Design and Development of a Placement Mechanism

for an Automated Packaging Machine

MASSAC SESINSTITUTE
By

Steven Ratner SEP 19 2019

B.S. Mechanical Engineering LIBRARIES C03
Boston University, 2015

Submitted to the Department of Mechanical Engineering

in partial fulfillment of the requirements for the degree of

MASTER OF ENGINEERING IN ADVANCED MANUFACTURING AND DESIGN

AT THE
MASSACHUSETTS INSTITUTE OF TECHNOLOGY

September 2019

©StevenRatner, MMXIX. All rights reserved.

The author hereby grants to MIT permission to reproduce

and to distribute publicly paper and electronic
copies of this thesis document in whole or in part
in any medium now known or hereafter created.

Signature of Author: Signatureredacted

Steven Ratner
Department of Mechanical Engineering
August 9, 2019

Certifiedby: Signature redacted-

David Hardt
echanical Engineering

Signature red aedt dI-""S"upervisor

Accepted by:
Nicolas Hadjiconstantinou
Professor of Mechanical Engineering
Chairman, Committee for Graduate Students
This page intentionally left blank.

2
 Design and Development of a Placement Mechanism
for an Automated Vial Packaging Machine
By

Steven Ratner

Submitted to the Department of Mechanical Engineering on 9 August, 2019,

in partial fulfillment of the requirements for the degree of
Master of Engineering in Advanced Manufacturing and Design

Abstract
This thesis describes the development of an automated packaging machine capable of

transitioning bulk vials into containers of 100 nested vials. Specifically, this thesis focuses on the

design of an automated placement mechanism that is used in the packaging machine to feed groups

of 10 vials into a tray for shipment. The placement mechanism is composed of a rake into which

the vials are funneled, allowing the rake to push a line of 10 vials forward, dropping below into a

tray. Creation of the placement mechanism aids the packaging machine automate the loading of

vials, decreasing labor, increasing throughput, reducing packaging components, and implementing

a layer of robustness to the process through automatic inspection and recording. An explanation

of antecedent packaging procedure along with industry priorities are reported along with the

methodology behind the mechanical design that went into creating the mechanism. The

constructed packaging machine is theoretically capable of packing 30 packages per hour.

Thesis Supervisor: David E. Hardt

Title: Professor of Mechanical Engineering

3
Acknowledgments
Thank you, Valentina.

4
5
Contents
1 Introduction ...................................................................................... . 13

1.1 Background and Motivation.............................................................13

1.2 O bjectives............................................................................... . 16

1.3 Scope................................................................................... . 16

1.4 Work Distribution...................................................................... 18

2 A utom ation ...................................................................................... . 19

2.1 Defining Automation.....................................................................19

2.2 Reasons for Automation Implementation............................................ 20

3 System Overview ............................................................................... . 21

3.1 Vial Accepter and Orienter.............................................................22

3.2 Transfer Line Feeder.................................................................... 25

3.3 Vial Placement Mechanism.............................................................28

3.4 Motor Selection & Programming...................................................... 30

3.5 Vision System & Industry 4.0 Connectivity...........................................30

4 Placement System Design......................................................................33

4.1 Design Methodology .................................................................... 13

4.1.1 Background Research........................................................ 33

4.1.2 Initial Sketches.............................................................. . 36

4.1.3 Prototype I..................................................................... . 44

4.1.4 Prototype ................................................................... . 46

4.1.5 Prototype III................................................................... . 50

4.1.6 Prototype IV ................................................................... . 54

6
 4.2 System Overview....................................................................... 65

4 .3 F lexure.................................................................................... . 67

4 .4 R ake...................................................................................... . 69

4.5 Tray Transport System.................................................................. 71

4.6 Cam Mechanism......................................................................... 74

4 .7 C hassis.................................................................................... . 76

4.8 A ctuators................................................................................. . 78

5 Placement System Performance............................................................. 80

5.1 Evaluation Methods.................................................................... 80

5.2 Perform ance............................................................................ . 81

6 Conclusions, Recommendations, and Future Work...................................... 83

6.1 C onclusions............................................................................ . 83

6.2 Recommendations and Future Work.................................................. 84

A Engineering Drawings ............................................................................... 87

