10-Dec-2010 - Conference call with PCC/SPS
Attendance:
● Dr. Alan Raisenen (RIT)
● Gary Sereico (RIT, P11582)
● Desirae Gilbert (RIT, P11582)
● Josh Rabau (RIT, P11582)
● Ryan McKnight (RIT, P11581)
● Rich Drinker (SPS - Rivets, Jenkintown)
● Chris Enright (SPS - die inspection)
● Jack Hyzak (PCC corporate)
PCC/SPS:
● PCC - $7 billion/yr, global company, castings/forging/fasteners
● SPS one of five PCC divisions
● 30 SPS sites worldwide
● Customers: Boeing, Airbus, Bell Helicopter
● Rivets for aerospace applications
○ Aircraft body/ aluminum skin
P11582: PCC Rivet Inspection Automation:
Rivet geometry and current inspection techniques:
● Concentricity - center bore to stem
● Land thickness - marked on drawing as 0.010-0.002
● Head protrusion thickness - land thickness and angle
● Both protruding head / flush head designs
● Samples are dash-5
● Largest is about same diameter as pen
● Current final inspection tool:
○ Comparator - tools
○ Micrometer / super micrometer - diameters
○ Tesascan
○ Fixed length gauges
● Lot size varies 1000s to 10000s
○ Inspect about 100/lot, test 25/lot
○ Total number inspected depends on customer requirement
○ Process tracking may lead to lower inspection requirements
● Information entered manually into lot acceptance software
Design concepts
● Display GO/NO GO output to operator taking measurements
● Capability of more detailed measurement output for inspectors and machine set up
○ Output dimensions
○ Process centering
● Data-basing, integrate with SPC
● Current systems available with cycle time 10-15 sec to scan - Depends on scan
● Resolution
● Determine ideas for individual part vs multiple part scanning
● Familiar with LabVIEW, can use LabVIEW to export data to excel
○ SQL database
○ May need to integrate with current lot acceptance software being used
● Device footprint approx 1-2 ft square, to fit on desk/cart
● Located in manufacturing environment
○ Oil mist in air
○ Suggest panel type cabinet, removable plexi covering, etc..
P11581: PCC Thread Role Die Measurement
Die Information
● The die we received as example is the typical footprint
○ The difference between dies depends on thread specifications
○ Some dies may be as small as 1” in height and 2” in length
● Dies are costly at $500-$1000 per set
○ Depending on process die life changes
○ Hot rolling- 1200-1500 pieces
○ Cold rolling- 500-600 pieces
○ This translates to around $1 a part in die costs
● Lots of different types
● Metric/standard/pitch/skew/etc
Important information
● This project will be useful in developing wear cause and effect to learn how dies perform
● Cycle Time- will need to be considered as the location in Jenkintown has 18 thread roll machines with dies changing frequently
● Usually if one die is bad then whole “release” of dies is bad
● If die is bad it might be able to be shimmed into place if known what dimensions are bad
● Data analysis and SPC will be useful to get better production control
Design concepts
● For operators taking measurements there should be a GO/NO GO display
○ Can be as simple as a green light and red light
● More detailed measurement results should be available for the engineers and inspectors
● LABVIEW is good option to be used for controlling
● Data can be stored in Excel from LABVIEW
● SQL is primary data base that they currently use
● Device footprint should be small and able to fit onto desk or cart
● Location of unit will be in manufacturing environment
○ Suggested to have a panel type cabinet with removable covering
● No contact measuring
● Move sensor, not die because of weight