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Situation
Situation
Operators are forming parts on the wrong part of the backgauge, forcing them to be scrapped.
Incorrectly formed parts cannot be reworked, so this small mistake results in wasted labour and material costs each time it occurs.
Task
Task
I have to design a new backgauge that will prevent operators from being able to form parts if they are not correctly positioned.
The solution must work for every part number on the brake press, thus should be connected to the control system of the machine.
Typical backgauge with no sensors
Action
Action
The first step was determining how the backgauge would look. I opted for a classic backstop with a stepped shape, providing a surface for the part to rest on.
I knew the design would have to incorporate a sensor that would provide feedback to the brake press, and elected for a limit switch, since the operator would be able to detect the mechanical actuation. A cutout the design was added to house the sensor and allow for wiring.
Perhaps the most important part of the design, is how the operator would actuate the switch, and on only the backstop of the design. I decided on a removable middle piece that is locked in with a set-screw from the side, and able to slide a set distance necessary for the sensor to actuate. To ensure the bottom step could not be used, the piece would sit recessed, so it could not be pressed; see below.
The new backgauge was wired into the machine's control system, and adjustments were made to each part program to account for the new backgauge geometry and placement.
Iteration 1 of Backgauge Design
Final(4th) Design, More Compact and Recessed Bottom Step
Results
Results
My design completely eliminated scraps related to incorrect placement on the backgauge, on the brake press it was installed on.
Management decided to begin the process of installing my design onto all the other brake presses on the floor!
Fabricated final design :)
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