Appendix E: Product Design Specifications The PDS is in its entirety with the requirements identified by the team as being the highest importance being: Capacity (at least 2000 books an hour must be cut) Accuracy (the radius of the cut will be with 1/64 of an inch) Adjustability (variability from 4.75 to 7.25 inches) Reliability Safety Cost (Less than $2500 to build) PDS Table E-1 Product Design Specifications Performance Requirement Customer Importance Metric Target Target Basis Verification Capacity Pinball Publishing *** # of books per hour >2000 Customer feedback Testing Accuracy of corner cutting Pinball Publishing *** inch <1/64 Customer feedback Testing Corner radius Pinball Publishing *** inch 1/4 Customer feedback Testing Adjustable to different book sizes Pinball Publishing *** inch x inch 3.5x5 / 5x7 Customer feedback Testing Accuracy of adjustability Pinball Publishing *** inch 1/16 Customer feedback Testing Scraps collected Pinball Publishing *** yes/no Yes Customer feedback Testing Movement during operation (Frame stability) Pinball Publishing *** yes/no No Team Inspection Operation time Pinball Publishing *** per day 10 Customer feedback Testing Product is semi- or fully- automated Pinball Publishing ** yes/no Yes Customer feedback Inspection Environment Requirement Customer Importance Metric Target Target Basis Verification
Temperature range Pinball Publishing * °F 40-80 Customer feedback Testing Humidity Pinball Publishing * % <95 Team Testing Noise User * dB <90 Customer feedback Testing Life in Service Requirement Customer Importance Metric Target Target Basis Verification Expected time in service Pinball Publishing *** years >5 Customer feedback Analysis / Testing Cost of Production Requirement Customer Importance Metric Target Target Basis Verification Budget (production cost) Pinball Publishing *** $ <2500 Customer feedback Expense sheet/ BOM Size and Shape Requirement Customer Importance Metric Target Target Basis Verification Portability User * # of people to move 1 Customer feedback Inspection occupied Pinball Publishing *** feet x feet <3x3 Customer feedback Measurement Weight Requirement Customer Importance Metric Target Target Basis Verification Maximum weight Pinball Publishing * pounds <400 Team Measurement Maintenance Requirement Customer Importance Metric Target Target Basis Verification Cost of weekly maintenance Pinball Publishing ** $ per week <10 Team Analysis / BOM Replaceable parts easily available Technician *** yes/no Yes Customer feedback Research / Design Specialty tools required Technician *** yes/no No Customer feedback Research / Design Serviceability (Easy to access) Technician *** yes/no Yes Customer feedback Inspection Unjamming time User *** minutes <3 Team Testing
Installation Requirement Customer Importance Metric Target Target Basis Verification Manpower to Install Pinball Publishing * people ≤2 Team Analysis Amount of time to install Pinball Publishing * days 1 Team Analysis Ergonomics Requirement Customer Importance Metric Target Target Basis Verification Number of operators Pinball Publishing *** people 1 Customer feedback Design Can be worked at all day User *** yes/no Yes Team Inspection / Testing Working position User ** position Customer feedback Design Safety Requirement Customer Importance Metric Target Target Basis Verification Guards Pinball Publishing *** yes/no Yes Customer feedback Inspection Emergency stop Pinball Publishing *** yes/no Yes Customer feedback Inspection Jam stop Pinball Publishing *** yes/no Yes Customer feedback Inspection Required safety warnings and labels Pinball Publishing *** yes/no Yes Team Inspection Aesthetics Requirement Customer Importance Metric Target Target Basis Verification Color, shape, form, finish (looks nice) Pinball Publishing ** yes/no Yes Customer feedback Inspection Quality and Reliability Requirement Customer Importance Metric Target Target Basis Verification Reliability Pinball Publishing *** % of time 95 Customer / Team Analysis / Testing Applicable Codes and Standards Requirement Customer Importance Metric Target Target Basis Verification
Electric wiring standards Standards *** yes/no Yes Regulations Research / Requirements Requirements mandated by government *** yes/no Yes Regulations Research / Requirements Professional society's codes and standards Society's *** yes/no Yes Regulations Research / Requirements OSHA safety codes OSHA *** yes/no Yes Regulations Research / Requirements Testing Requirement Customer Importance Metric Target Target Basis Verification Perform industry standard Pinball Publishing * yes/no Yes Team Requirements/ Testing Tests required to verify performance Pinball Publishing ** yes/no Yes Team Testing Company Constraints and Procedures Requirement Customer Importance Metric Target Target Basis Verification Compatibility with other machines