B B ill of M aterials......................................................................................137

B ibliograp hy ................................................................................................ 139

7
List of Figures

1-1 Side view of a 350pl QuanRecovery vial.............................................14

1-2 An advertisement for QuanRecovery vials and plates with the inclusion of

chem istry socks [1]................................................................... . 14

1-3 A package containing 100 1ml vials with QuanRecovery treatment..............15

1-4 Functional automated packaging machine prototype .............................. 17

3-1 Annotated layout of the protype machine [5] ....................................... 21

3-2 First stage of the automated packaging machine, vial accepter and orienter.....22

3-3 First stage of the automated packaging machine with the outer shell of the vial

orienter bowl removed to reveal sorting acrylic sorting fins along the outer shell of

the feeder [5].......................................................................... . 23

3-4 Drawing of the inner segment of the vial orienter displaying the 'height qualifier'

pushing unoriented vials out of the 'scallops' while leaving oriented vials to pass

through the system [5]................................................................ . 24

3-5 Second stage of the automated packaging machine, transfer line feeder.........25

3-6 Picture of the vial transfer line system indication the position of major components

[5 ]........................................................................................ . 26

3-7 Picture of the transfer line feeder in the initial state as vials are being loaded into

the queue position [5]................................................................. . 27

3-8 Picture of the transfer line feeder in the final state as a loaded vial is being pushed

into the orienting system [5].......................................................... 27

3-9 Third stage of the automated packaging machine, vial placement mechanism......28

8
3-10 Front side view of the rake holding 10 vials with the biasing block extended. The

rake is highlighted in red while the biasing block is highlighted in yellow. Be purple

arrow represents the direction in which the biasing block actuates while the green

arrow is pointing to a microswitch that senses the extension of the rake [5].......29

3-11 Machine vision algorithm's output when counting 100 vials. The image is

positioned with a camera pointing down towards the top of the vials. Each circle

and diamond represents one counted vial as captured by the vision system. The

picture is converted to black and white [5].......................................... 31

4-1 Picture of Arpac's automated bottle stacking mechanism leveraging a solenoid to

push a line of bottles into an 8 by 8 matrix [6]....................................... 34

4-2 Picture of Crayola's crayon packaging mechanism with gravity fed crayon pusher

m echanism [7].......................................................................... . 35

4-3 Sketch of the pallet loading mechanism initial brainstorming idea. Output tube from

top bowl feeder shown on the upper left side of the sketch. Solenoid motor pushing

vials into line shown on the middle left side of the sketch. 1Ox vials lined up above

tray shown in the middle of the sketch............................................... 36

4-4 Isometric sketch of the pallet loading mechanism initial brainstorming idea.

Aligned vials sitting above a partially full tray displayed in the sketch. 30 to 45

degree angle indication for the slope at which the tray will sit. Opening door sitting

beneath aligned vials................................................................ . 37

4-5 Side view preliminary concept sketch of rake mechanism displaying the motion of

the rake moving over the vials as drawn by Diarny Fernandes [5]................39

9
4-6 Top-down view of pushing mechanism (solid black bar) connected to a solenoid

(square with directional) feeding aligned vials into tray below................... 40

4-7 Isometric view of pushing mechanism concept displaying aligned vials sitting in

front of pusher on top of a tray with one row of loaded vials.......................41

4-8 Sketches of the three-sided slider mechanism connected to a track on which the

slider can move in one axis when actuated by a solenoid. The solenoid is indicated

by the letter 'M' for motor in this picture............................................ 42

4-9 Isometric sketch of the three-sided slider connected to the track system with the

solenoid, lettered 'M', sitting behind the slide...................................... 43

4-10 Side view of prototype I............................................................... 45

4-11 Isometric view of L-bracket on the left with U-shaped channel on the right.....46

4-12 Top view of prototype II............................................................... 47

4-13 Side view of prototype II............................................................. 47

4-14 Top view of flexure acting as a linear slide on one of the lathes from 2.72.......48

4-15 Front view sketch of a rake holding vials sitting above a tray holding vials. The

back square on the right side represents a pushing block connected to a voice

co il.................................................................................... . . 49

4-16 Front view of a 3D printed rake with notch for biasing block cut out on the left

sid e .................................................................................... . . 49

