BENTELER AUTOMOTIVE INC'

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BENTELER AUTOMOTIVE INC.
19-Nov-09
SENIOR PROJECT PROPOSAL
Prepared for Curt Connell John Hornbach
Created By Brian Crouch Kent Fannin John
Sanford Ryan Snip Tia Stanley
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OUTLINE
19-Nov-09

• Project Definition and Description
• Technical Feasibility
• Resources Required
• Budget
• Schedule
• Summary and Closing
• Questions and Answers

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CURRENT PROBLEM
19-Nov-09
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RISK AREAS
19-Nov-09
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PREVIOUS SOLUTION ATTEMPTS
19-Nov-09

• Ultrasound Before Laser
• Problems with this check
• Contamination of couplant
• Bowed tubes
• Possible risk areas before assembly

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PROPOSED SOLUTION CRITERIA
19-Nov-09

• 100 Check
• No increase of current cycle time
• Inline
• Eliminate risk areas
• Ease of operation
• Low cost
• Environmentally friendly

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RESEARCHED SOLUTIONS
19-Nov-09

• Weight Marking System After Laser
• Ultrasound System After SWC
• Thickness Gauge System Before SWC
• Load Cell System In SWC

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WEIGHT MARKING SYSTEM
19-Nov-09

• Pros
• 100 check
• Part number marking
• Reliability in checking parts
• Cons
• Cost of implementation (10-15k)
• Complicated machine
• Many points of failure
• Risk areas after check

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ULTRASOUND THICKNESS GAUGE
19-Nov-09
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ULTRASOUND SUMMARY
19-Nov-09

• Pros
• Ability to measure after welding
• Eliminate all risk areas
• Inexpensive (4,500)
• Readings as accurate as (0.001mm)
• Cons
• Seam measurement
• Applying couplant to device

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ELECTRONIC THICKNESS GAUGE
19-Nov-09
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THICKNESS GAUGE SUMMARY
19-Nov-09

• Pros
• Inexpensive (4,500)
• Readings as accurate as (0.001mm)
• Environmentally friendly no additional material
• Cons
• Possible seam measurement
• Possible risk areas must measure before
  assembly
• Difficulty with taper cuts
• Burrs could cause inaccurate readings

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LOAD CELL SYSTEM
19-Nov-09
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LOAD CELL IMPLEMENTATION
5-April-01
V-block Tube Locator
Area for Load Cell
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LOAD CELL PROCESS FLOW
19-Nov-09

• Part number entered at setup
• Load cell logic loads lower limit
• Tube is loaded - measurement is taken
• If the tube passes green light, part is welded
• If the tube fails red light, part to reject bin

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LOAD CELL SUMMARY
19-Nov-09

• Pros
• Inexpensive (3,800)
• Implement on existing tooling, designed on new
  tooling
• Accurate weight measurement 0.0004 lb
• No risk areas - checked as assembled
• Environmentally friendly
• Cons
• Rejected tube occurs operator intervention is
  required

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RANKING MATRIX EXAMPLE
19-Nov-09
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LOAD CELL DESIGN EXAMPLE
19-Nov-09
Tube Weights (lbs)
Nominal Tube Dimensions 537 x 31.8 x 1.8mm
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TECHNICAL FEASABILITY
19-Nov-09

• OSHA Approved
• Training
• Time Management
• Availability of Tooling
• Availability of Ordered Parts
• Durability Within SWC

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ENVIRONMENTAL IMPACT
19-Nov-09

• Reusability of Components
• Scrap
• Recycle

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BUDGET
19-Nov-09
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SCHEDULE
19-Nov-09

• Major Milestones
  Completion Date (tentative)
• Proposal Approval 4/13/01
• Design Testing 4/19/01
• Design Completion 4/26/01
• Components Ordered 4/27/01
• Programming Complete 5/25/01
• Build/Assembly/Debug 6/26/01
• Total System Test 7/03/01
• Revisions 7/07/01
• Documentation Complete 7/12/01
• Project Sponsor Approval 7/16/01

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PERSONAL ASSIGNMENTS
19-Nov-09
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SUMMARY AND CLOSING
19-Nov-09

• Lowest Cost Solution
• Implemented at SWC
• Application Specific
• Simple yet Effective
• Operator Friendly

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QUESTION AND ANSWERS
19-Nov-09
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