monetary constraints however we were not able to follow through with these changes One change to the prototype we decided on was to change the material of the moveable plates As discussed earlier when the HDPE was cut the plates bowed This caused problems in our prototype operation For the final design we decided to use MDF instead of the HDPE We considered several other materials to switch to such as steel and a different plastic than HDPE We decided that steel or another metal would cause the plates to be too heavy and require too much force to turn the paddle We decided not to use another plastic since there could be a chance that the plastic would bow again when it was cut We initially decided to use HDPE because we wanted a smooth surface to allow the paper to slide off easily However we believe that wood with treatment to make it smoother such as polyurethane would be sufficiently smooth to allow the paper to slide off easily
51. l drill Cut Tap Assem Insp amp Up out alumin CNC end of and lever to end of ble Clean CNC sheet umfor Mill handle tap length lever Paddle Up Mill handle hole in and handle Handl e a total time to 0 25 1 0 1666 0 25 0 333 0333 0 1666 0 1666 0 0833 0 25 complete 3 operation s in hours b labor rate for 12 20 12 12 20 12 12 12 12 12 the operation hr c Labor cost 3 20 2 3 7 4 2 2 1 3 axb d basic overhead 1 1 1 1 1 1 1 1 1 1 factor e Equipment 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 factor f Special 0 25 0 25 0 0 25 0 25 0 0 0 0 0 operation toleranc e factor 8 55 5 8 18 10 5 5 2 8 labor overhead eq uipment cost c x 1 d e f h purchased 50 10 15 0 0 0 6 0 2 0 materials compon ents cost Total Cost 157 64 Table A3 5 Cost details for roller assembly Roller Assembly Operati Operati Operati Operati Operati Operati Operation 7 Operati 1 2 3 4 5 6 8 Rough Set Up Turn Apply Cut Drill Assemble Insp amp cutinto CNC down Rubber Alumin holes Frame Rollers Clean two Mill Diamet Film um for and Motor Up pieces ers Frame thread a total time to 0 083 0 25 0 166 0 0833 0 333 0 5 0 1666 0 25 complete operation s in hours b labor rate for the 12 12 20 12 12 12 12 12 operation hr c Labor cost axb 1 3 3 1 4 6 2 3 d basic
52. n detail After these evaluations were performed a few changes were implemented into the concept for the possibility of being used in the prototype The main result of the FMEA analysis led to several design mock ups to validate whether the design would work in a crude prototype which is discussed in section 7 2 below For the FMEA evaluations we used a rating system using scores of 1 10 One represents a low severanee probability and a 10 is the highest or most severe likely A more thorough description of the rating system is explained on the Senior Design website at http www ent ohiou edu me470 SnrDesign05_06 me471 FMEA amp Reliability06 pdf 26 The main failure modes identified and evaluated are as follows Paddle Assembly Deflection Fracture of Paddle Material Wear Groove and Press Fit Pin Box Plates Spring Assembly Pins Plates seize Improper Insertion of paper Corrosion Wear of springs Roller Assembly Paper jams Gear Fracture Motor Failure Electrical Hazard Motor Overheating After evaluation each of the assemblies we came up with a few recommendations to our design that could help reduce the risk priority number and therefore potentially make the design better For the paddle assembly we decided to make a press fit pin that would sit in the front lower wall rather than on the paddle handle This ensures an easy replacement in case the pin would break and would not require a new handle
53. nce our project is limited to only one application a production volume of only one device was considered in deciding the manufacturing cost Table 8 1 summarizes the costs and time required for the manufacturing of each sub assembly To determine these costs we specified each operation needed to complete a sub assembly We then determined the time required to complete each operation and assigned a labor and overhead cost based on the relative difficulty of the operation Cost worksheets detailing the cost of each operation are given in the Appendix The construction and assembly for manufacturing should follow the same procedure as outlined for the prototype see Section 7 3 Table 8 1 Manufacturing cost and time Sub assembly Total Time Labor Overhead Cost Materials Cost Total Cost Outer box 4 112 50 21 133 50 Paddle 2 67 124 33 155 Plates 1 58 64 57 121 Rollers 1 83 60 198 258 Electrical system 1 42 43 32 75 Whole assembly 11 5 403 50 341 742 50 The main components of the outer box and paddle assemblies were the labor costs labor time To keep these costs down we used the same screw sizes throughout the whole MDF box We also eliminated the need for tight tolerances This reduced the amount of different operations which in turn kept the labor time and cost down The paddle was made from several separate pieces including the two blades This made the paddle assembly easy to manufact