4-17 Left side view of prototype III........................................................ 51

4-18 Right side view of prototype III...................................................... 52

4-19 Top side view of prototype III........................................................ 53

4-20 Top side isometric view of prototype IV............................................. 56

10
4-21 Left side isometric view of prototype IV.............................................57

4-22 Isometric view of cam mechanism................................................... 58

4-23 Offload ramp attached to back of chassis.............................................59

4-24 Tray queue attached to front of chassis.............................................. 61

4-25 Tray slider sitting on top of guide grooves........................................... 62

4-26 Mounting brackets with variable angle holes........................................63

4-27 First row assistance edge on back wall of tray slider............................... 64

4-28 Gate funneling incoming vials into rake............................................. 65

4-29 Final vial placement mechanism..................................................... 66

4-30 Solidworks static force simulation on flexure....................................... 67

4-31 Technical drawing of flexure geometry.............................................. 68

4-32 Left side view of rake.................................................................. 70

4-33 Front side view of rake............................................................... 71

4-34 Bottom side view of tray transport system.......................................... 72

4-35 Isometric view of tray slider mechanism.............................................74

4-36 Cam mechanism connecting to the flexure.......................................... 75

4-37 Technical drawing of cam geometry................................................. 76

4-38 Isometric view of chassis displaying four main sections.......................... 78

11
12
Chapter 1

Introduction

This chapter outlines the background and motivation behind Waters' request for an

automated packaging machine to be designed and constructed. Furthermore, the project's

objectives, scope, and work distribution are reviewed to provide the reader with a proper

understanding of the program's purview.

1.1 Background and Motivation

The analytical laboratory instrument manufacturing company, Waters, produces a

comprehensive range of system solutions for the life sciences industry. Liquid chromatography

and mass spectrometry machines are the center of Waters' product offering. As a holistic supplier

of its services, Waters provides auxiliary goods to support its laboratory instruments.

One such auxiliary product, QuanRecovery, was introduced to the market in Q2, 2019.

QuanRecovery minimizes the effect of sample loss due to non-specific binding and ionic

interactions through a proprietary treatment. This treatment is applied to the interior surface of Iml

vials, shown in Figure 1-1, that are sold to laboratories globally. Through a successful marketing

campaign, propelled by the addition of free chemistry socks with every order, a well-known

favorite amongst scientists and procurers alike, Waters' obtained excellent early adoption after

considerable initial interest as a result of marketing efforts and product quality. Figure 1-2 displays

an advertisement of the QuanRecovery vials along with the aforementioned chemistry socks.

13
 Figure 1-1: Side view of a 350piQuanRecovery vial. Vial measures 12mm in diameter at

the base by 32mm in height.

Figure 1-2: An advertisement for QuanRecovery vials and plates with the inclusion of chemistry

socks [1]. Note: Chemistry socks and vials are not drawn to scale. This figure represents the

advertisement Water's used to allure customers to buy QuanRecovery vials.

Waters sells the 350pl vials in packs of 100, as shown in figure 1-3. Experimentation

indicates a human takes 2 minutes to package 100 vials by hand. With an estimated labor rate of

14
15 dollars per hour, close to 0.5 dollars per pack could be eliminated with an automated system.

Additionally, hand packaging is disadvantaged in the precision of vial placement and the

containment of external particulate. The human packagers have been known to input 99 vials

instead of 100 vials, leading to an increased probability of breakage during transit. Due to the

uncertainty of vial count, Waters is forced to label similar products packages as having

'approximately 100' vials instead of '100' vials. With the introduction of this automated system

into the first QuanRecovery production line, Waters will be able to label the packages as'100'.

Figure 1-3: A package containing 100 350pl vials with QuanRecovery treatment. Note: Vials in

the package are positioned in a 10 by 10 matrix with every other row being staggered to nest in

as tight packed of a position as possible. All vials are facing 'upward' with their opening situated

at the top of the container.

15
 The downsides of Water's current packaging methods prompted the company to enlist help

from the 2019 MIT MEng cohort to develop an automated solution that would robustly place 100

vials into each container. This thesis describes the solution that was created to replace Waters'

human packaging system.