Pinball Publishing *** yes/no Yes Customer feedback Design / Inspection Documentation Requirement Customer Importance Metric Target Target Basis Verification Schematics & coding provided Technician *** yes/no Yes Customer feedback First Hand Legal Requirement Customer Importance Metric Target Target Verification Relevant patents violated Legal *** yes/no No Legal necessities Research Timelines Requirement Customer Importance Metric Target Target Basis Verification Whole design project / milestones included Capstone *** yes/no Yes Course requirements Hand Final product to be delivered by June 2011 Pinball Publishing *** yes/no Yes Customer requirements Hand Disposal Requirement Customer Importance Metric Target Target Basis Verification
Part Model Part Name Part System Manufacturing Required Part Description Nut Mount Adjustment Yes Steel bracket connecting the lead screw nut to the top plate Right Lead Screw Adjustment Yes Precision steel acme threaded rod with 16TPI right hand threads. Machined ends for coupling connection and bearing support Shaft Retaining Ring Adjustment No external retaining ring. Keeps the lead screw machined end in the mounted bearing Air Power No Allows filtering of impurities, precise air regulation, and lubrication of internal moving parts. 150psi max pressure, 45CFM max. ¼”NPT ports Solenoid Valve Air Power No 4-way, 2-position air valve. 1/4”NPT ports. Allows switching of air between the 2 linear actuator ports Tie Rod Air Cylinder Air Power No pancake actuator. 1-½” cylinder bore, 1” stroke length, 1/8”NPT ports Part Model Part Name Part System Manufacturing Required Part Description
Horizontal Member Frame Yes 11gauge steel square tube used for the top and bottom horizontal support members Left Panel Frame Yes 24gauge galvanized sheet metal. Hole at corner for power switch. Fastens to frame with machine screws Rear Panel Yes 24gauge galvanized sheet metal. Cutouts for power cord, air supply from regulator, and scrap slide. Fastens to frame with machine screws Panel Frame Yes 24gauge galvanized sheet metal. Hole at top for hand wheel. Fastens to frame with machine screws Shelf Frame Yes 24gauge galvanized metal. Provides mounting surface for solenoid and controller Vertical Member Frame Yes 11gauge steel square tube used for the vertical support members Part Model Part Name Part System Manufacturing Required Part Description
Linear Shaft Linear Motion No Hardened precision shaft. Supports top plate under loading Spacer Linear Motion Yes Machined aluminum block provides mounting surface to connect the pillow block to the plate Shaft Mount Linear Motion No Steel shaft mounts support the linear shaft Bearing Retaining Ring Linear Motion / Transmission No Retaining ring keeps the linear plain bearing in the pillow block housing Linear Plain Bearing Linear Motion / Power Transmission No Linear plain bearing provides maintenance free motion on linear shaft and vertical pull bar Pillow Block Linear Motion / Power Transmission No Aluminum housing provides mounting of linear plain bearing 1/4NPT Pipe Adapter Plumbing No Solder-joint copper tube fitting allows the joining of the copper piping to the regulator and solenoid ports
Part Part Name Part System Manufacturing Required Part Description 1/8NPT Pipe Adapter Plumbing No Solder-joint copper tube fitting allows the joining of the copper piping to the air cylinder ports Pipe-In Plumbing No Copper tubing provides air supply from the regulator to the solenoid Pipe-Out Plumbing No Copper tubing provides air supply from the solenoid to the air cylinder Vertical Pull Bar Power Transmission Yes Steel rod transmits actuator motion to the load bar Bearing Bracket Power Transmission Yes Steel sheet metal bracket provides support to the pillow block for the vertical pull bar Bushing Power Transmission No Nylon bushing guides and protects the vertical pull bar Bushing Holder Base Transmission Yes Machined aluminum bushing housing mounts to the
Part Model Part Name Part System Manufacturing Required Part Description Bushing Holder Clamp Transmission Yes Machined aluminum clamps the bushing to the base Horizontal Pull Bar Power Transmission Yes Steel square bar transmits actuator motion to the vertical pull bars Load Bar Transmission Yes Steel flat stock transmits actuator motion to the cutting dies. 2 thumb screws allow easy removal from pull bars Scrap Container Scrap Disposal Yes 24gauge galvanized sheet metal guides scraps into the scrap slide. Mounts to the bottom of top plate Slide Scrap Disposal Yes 24gauge galvanized sheet metal transports the scraps from the scrap container to the outside of the device assembly Top Mount Disposal Yes 24gauge galvanized sheet metal mounting bracket supports the scrap slide. Mounts to the bearing bracket Part Model Part Name Part System Manufacturing Required Part Description