54. nces Figure 8 1 shows the basic structure of the device which includes the 4 handle on the paddle to decrease the amount of user input the slot opening for the newspaper to slide into and the hinged top portion of the box for easy maintenance access Figure 8 1 Newspaper folding device 39 The handle for the paddle was designed for optimum user comfort and ease of use The 4 extension arm provides a mechanical advantage so that on average the user only needs to input 5 pounds of force The ball on the end of the handle also adds additional ergonomics for Z the user while rotating the paddle The slot on the side of the box was designed so that the user will know the newspaper is properly loaded when the end of the newspaper is flush with the outside wall where the slot is located The dimensions of the box were made specifically for this feature so that the newspaper is correctly oriented with the paddle to ensure proper location for creasing Hinges were used for the top of the box to allow the supervisor to easily perform maintenance on the device or clear any paper jams that may occur This provides access to all the moving components of the assembly when needed but also protect the user from potential injuries The main part of the design is made up of a HDPE paddle blade which holds the newspaper and two HDPE moveable plates which provide the initial crease for the z fold as seen in Figure 8 2 below HDPE was chosen because it
55. num Angle Stock UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 2510 250 14 20 00 2 500 REVISION HISTORY REV DESCRIPTION DATE APPROVED CATALYST Ohio University Senior Design Team 2 sr UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES ANGLES 310 3 PL 0005 Roller Shaft SUE NO 26 FILE NAME 026_RollerShaftipartnum26l dft WEIGHT SHEET OF REV
56. o improve efficiency help perform certain tasks or improve their physical abilities so that employment quality and opportunities are increased 2 0 Customer Needs Assessment Team Catalyst has chosen to work with SW Resources This company hires people with disabilities The team is working specifically with Mail Plus a division of SW Resources The customer needs were collected from communication with SW Resources which included trips and emails During these trips the team talked with Kellie Conrad and various workers in Mail Plus The team discussed with these people the problem they are having This problem involves the Wally s Wimpy s weekly football digest which must be z folded and placed in an envelope The total package must be less than 5 8 inch thick The team observed the workers performing the task using the current solution After this was observed the team discussed the process with the workers and found out what they liked and disliked about the current solution The team also discussed any solutions the workers might have to the problem After these observations and discussions the team came up with the following customer needs list Table 2 1 Initial Customer Needs List Flatten Papers Ability to Handle Staples Ability to Handle Various Thicknesses Increase Efficiency Safe 500 hour total process based on unknown number of people Fold Papers in Different Configurations Stuff in Envelope Manually Driven
57. oldin 22 amp source gbs_selected_pages amp cad 0_1 PPA1 M1 Resource 4 http www google com patents 7id Tnl9AAAAEBAJ amp printsec abstract amp zoom 4 amp dq paper folder PPA1 M1 Resource 5 http en wikipedia org wiki Folding machine Figure 1 Left Office Zone 207M Paper Folder http www officezone com pdffiles Product Brochure php PageName mbm 207m paper folder Accessed October 21 2008 Right Office Zone Martin Yale P7400 Paper Folder http www officezone com pdffiles Product Brochure php PageName my7400 Accessed October 21 2008 Figure 2 Left Office Zone 10560 Dahle Paper Folder http www officezone com pdffiles Product Brochure php PageName dahle10560 Accessed October 21 2008 Right Office Zone FD 305 Paper Folder http www officezone com pdffiles Product Brochure php PageName fd305 desktop folder Accessed October 21 2008 45 Appendix A1 FMEA Worksheets Subsystem 1 Box Movable Plates Spring Subassembly Failure Modes and Effects Analysis for Safe Reliable Effective Designs Step 1 Provide a description of the full system including all subsystems and accessories in all modes of operation including storage setup transportation operation cleaning maintenance etc If possible please include sketches with users in operating positions for the main operating modes This information can be included here or as an attachment to this document Subsystem 1