1.2 Objectives

The project proposed to design an automated system that would take a pile of vials and

correctly place them facing upwards in groups of 10 by 10 to fill a I00-vial container in a

repeatable manner. The key objectives were as follows:

- Receive a bulk pile of unoriented vials and place them in a 10 by 10 matrix facing

upwards in a vial package.

- Package a minimum of 100 vials per 2 minutes.

- Minimize external particulates from accumulating within the vials.

- Validate that 100 vials are placed into each package.

- Keep development and production costs under $10,000.

1.3 Scope

The project scope was contained to developing and building a functional prototype,

displayed in Figure 1-4 below, that could be used to demonstrate the potential for the proposed

automated machine. Once the prototype was complete and working, engineering drawings of each

custom component were made along with an assembly and user manual. This way, Waters could

manufacture and operate future iterations of the machine as production levels deemed necessary.

16
 Figure 1-4: Functional automated packaging machine prototype. A) Vial acceptor and

orienter. B) Transfer line feeder. C) Vial placement mechanism. D) Control panel. Note: Orange

17
arrows represent the path vials flow as they make their way through the machine. Loose vials are

placed in the vial acceptor and orienter, moved through the transfer line feeder, then stacked in

the vial placement mechanism.

1.4 Work Distribution

The system was split into five main tasks as listed below:

(1) Orienting the vials from a bulk unorganized state.

(2) Feeding the oriented vials into the placement mechanism through a transfer line.

(3) Packaging the vials into trays.

(4) Validating the packaged vials to ensure they are correctly placed.

(5) Motor selection and control.

Initially, all of the group members worked on each of the tasks together. However, after

the inceptive brainstorming stage was complete, the five tasks were split between each of the

teammates for the sake of efficiency. The owners of each task are as follows: (1) Zhengyang Zhang

[2], (2) Efstratos Moskofidis [3], (3) Steven Ratner, (4) Siyang Liu [4], (5) Diarny Fernandes [5].

18
Chapter 2

Automation

This chapter presents a definition for automation; one that will be used as the premise for

why the packaging machine creation is relevant in the 2 1St century. Furthermore, the societal

impact of automation is briefly explored.

2.1 Defining Automation

In the history of the manufacturing industry, the transition from hand-made to automated

work has taken many forms over the last quarter-century. Current buzzwords such as machine

learning, data analytics, artificial intelligence and the Internet of Things (IoT) are redefining what

popular belief would have once suggested was the face of automation: robotics. Even over the last

five years, many questions have been raised about what truly defines automation and where it is

going. In the workplace there are concerns over the ethics of replacing the human being with a

machine. In the home there is concern over data collection and privacy, where both logical and

physical machines are recording what we say, tracking products and services we prefer, and

tailoring the media we consume to our analyzed behaviors. It is easy to get lost in the many

thousands of online articles warning of the impending danger of becoming a more mechanized

civilization. However, from the perspective of an engineer, we must see the state of the art for

what it is in order to extract from the hysteria the truly plausible implications of increasing

automation.

For the purposes of this thesis, automation will be defined as the use of a computer-guided

mechatronic system to perform a physical task with little to no human intervention. The system

may also collect data on its environment and respond to stimuli in that environment. However, it

19
is not necessary for the system to do so in order to abide by this crude definition of automation. In

this thesis we will focus specifically on what the human being relies on the machine to do and

what types of mechanical intervention can be considered automation by this definition. We will

explore the motivations for implementing physical automated systems on the factory floor and not

software-only solutions such as data analytics and machine learning. These are for another

technical discussion that is out of the scope of this particular thesis. For more detailed work on

Industry 4.0 integration for this project, refer to Siyang Liu's thesis: Design and development of

an automated inspection system for vials [4].

2.2 Reasons for Automation Implementation

Increasing throughput, reducing injury from repetitive motion or boredom, and making

manufacturing less costly may immediately come to mind as the main motivations for the

manufacturing industry to implement automation. With a computer-controlled machine the

benefits are nearly immediate to understand: the company no longer has to pay an employee's

hourly wage, insurance or other benefits just so he or she can continuously perform a single task

or flow of tasks. The employee may then seek more engaging, personally fulfilling or challenging

work.

