Automated Ball Drop Machine Design
Problem statement
One of the most important qualities of a hand tool is their durability, as it has been shown to be a major influence when choosing among product offerings for purchase [1]. Hand tools are used in very vigorous applications in which it is critical they don’t succumb to impact. Milwaukee Tool recognizes this vital characteristic for their products, and in turn, have a robust impact testing methodology to verify the durability and longevity of their designs. In their current testing system, technicians manually pick up a 15lb steel ball and attach it to an electromagnet to be released from a height onto a tool below. This procedure occurs repeatedly, potentially hundreds of times, until the tool fails. This repetitive overhead heavy lifting causes major physical strain on their workers, and per OSHA guidelines, poses an ergonomic risk [2]. Furthermore, in the current process there is the potential for inaccurate data collection, as the technician needs to manually count the number of ball drops. Our goal is to create an automated solution to drop and pick up the steel ball without the need for human assistance, as well as to implement a Programmable Logic Controller (PLC) system that automatically keeps track of the number of times the ball gets dropped before the tool fails. This will not only improve the accuracy and efficiency of the testing procedure, but it will also make the testing process ergonomically safer for Milwaukee Tool lab technicians. Our final design solution will benefit the client by allowing them to have a more efficient testing method for their tools, the consumers by ensuring that the tools sent to market are indeed durable enough to withstand heavy impacts, and the lab technicians by improving their job safety and comfort. [1] “Choosing hand tools,” Choose Hand Safety – CPWR | What Should I Look for in a Hand Tool? [Online]. Available: https://choosehandsafety.org/choosing-hand-tools/look-for-hand-tool. [2] OSHA, “Identifying and Addressing Ergonomic Hazards Workbook”, U.S. Department of Labor [Online], pg. 9. Available: https://www.osha.gov/sites/default/files/2018-12/fy15_sh-27643-sh5_ErgonomicsWorkbook.pdf
Team members
Bryan Bartlett – leader
Hayden Eisenrich – communicator
Ameya Kulkami – accountant
Sarah Clausen – admin
Client
ZhengMing Lee, Milwaukee Tool