58. olding process Operating mode when failure could occur Potential Failure Mode Feeding Rollers Crinkling of paper ripping Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 5 5 Potential Cause s Mechanism s of Failure 7 7 Probability of occurrence OCC Current Controls for Detection and Prevention 10 10 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 350 350 6 Include some discussion justification for the rating for severity SEV No danger but may ruin product 7 Include some discussion justification for the rating for probability of occurrence OCC To be conservative the occurrence is assumed rather high as we think this will be one of our larger issues 8 Include some discussion justification for the rating for probability of detection DET This is rated high because the box is enclosed and there is no way to tell if there is an issue until the paper is already ruined or not fed into the rollers 9 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for completing the actions and the completion date Ensure smooth surfaces and design rollers to be close to paddle assembly to reduce travel distance 10 Notes on Completed Actions N A
59. opposite side of insertion to minimize error and to simplify the design for the user to operate Inside the box are two moveable plates The lower plate is spring loaded and both plates move along four guide pins As the paddle rotates 180 degrees the moveable plates provide enough resisting force to crease the paper on both sides simultaneously while minimizing the input force for the user Once folded the user moves the paddle forward along the groove and pin and the paper is automatically fed into rollers powered by a motor The rollers crease the paper as it travels through the rollers and out the back into a bin 24 Figure 6 1 Solid Edge image of final concept N Figure 6 2 Side view Solid Edge image of final concept 25 m 2 Figure 6 3 Back view Solid Edge image of final concept 7 0 Prototype Design Development and Testing 7 1 FMEA Before any mock ups or prototypes were built several failure modes amp effect analyses FMEA were conducted to validate our concept selection This was broken down into our main subassemblies which consisted of the moveable plates springs box assembly roller assembly and the paddle assembly An evaluation was performed on each assembly per instructions provided by Dr Kremer via the Senior Design website These worksheets can be found in the appendix labeled FMEA Worksheets Several failure modes were identified and the most relevant ones were chosen to evaluate i
60. out seizing a mock up was constructed using plywood steel tubing for guide pins and four springs Two pieces of ply wood were used for stationary supports for the top and bottom of the guide pins Two more pieces of plywood were used as the movable plates Four holes were drilled into the plates precisely to the diameter of the guide pins The apparatus was put together with the springs between the movable plates and the stationary supports The rapid prototype paddle was placed between the movable plates and rotated On this attempt the movable plates seized up The holes in the movable plate were slowly cut into slots testing between each enlarging into the movable plates did not seize when the paddle was rotated This showed that the movable plates needed to have slots cut for the guide pins to allow for smooth operation and no seizing Figure 7 2 Moveable plates guide pins mock up 30 For the roller experiment the gap must allow the paper to be easily fed and grabbed without the paper Jamming or adding unwanted creases The rollers must be able to easily pull the paper out of the paddle If this does not occur the user will have to remove the paper which could be a potential safety hazard If the paper does not go through the rollers it will not be the correct thickness The gap must also be close enough to flatten the paper to a final thickness of less than 5 8 If the paper is not flatten enough the machine will fail its task To find th
61. overhead 1 1 1 1 1 1 1 1 factor e Equipment factor 0 5 0 5 0 5 0 5 0 5 0 5 0 5 0 5 f Special 0 0 25 0 25 0 0 0 0 0 operation tolerance factor 3 8 9 2 10 15 5 8 labor overhead equi pment cost 1 d e f h purchased 40 0 10 15 23 0 110 0 materials compone nts cost Total Cost 258 65 A4 User Manual Paper Folding Device User Manual Table of Contents 1 0 How to Operate the Device n n sese 67 2 0 How the System ege 69 ERUNT EIDIChchI CMM 72 3 1 eang a Ee EE 72 3 2 Roller S EAE e VE ao gata Ends 73 3 3 Paddle Assembly tede Qm i e n EC aq eA aypa RT EEEE 73 3 4 y 74 4 0 Replacement Parts List 75 66 1 0 How to Operate the Device Step 1 Ensure handle lever is in proper starting position as shown in Figure 1 Figure 1 Step 2 Load newspaper into slot of box as shown in Figure 2 The paper should be orientated so that the Wally s and Wimpy s name is face up and the creased edge is facing towards you as shown in Figure 3 E M Wally s amp Wimpy s You Facing This Way Figure 2 Figure 3 Step 3 Rotate handle of paddle 180 degrees clockwise left to right as shown in Fig
