Date of Award

2021

Degree Type

Capstone Project

Abstract

Team 2 (MAG-Shine) was given the responsibility of increasing the ergonomics and e ciency of the current magnet polishing process at MagSeal, while also decreasing the fatigue on the operator and maintaining safe operation. The current process is one of hand-operation and only polishes one magnet at a time, resulting in fatigue and lacking in efficiency. The purpose of the polishing process is to expose porosity within the cast magnet early on before more modi cations are made to the geometry, as to not waste production time on a defective work piece. After gaining an understanding of the problem and how the current process works, the team went into researching possible solutions. Relevant literature and patents were investigated to reveal what information currently exists on solving the proposed issue. Concepts were then generated by each team member, resulting in a total of 108 design concepts based on the design specifications provided by MagSeal. A Pugh analysis was performed on all of the concepts to narrow them down to three top designs. Further analysis was done using a Quality Function Deployment (QFD) analysis to compare the top three designs against the current MagSeal polishing stand to come up with the preliminary design.

Through testing, engineering analysis, and further design considerations, the preliminary design was refined, modeled, and motion of the system was animated. A few prototypes were then made to verify functioning and served as testing apparatuses. Multiple rounds of testing of 3D printed prototypes and consultations with Professor Nassersharif and MagSeal led to multiple design changes on the preliminary design. Components such as motors and speed controllers were also tested. Some motor tests failed which led to a final motor choice picked out by the team and verified by MagSeal.

The final design employs a motion mechanism that consists of a motor, flywheel, and track system mounted to a metal base. The motor pushes a magnet carrier along the track system, and across polishing paper, to automatically polish the magnet(s). The device that holds the magnet(s) is adjustable so as to be able to grip a wide range of magnet diameters and thicknesses. The device increases efficiency and ergonomics by polishing multiple magnets in a timely manner while automating the process to reduce the fatigue on the operator.

Comments

Sponsor: MAGSEAL

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