20
Chapter 3

System Overview
This chapter provides a synopsis of the vial packaging system's features, layout, and

operation. Specifically, the system is broken down and detailed through its five principal

components. Figure 3-1 below displays the final layout of the prototype machine.

Bulk Vial Loading

L Rotary Vial Feder

Transfer
Channel

f~.7~

Cam
Actuator and
Transfer Une

Figure 3-1: Annotated layout of the protype machine [5].

21
3.1 Vial Accepter and Orienter

The vial sorting system is the first stage of the automated machine. It accepts loose vials in

bulk and outputs singulated vials, all with the same final orientation. Figure 3-2, 3-3, and 3-4 below

displays the setup of the vial sorting system, resembling a bowl feeder.

Figure 3-2: First stage of the automated packaging machine, vial accepter and orienter. A) Vial

orienter bowl stand. B) Vial orienter bowl. C) Internal vial orienter bowl motor. D) Oriented vial

exit point. E) Drive belt. F) External vial orienter bowl motor.

22
 Teknic
Clearpath*
servomotor

rT~~ 4
a

Outer stage with Center stage with Drive belt

sorting fins rotating foam cone

Figure 3-3: First stage of the automated packaging machine with the outer shell of the vial

orienter bowl removed to reveal sorting acrylic sorting fins along the outer shell of the feeder [5].

23
 BACKUP TOOLING HEIGHT
RING RING QUALIFIER

INNER WALL SCALLOPS

OF BOWL
Figure 3-4: Drawing of the inner segment of the vial orienter displaying the 'height qualifier'

pushing unoriented vials out of the 'scallops' while leaving oriented vials to pass through the

system [5].

The sorting system contains by three primary components: a center disk that accepts loose

vials and transports them, a bowl with scallops that singulates vials, and viarious selectors that

retain vials facing the desired orientation while rejecting non-oriented vials. The inclined center

disc rotates, applies centrifugal force on vials, and propels them onto the scallop pockets. The

bowl also rotates continuously and moves the vials past series of passive mechanical selectors

which reject vials that are not properly nested within the scallops and not facing the right

24
orientation. The rejected vials are returned to the center of the bowl and recirculated; the retained

vials are pushed out of the bowl and move on to transfer line.

For a more detailed overview on the design, development, and performance of the vial

sorting mechanism, refer to Zhengyang Zhang's master's thesis: Design and development of an

automated sorting and orienting machine for vials [2].

3.2 Transfer Line Feeder

The transfer line feeder is the second stage of the automated machine. It receives sorted

vials from the vial accepter and orienter and transfers them to the vial packaging mechanism at the

proper cadence and alignment. Figures 3-5, 3-6, 3-7, and 3-8 below displays the transfer line

feeder.

Figure 3-5: Second stage of the automated packaging machine, transfer line feeder. A) Cam

mechanism. B) Vial pusher. C) Vial turner.

25
 Vial queuing rollers
(with added twist to
provide correct
alignment of the vials
with the rake)

Transfer line channel

(receives vials from
rotary bowl feeder)

Vial in pre-transfer
position

Spring-loaded pusher
block (to transfer
vials into rollers)

Ball bearing to
provide rolling
contact between cam
and pusher block

Cam

Cam stepper motor

Figure 3-6: Picture of the vial transfer line system indication the position of major components

[5].

26
 Vials loaded from
rotary bowl feeder

Pusher block in ready

position

-Spring relaxed

a
Vial in ready position

Figure 3-7: Picture of the transfer line feeder in the initial state as vials are being loaded into the

queue position [5].

Vials loaded from

rotary bowl feeder
remain in position
during push thanks
to cutaway in pusher
block

. Pusher block in
engaged position

Spring compressed

Vial(not visible)
CI pushed into queuing
AtM rollers
- 6

Figure 3-8: Picture of the transfer line feeder in the final state as a loaded vial is being pushed

into the orienting system [5]

27
 The transfer line feeder contains three subsystems: a channel acting as a queue accepting

vials from the sorting and orinenting system, a vial pushing mechanism that propels vials through

a turner, and a turner that orients vials at the correct inclination to match with the placement

mechanism's angle.

For a more detailed overview on the design, development, and performance of the transfer

line feeder, refer to Efstratios Moskofidis' master's thesis: Design and development of a transfer

system for an automated vial packaging machine [3].