62. per through the side slot It was difficult to insert the paper because it either hit the top or bottom movable plate or the paper had trouble going through the paddle The paper hitting the movable plates arose from material selection After the groove was cut across the plates internal stresses were released that caused the plates to bow This bowing prevented the plates from sitting flush with the paddle The bowing also caused the plates to cover the loading slot To solve this problem with the prototype stop tabs were added to the side of the box which prevented the movable plates from covering up the loading slot Figure 7 5 shows these tabs Figure 7 5 Movable plate bowing To allow for easier insertion into the paddle larger chamfers were sanded into the blades This created a bigger opening in a ramp for the paper to slide into See Figure 7 6 37 Chamfer size Figure 7 6 Paddle blade chamfer After the handle had been rotated and the paper was folded the handle was pushed forward to feed the paper into the rollers This is where the next problem arose As the paper went through the rollers it bunched up and when the end of the paper reached the rollers it would no longer go through the rollers This problem occurred because the already creased end of the paper was last part of the paper to go through the rollers This crease prevented the paper that was bunching up from smoothing out because it had nowhere to go To try to fix
63. required in employment Companies and employers have goals and objectives to meet and many times hiring a disabled person may hinder them from reaching that goal efficiently This poses a problem to society as all people have the basic needs of life that must be fulfilled Many of these needs require money in order to buy goods and provide shelter but not every disabled person is capable of employment due to their handicap In fact in 2005 2007 only 36 7 of the U S population was employed that had any disability compared to the 74 6 employment rate for citizens with no disabilities U S Census Bureau The percentage of citizens employed decreases as disability severance increases With this in mind it has been taken upon the senior mechanical engineering class to find an achievable solution to help disabled citizens find maintain improve employment through the assistance of mechanical devices and or processes As engineers we seek to improve the quality of life for all and help assist in others needs Although no single person is capable of accomplishing all the tasks in life we as a team are going to take it upon ourselves to try to help disabled people in the employment environment To assist our class in our problem solving we will be partaking in a design competition held by the National Industries for the Severely Handicapped This organization NISH has specific guidelines and requires that students work with people or organizations that
64. rformed regularly and springs are selected to allow paddle rotation Select material with low friction coefficients 5 Notes on Completed Actions N A 52 Potential Failure 4 mproper fold of paper Operating mode when failure could occur Potential Failure Mode Folding Improper Fold Initial After Action Evaluation Results Potential Effect of Failure Severity SEV 4 4 Potential Cause s Mechanism s of Failure 6 6 Probability of occurrence OCC Current Controls for Detection and Prevention 10 10 Probability that failure is detected and prevented DET Risk Priority Number RPN SEV OCC DET 240 240 1 Include some discussion justification for the rating for severity SEV No danger but device will not complete task as desired but still may work 2 Include some discussion justification for the rating for probability of occurrence OCC As many things could cause this it is assumed to occur but no testing has been completed yet 3 Include some discussion justification for the rating for probability of detection DET As the paddle will be enclose in the box it will be hard to see if the paper is not folding properly until after it has come out of the rollers 4 Recommended actions to achieve acceptable risk Make specific recommendations for action and include some discussion of the alternatives that were considered the person s responsible for
65. t Side Roller Assembly h D Press Fit for Bearings recs 500 Use Standard 1 5 X 25 Aluminum Stock os Width and Thickness REV UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 21 0 3 PL 0005 SUE 23 FILE NAME 023 Right Side Roller Assembly Ipartnum23 dft SHEET OF REVISION HISTORY REV DESCRIPTION DATE APPROVED J 125 ce pi sis 4 10 32 UNF 1 cr 2X I 4 20 UNC 1 OF 1 2 gi 512 2 0 625 002 Y 188 4500 1 1 219 y 500 P BIBLE LEE 250 A 750 06 09 09 DR CATALYST Ohio University Senior Design Team 2 Left Side Roller Assembly 24 FILE NAME 024 Left Side Roller Assembly partnurn24 dft SHEET OF D Press Fit for Bearings Use Standard 1 5 X 25 Aluminum Stock as Width and Thickness SUE OWC NO REV UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES INGLES 21 0 3 PL 0005 REVISION HISTORY REV DESCRIPTION DATE APPROVED 000 24 D250 2X 216 ka 125 1 000 CATALYST Ohio University Senior Design Team 2 REV Use Standard II X I 125 Alumi
