The project task is to automate the loading of a Gardner Dual Disk Grinder (below) for Ingersoll-Rand.  Small steel objects, called hammers, are produced for use in the Ingersoll-Rand impact wrenches.  These hammers are used to generate motion within the transmission case of the wrench.  Because the operation of these hammers is essential, it is important that they be manufactured correctly.  Part of this manufacturing process calls for the grinding of both sides of this hammer.  This grinding eliminates unwanted surface defects, thus increasing the fatigue life of the hammer.  Currently, an operator hand feeds these parts into the grinder.  However, I-R wishes to automate the process for reasons that will soon be explained.

            -Operator will be freed up to perform other tasks
                    -Increase efficiency of employee
                    -Results in lower net cost to produce hammers
            -Decrease chance of injuries to employee suchs as abrasions and carpel tunnel syndrome
            -Increased operating speed of the dual disk grinder to maximum capacity

      -Ability to continuously run for 30 minutes without reloading parts
        -Human Factors
                -Easy to load parts
                -Easy to fix mishandled part
         -Interface with Grinder
                -Does not impede grinder wheel
                -Easily removable
         -Light Weight
         -Low Cost

    The concept design is divided into 4 stages:
            1) Vibrating bin
            2) Conveyor w/ gating system
            3) Part chute
            4) Part stack.
    Stage descriptions follow these pictures.

    The object shown below is a hammer, the object of placement.  The hammer will be referred to below as the "part."

1)  Vibrating Bin
        -Designed to hold approximately 1000 hammers for 30 minutes of continual run time (based on a wheel rotation of .8 RPM)
        -Parts will exit on the bin chute one at a time (i.e. singulation)
            -Accomplished by vibrating parts to prevent backup
            -Bin chute allows only one part to pass at a time by way of dual magnet timing system
                -Two magnets, one placed at beginning of chute, other at chute midpoint
                -A part held by magnet at top, is released and falls to second activated magnet
                -Another par is held in place at top, so now 2 hammers are on chute
                -Bottom magnet releases part, and it falls onto conveyor belt
                -First magnet releases its part and is caught at the reactivated bottom magnet
                -Process repeats every 2.3 seconds (every 2.3 seconds a part is loaded in the rotating wheel)
                -This prevents backups of hammers throughout the systems
        -Chute contains "kickers" that will orient the part length-wise before landing on conveyor

2)  Conveyor with Gating System
        -Parts enter length-wise onto conveyor (either in 0 or 180 degree orientation)
        -Using the part's center of mass, a gating system was devised to rotate part if
            not in the desired orientation
        -Curved gate at end of conveyor, straightens part before entering part chute

3)  Part Chute
        -Parts slide onto chute at end of conveyor
        -Chute is "S" shaped to allow horizontal entry into part stack
        -Ledge prevents parts from bouncing back onto the chute
            after reaching the part stack

4)  Part Stack
        -Inside dimensions replicate outside perimeter of parts
        -Close tolerance to ensure vertical placement of parts into grinder wheel
        -Placed approximately 1/2 of part height above grinder wheel
        -Holds 5 parts at one time to ensure continual loading of grinder wheel
        -Part falls into wheel, 4 remaining parts drop, stack is reloaded by waiting part

    -Process validation accomplished by 2 methods
            -Working Model 2-D Analysis
                    -Bin chute model was developed that prevents back up of parts
                    -Gating system input into program to verify use of center-of-mass turning system
                    -Yielded positive results (100% success rate)
                    -Model of parts stack and chute demonstrates that placement system is a valid approach

            -Prototype Fabrication
                    -Parts bin was built
                    -Treadmill acted as conveyor belt
                    -Gating system built on treadmill
                    -Part chute fabricated
                    -Part stack rapid prototyped in Learning Factory

   -Given the complexity of the task at hand (and without use of pick & place systems) system works
            extraordinarily well
    -Unable to fully test the electromagnetic timing system, but easily accomplished in work environment
    -Parts successfully oriented using center-of-mass gating system
    -Parts slide into stack easily
    -Placement of parts from stack into wheel successfully accomplished

    -Better framing system for assembly of 4 stages
     -Dual magnetic timing system should be attempted and tested