The team’s goal is to design and test a prototype and procedure that will automate the insertion of the Kong toy instructions into the cardboard packaging. This automation will increase the speed at which the product is packaged and will serve as an aid to workers with limited dexterity who find the task cumbersome

Cuthbert, Ashley N

Innocenzi, Rachael L

Smith, Marianna R

English

The University of Akron

The University of AkronIdeaExchange@UAkronHonors Research Projects The Dr. Gary B. and Pamela S. Williams HonorsCollegeSpring 2015Senior Design:KONG Toy Instruction-ManualInsertionAshley N. CuthbertUniversity of Akron Main Campus, anc36@zips.uakron.eduRachael L. InnocenziThe University Of Akron, rli5@zips.uakron.eduMarianna R. SmithThe University Of Akron, mrs108@zips.uakron.eduPlease take a moment to share how this work helps you through this survey. Your feedback will beimportant as we plan further development of our repository.Follow this and additional works at: http://ideaexchange.uakron.edu/honors_research_projectsPart of the Electro-Mechanical Systems Commons, and the Manufacturing CommonsThis Honors Research Project is brought to you for free and open access by The Dr. Gary B. and Pamela S. WilliamsHonors College at IdeaExchange@UAkron, the institutional repository of The University of Akron in Akron, Ohio,USA. It has been accepted for inclusion in Honors Research Projects by an authorized administrator ofIdeaExchange@UAkron. For more information, please contact mjon@uakron.edu, uapress@uakron.edu.Recommended CitationCuthbert, Ashley N.; Innocenzi, Rachael L.; and Smith, Marianna R., "Senior Design:KONG Toy Instruction-Manual Insertion" (2015). Honors Research Projects. 45.http://ideaexchange.uakron.edu/honors_research_projects/45SENIOR DESIGN:KONG TOY INSTRUCTION-MANUAL INSERTION F O R  W E A V E R  I N D U S T R I E S  G R O U P  M E M B E R S :  A S H L E Y  C U T H B E R T,  R A C H A E L  I N N O C E N Z I ,  M A R I A N N A  S M I T HP R O J E C T  A D V I S O R :  D R .  J E R R Y  D R U M M O N DM a y  1 ,  2 0 1 5OverviewIntroductionProblem DefinitionDesign DescriptionEvaluationRecommendationsIntroductionWEAVER INDUSTRIESFounded in 1971 as a non-profit organization.Provides vocational training and employment opportunities for individuals with developmental disabilities.The Cuyahoga Falls Facility◦ Packages dog chew toys for Kong Company ◦ 6 million+ Kong toys manually packaged at this facility per year Problem DefinitionCurrent Packaging Method◦ Instruction manuals are inserted into the cardstock by hand before the toys are packaged (Figure 1).Figure 1Project ScopeISSUE• Limited Dexterity • Limited Motor ControlOBJECTIVE• Design & Build a TOOL• To enhance ease of procedure for employeesREVISED OBJECTIVE• Design & Build an AUTOMATED MECHANISM• To enhance ease of procedure for employees• To enhance speed & efficiency of procedureDesign Requirements1. Adjustable for different size packaging2. Automate manual insertion process3. Increase current production rates per employee4. Minimize cost to manufacture5. Protect employees from pinch points and electrical componentsDeliverablesDesign RequirementImportance Units Minimum Goal Ideal Goal1. Adjustable for different size packaging Medium Inches Provided Cardstock SizeMin: 6.5” x 4”Max:9.5” x 6”2. Automate manual insertion processHighPass / FailActivated manual insertion by push-button, manual removal of cardstock.Activated insertion by push-button and removal of cardstock.3. Increase current production rates per employeeHighManuals / Min7.7 104. Minimized cost to manufactureHigh Dollars Within $500 Budget Less than $2505. Employees protected from pinch points and electrical componentsHighPass / FailElectrical components are covered, wedge mechanism is covered and e-stop is in place.Component is completely sealed and only needs to be opened to re-fill manuals and cardstock packaging.Design DescriptionDESIGN #1PROS:• Manual• Use of only (1) hand• Holds multiplecardstockCONS:• Not automated• Does not hold multiple instruction manualsFigure 1The operator would manually slide the arm into the cardstock and open the cardstock via rotation of the tapered flag on the end of the tool.DESIGN #2PROS:• Automated• Use of (1) hand • Holds multiple cardstock• Holds multipleinstruction manualsCONS:• Slider mechanism more complicated to design• Reduced ease of speed variabilityFigure 2The operator would press a button that causes one rotation of the wheel to insert one instruction manual. The operator then removes the “stuffed” cardstock and begins the process again.DESIGN #3PROS:• Automated• Use of (1) hand• Holds multiple cardstock• Holds multipleinstruction manuals• Enhanced speed variabilitySELECTED FOR BUILD Figure 3This design utilizes a rack & pinion set-up above the work bench.Figure 4This design utilizes a rack & pinion set-up above the work bench.DESIGN #3PROS:• Automated• Use of (1) hand• Holds multiple cardstock• Holds multipleinstruction manuals• Enhanced speed variabilitySELECTED FOR BUILDDESIGN #3PROS:• Automated• Use of (1) hand• Holds multiple cardstock• Holds multipleinstruction manuals• Enhanced speed variabilityBUILTFigure 5Table1. Table Stand2. Instruction Manual Box3. Packaging Cardstock Box123Mechanism1. Wedge2. Rack & Pinion3. Stepper Motor132ControlsHardware1. Microcontroller2. Stepper Motor3. Push-Button4. Arduino Uno4123Controls2. Software – Code