66. t side for loading per drawing 17 Cut mortises for hinges and guide rod supports per drawing 17 Cut MDF for left side of box per drawing 18 Drill holes for motor and motor cover in left side per drawing 18 9 cut mortises for guide pin supports per drawing 18 10 Cut MDF for bottom of box per drawing 5 11 Drill holes for guide pin and roller setup in bottom per drawing 5 12 Cut MDF for back of box per drawing 6 13 Cut slot in back per drawing 6 14 Cut top of box per drawing 13 15 Cut mortises for hinges per drawing 13 16 Clamp sides to bottom and mark holes for screws 17 Drill holes for 10 wood screws 11 2 long 18 Screw sides to bottom 19 Clamp back to sides of box 20 Mark and drill holes for 10 wood screws 122 long 21 Screw back to sides 22 Clamp bottom front to box 23 Mark and drill holes for 10 wood screws 11 long 24 Screw bottom front to sides of box 25 Clamp top front to box 26 Mark and drill holes for 10 wood screws 112 long 27 Screw top front to sides of box 28 Screw hinges to top of box 29 Screw hinges to right side of box 30 Mark holes in side of top and left side for latches 31 Screw latches to the side of top and left side Do cM ON The paddle consists of five parts the two blades handle lever and knob The lever and handle are cut from aluminum round stock and the blades are made from HDPE The CNC mill was used to make the blades and handle See Appendi
67. that moves the belt with the paper stop to a new position defined by the user input The automatically adjustable 13 paper stops require the input from a user on the type of fold and paper but not the user s intervention in the adjustment of the paper stops Another patent researched was for a finisher connected to a digital copying machine that folds output paper into a z fold This is not quite applicable for our use but has claims for the z folding technique This can be found at http www patentgenius com patent 3995849 html Another researched patent was found from http www patentgenius com patent 3995849 html The machine is a sheet folding machine of the type having three elongated rollers and a pocket said pocket having a pair of elongated lip members extending parallel to the axes of said rollers and into a space provided between two of said rollers said lip members forming between them an elongated opening for guiding between them a sheet such as a paper sheet or a carton to be folded into the pocket elements defining opposite walls of said pocket one of the wall elements having a portion adjoining the opening of the pocket and secured to one of the lip members adjustably in a direction transversely to the opening and extending into close proximity to an entrance surface of the respective lip member whereby the width of said opening is adjustable to different sheet thicknesses without changing the position of the lips relative to
68. there is a paper jam so that the operator may open the device and remove the paper or remove any necessary components if needed 27 The outer box assembly with the plates and springs was the last subassembly to be evaluated on our device The main concern for this was improper loading of the paper and the possibility of the moveable plates seizing After FMEA we considered using lubrication on the guide pins and moveable plates This would help prevent seizing and jamming of the plates against the guide pins It would also be recommended that a supervisor regularly check and clean the guide pins to avoid dust and dirt build up A maintenance schedule would help ensure the pins are lubed as necessary as well as cleaned Another main concern was the loading of the paper into the box Via FMEA analysis we can concluded that it may be necessary for some guide ramps or rails to load the paper into the slot We also considered using a clear material such as plexi glass on the opposite wall so the user can see visually on both sides if the paper is loaded properly The box will be designed so that the paper will sit flush with the outside of wall that it is loaded so that the user can see that it is straight The plexi glass would ensure that the paper did indeed go all the way through the paddle and is sitting flush with the opposite wall Comparisons of the risk priority numbers before and after FMEA are shown in Table 7 1 below This table reflects how we th
69. this problem the paper was inserted with the creased end going in first This fixed the problem of the bunching and jamming of the paper in the rollers It however created another problem the z fold did not come out straight See Figure 7 7 The paddle is shorter than the paper which makes the paper hang out so when it is pushed forward the rollers can grab the paper By placing the pre creased end of the paper toward the rollers first meant that this creased end did not get folded over the paddle When the paper was pushed into the rollers it creased at random spots which made a crooked z fold The decision was made to turn the paper around again and make the pre creased end go through the rollers last To fix the original problem the roller gap was increased until the paper no longer bunched up This increased roller gap still flattens the paper to less than 5 8 38 Bunching when pre creased Crooked fold when pre end went through rollers last creased end went through Figure 7 7 Paper folds 8 0 Final Design Design Refinement 8 1 Final Design For a description of operation and maintenance of the design see the user manual located in Appendix 4 The final design concept chosen was a wooden box that houses a rotating paddle two moveable plates and a set of rollers driven by an AC motor MDF wood was chosen because it is cheap Also it is easy to make rough cuts with MDF which was acceptable since we did not require tight tolera
70. trical sub assembly consists of the wiring harness and switches Electrical System Assembly Procedure Cut 1 piece of 16 gauge wire 15 long Cut 2 pieces of 16 gauge wire 6 long Cut 2 pieces of 16 gauge wire 3 long Soldier 15 long wire and one 6 long wire to push button switch Attach male quick connectors to ends of these wires CA dx Ups 35 ND 10 11 12 Soldier the two 3 long wires to the toggle switch Attach female quick connectors to ends of these wires Attach a male quick connector to one end of the fuse holder Attach a female quick connector to one end of the fuse holder Attach a male quick connector to one lead on the motor Attach a female quick connector to one lead on the motor Final connections will be made during final assembly The four sub assemblies are added together during the final assembly The movable plates are added as well as the motor and motor cover Final Assembly Procedure 1 2 22500 r3 Oxon 13 14 15 16 17 18 19 20 21 22 23 24 25 26 231 Screw motor onto left side of outer box Screw push bottom switch holder to left side of out box making sure that button is slightly higher than top edge of the left side of outer box Slide motor cover over motor and screw into left side of box Add wiring harness using wiring diagram Slide coupling onto motor shaft and tighten set screw Screw roller setup to bottom of box using pre drilled holes
71. up was made with 1 8 thick by 1 27 wide aluminum bar stock This was connected to the sides using 1 aluminum angle stock and 10 32 machine screws 3 8 long The angle stock was also placed at the bottom of the sides of the roller setup These are used to attach the roller setup to the outer box See Appendix A5 Roller Setup Assembly Procedure Cut aluminum roller frame stock to length per drawings 23 24 Using CNC mill cut bearing seats Drill and tap holes for 10 32 machine screws per drawing 523 24 Cut PVC stock for rollers to length per drawing 50 Using lathe drill hole 1 deep for 4 20 tap in ends of PVC Tap hole 4 20 left handed Cut 4 stainless steel rod to length for roller axles per drawings 26 7 Thread ends of axles 4 20 left handed per drawings 3426 7 9 Screw axels into rollers 10 Cut rubber film to fit on roller 11 Using super glue attach rubber to the roller with the drive axle 12 Press fit bearings into bearing seats 13 Attach aluminum angle pieces to the sides of the roller setup 14 Insert axles through bearings on roller sides 15 Attach top support to roller setup 16 Cut 1 4 stainless steel rod for idler pulley shaft per drawing 20 17 thread end of idler shaft 14 20 per drawing 20 18 screw idler shaft into side of roller setup 19 Slide pulleys onto axles and tighten set screws on the two roller axles 20 Put belt around pulleys 2 Slide coupler onto drive axle Qo Ov Eo E The elec
72. ure and assemble which made the labor and overhead costs lower than if we had made the paddle from one piece of material The driving cost in the roller assembly was the materials cost The materials were so expensive due to the number of different materials that were used motor PVC aluminum silicone rubber One way we tried to reduce this was by using the same fasteners throughout the whole roller frame which would lower costs due to economy of scale and also lower labor costs Another way we lowered costs was by using the spider shaft coupling to connect the motor to the rollers The spider shaft is a special coupling that allows for some flexibility in the connection This eliminates the need for a tight tolerance when connecting the rollers to the motor and therefore lowers labor time and cost To make the entire device easy to assemble and manufacture we decided to use a hinged top for the outer box sub assembly This allows for very easy access to all of the internal components of the device With easy access each sub assembly can be worked on separately 43 This lowers the total time needed to assemble the whole device and therefore lowers the labor costs 9 0 Conclusions From these results we have concluded that our current design does not fully meet our projects objectives and therefore it will not benefit SW Resources to deliver the product as is The main factor in this decision is that it currently is not easy to use