Function BlockDefinitions• Input       – Push Button• Output    – Motor Step • Output    – Motor Direction“rotateDegree”Command• Rotate shaft CW 410° at a speed of 0.05• Wait 1 sec• Rotate shaft CC 410° at a speed of 0.1• Wait 1 secApplication• Press Push-button (completes circuit)• Runs “rotateDegree” command ONCEEvaluationFinal PrototypeFinal PrototypeEvaluation ResultsDesign RequirementImportance Units Minimum Goal Ideal Goal Test Method Status1. Adjustable for different size packagingMedium InchesDim’s of cardstock we were givenMin: 6.5” x 4”Max:9.5” x 6”Adjustable boxes PASS2. Automate manual insertion processHighPass / FailActivated manual insertion by push-button, manual removal or cardstock.Activated insertion by push-button and removal of cardstock.Wedge inserts manual without human interactionPENDING3. Increase current production rates per employeeHighManual / Min7.7 10 PENDING PENDING4. Minimize cost to manufactureMedium Dollars Within $500 Budget Less than $250 $400 PASS5. Employeesprotected from pinch points and electrical componentsHighPass / FailElectrical components are covered, wedge mechanism is covered and e-stop is in place.Component is completely seal and only needs to be opened to re-fill manuals and cardstock packaging.PENDING PENDINGNext Steps…Material Selection◦ Current: economical and workable◦ Suggested: use aluminum to tighten tolerances & re-design spring locationsMechanism (Motor/Wedge/Rack & Pinion)◦ Current: lightweight, durable & easy to install◦ Suggested: stronger motor & additional wedge iterationsControls◦ Current: simple, long life & adaptable◦ Suggested: add emergency stopFurther Automation◦ Removal of card ◦ Holding card in place during insertion◦ Continuous cycle vs. one-time cycleEase of Loading Cards & InstructionsTHANK YOU!Contact Information:◦ Marianna Smith mrs108@zips.uakron.edu◦ Ashley Cuthbert anc36@zips.uakron.edu◦ Rachael Innocenzi rli5@zips.uakron.edu◦ Dr. Jerry Drummond drummon@uakron.eduAppendixAppendix – ResponsibilitiesTask LeadInitial Project Design AllConcept Drawings Rachael InnocenziElectrical & Instrumentation Ashley CuthbertConstruction Marianna SmithTesting & Evaluation AllAppendix – Part DrawingsPlease note:The following part drawings were created before production.  As the build progressed, dimensions were changed and components were added as needed.Appendix – Part DrawingsTable TopAppendix – Final Concept Drawings (1)Appendix – Final Concept Drawings (2)Appendix – Final Concept Drawings (3)Appendix – Final Concept Drawings (4)Appendix – Part DrawingsTable TopAppendix – Instruction Manual Box Drawings (1)Appendix – Instruction Manual Box Drawings (2)Appendix – Instruction Manual Box Drawings (3)Appendix – Cardstock Box Drawings (1)Appendix – Cardstock Box Drawings (2)Appendix – Cardstock Box Drawings (3)Appendix – Part DrawingsStepper MotorAppendix – SchematicMicrocontrollerAppendix – SchematicMotor ControllerAppendix - Code////////////////////////////////////////////////////////////////////©2011 bildr//Released under the MIT License - Please reuse change and share//Using the easy stepper with your arduino//use rotate and/or rotateDeg to controll stepper motor//speed is any number from .01 -> 1 with 1 being fastest -//Slower Speed == Stronger movement/////////////////////////////////////////////////////////////////#define DIR_PIN 2#define STEP_PIN 3const int BUTTON_PIN = 12;       // variable for push button pinint buttonstate = 0;             // variable for push button statusAppendix – Code (cont’d)void rotateDeg(float deg, float speed){ //rotate a specific number of degrees (negitive for reverse movement)//speed is any number from .01 -> 1 with 1 being fastest - Slower is strongerint dir = (deg > 0)? HIGH:LOW;digitalWrite(DIR_PIN,dir); int steps = abs(deg)*(1/0.225);float usDelay = (1/speed) * 70;for(int i=0; i < steps; i++){ digitalWrite(STEP_PIN, HIGH); delayMicroseconds(usDelay); digitalWrite(STEP_PIN, LOW); delayMicroseconds(usDelay); }} Appendix – Code (cont’d)void setup() { pinMode(DIR_PIN, OUTPUT); pinMode(STEP_PIN, OUTPUT); pinMode(BUTTON_PIN, INPUT);} //This example code is in the public domain.//"switch code" from the rduinoclassroom.com (Smiley)void loop(){ // Get the state of the push buttonbuttonstate = digitalRead(BUTTON_PIN);Appendix – Code (cont’d)//Ask, "is the button pressed?"//If YES, the buttonstate is HIGH.if (buttonstate == HIGH){//rotate a specific number of degrees rotateDeg(-410, 0.05); delay(1000);rotateDeg(410, 0.1);  //reversedelay(1000); }}Appendix – Wiring Diagram Note: The picture to the left shows the simple schematic for powering the stepper motor.  In order to power the Arduino Uno from the wall connection also, connect wires from the “GND” and “+5V” of the Easy Driver to the “GND” and “5V” of the Arduino Uno.To insert the button into the controls, we used the concept shown in the picture above and taken from the tutorial on the Arduino Environment website (http://www.arduino.cc/en/Tutorial/Pushbutton)  However, the button pin connection was changed to position 12 on the Arduino Uno.  Appendix –Materials & SuppliersAppendix –Materials & Suppliers

Senior Design:KONG Toy Instruction-Manual Insertion

https://ideaexchange.uakron.edu/cgi/viewcontent.cgi?article=1131&context=honors_research_projects

Senior Design:KONG Toy Instruction-Manual Insertion

Abstract

Similar works

Full text

Available Versions

The University of Akron