73. ures 4 amp 5 67 Step 4 Push handle forward away from you until it stops and can t move any further as shown Figure 6 Step 5 Pull handle backward towards you until it can t move any further as shown in Figure 7 68 Figure 7 Step 6 Rotate handle of paddle 180 degrees counterclockwise right to left as shown in Figures 7 amp 8 Figure 7 Figure 8 Step 7 Repeat steps 1 through 6 to fold additional newspapers 2 0 How the System Works 1 When paper is loaded into the device it will go in between two moveable plates and paddle blades The interior box dimensions are made to fit the paper exactly so that it aligns centered and in the correct position 69 2 Once the paper is loaded correctly the paddle handle is rotated 180 degrees The rotating motion causes the paddle blade to be in contact with the moveable plates at all times This folds the paper on both sides in opposite directions creating the z fold 3 The bottom moveable plate is supported by springs to hold it in position and force the plate against the paddle during folding The springs are located on the 4 corners of the plate for even distribution 70 4 Once the paper is folded it is fed into a roller system that is driven by 75 rpm AC motor The Rollers flatten the paper to the required thickness and eject the paper out of the back of the device The motor is housed outside the device for easy maintenance and r
74. x It turns the system off when the lid is open If the system is not running make sure the lid is closed properly such that it contacts the switch This safety feature will allow work to be done inside the box without the system running however when working inside the box make sure the power switch is turned off before performing any maintenance or work inside the box Item 4 Motor The motor drives the roller system in order for this to happen the device must be plugged in power switch on the fuse in the on position and the lid shut to contact the safety 72 switch If this does not occur turn the power switch off and unplug the cord from the wall Then open the lid and check the wiring Make sure all the wires are securely connected to each component if they are secure the motor may need to be replaced 3 2 Roller System The roller system is located in the rear of the box and consists of two rollers the rubber film on the lower roller the mounts the motor drive connection and the track belt system The trouble shooting process for the roller system is summarized below Refer to Tables 1 and 2 for each individual part number 1 Motor drive connector This connection connects the drive arm of the motor to the bottom roller If the system isn t operating make sure there is a good connection between the shaft of the motor and that of the roller Item 2 Rubber film The rubber film on the lower roller aids in pull
75. x A5 Paddle Assembly Procedure Rough cut 3 8 thick HDPE for paddle blades Using CNC mill cut out blades per drawing 16 Cut 1 diameter aluminum rod to length for handle per drawing 1 Using CNC mill cut tab at end of handle groove and drill and tap hole for 1 per drawing 1 Cut 1 2 diameter aluminum rod to length for lever per drawing 14 Thread ends of lever 2 13 Screw knob onto lever Screw lever into handle Using 10 32 flat head machine screws place handle tab between blades and screw together Bopp e 34 The roller setup consists of two PVC rollers an aluminum frame and a belt system The rollers were cut from 2 diameter PVC to 5 347 long On each end of the rollers 1 deep holes were tapped with a left hand 1 4 20 tap These threaded holes were used to screw in the axles for the rollers They were threaded left handed because of the direction the rollers rotate If they were not left handed the motor would unscrew the axles as it rotated which is not desired By using the left hand threads the motor is constantly tightening the axles into the rollers The axles are made out of stainless steel rod which was also used for the guide pins for the movable plates The sides of the roller setup were constructed from thick by 1 Le wide aluminum bar stock The CNC mill was used to add two holes in each side Bearings were press fit into these holes The top support of the roller set

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