3.3 Vial Placement Mechanism

The vial placement mechanism performs two primary tasks: loading the oriented vials into

a tray and queueing empty trays to be loaded with vials. Figures 3-9 and 3-10 below displays a

diagram of the placement mechanism with the major components labeled.

AA

Figure 3-9: Third stage of the automated packaging machine, vial placement mechanism.

A) Empty tray entrance. B) Tray loading section. C) Oriented vial entrance. D) Packaged tray

28
 exit. Note: Orange arrows represent the movement ofthe trays through the packaging

mechanism. Blue arrows represent the movement of vials through the packaging mechanism.

Figure 3-10: Front side view of the rake holding 10 vials with the biasing block extended. The

rake is highlighted in red and the biasing block is highlighted in yellow. Be purple arrow

represents the direction in which the biasing block actuates and the green arrow is pointing to a

microswitch that senses the extension of the rake [5].

Positioned after the transfer line feeder, the placement mechanism funnels a line of 10 vials

into the rake. The cam applies force through the flexure, acting as a linear slide, to the rake. This

force propels the rake forward, positioning it over the tray, allowing vials to drop into their final

placement. After each stroke of the rake, the tray slider steps down to the next empty row, allowing

the process to repeat.

When a tray is loaded with 100 vials, the tray slider moves down to the offboard ramp,

where the full tray is able to slide out towards the vision system. After the full tray has been

29
discharged, the tray slider moves back up; permitting the next empty tray to fall into place on the

tray slider.

For a more detailed overview on the design, development, and performance of the vial

placement mechanism, refer to chapters four through six in this thesis.

3.4 Motor Selection & Programming

The machine utilizes several motion axes to achieve reliable vial packaging. The following

list describes all motors and actuators used on the machine:

Vial rake - 24 VDC stepper motor (operating a cam)

Tray lead screw - 24VDC stepper motor (direct drive)

Vial-biasing block - 120VAC linear solenoid

Transfer line feeder - 24 VDC stepper motor (operating a cam)

Rotary bowl feeder (center stage and sorting ring) - Teknic @ ClearPath TM servomotor

with integrated motor controller

Sensors are placed throughout the machine layout to provide feedback on the machine's

performance:

Transfer line sensor: standard 24VDC optical sensor

Vial counter: standard 24VDC optical sensor

Rake actuation counter: 24VDC microswitch, wired normally open

For a detailed overview of the motor selection and programming of the machine, please

refer to Diarny Fernandes' master's thesis: Design and development of a precision packing stage

and master control system for an automated vial packaging machine [5].

3.5 Vision System and Industry 4.0 Connectivity

30
 The last stage of the packaging machine is automated inspection and data transfer. The

machine needs to produce exactly 100 vials packaged in'a plastic tray in a robust fashion.

Therefore, an automated inspection system is developed to confirm the correct number of vials in

a package. In addition, Waters needs to keep track of the manufacturing data of the packaging

machine since the packaging process happens at a remote offsite location. As such, a data

delivery system is also developed to post operational data in a server so that Waters can monitor

the machine performance in real time. Figure 3-11 below displays a picture of representing the

machine vision algorithm's output when counting 100 vials.

Figure 3-11: Machine vision algorithm's output when counting 100 vials. The image is

positioned with a camera pointing down towards the top of the vials. Each circle and diamond

represents one counted vial as captured by the vision system. The picture is converted to black

and white [5].

31
 The automated inspection system is enabled by a Raspberry Pi 3 Model B+ and a

Raspberry Pi NoIR Camera module with infrared capability. As a completed package of vials exits

the packaging stage, it enters a black box with the camera installed on the ceiling. The black box

is selected in order to create a controlled lighting environment for the camera to deliver a robust

performance. Both white LEDs and Infrared LEDs are selected to provide adequate lighting inside

the black box so that the camera can capture all the features in the package. The Raspberry Pi

is set up with Python 3 and OpenCV to run feature recognition algorithms.

Once the image recognition algorithm finishes running. The output data is stored in the

SD card with Raspberry Pi, which will be keeping track of the machine uptime and total number

of properly packed packages that have been produced. Along with some other crucial operational

data such as machine throughput rate and machine uptime, the data will be sent through ethernet

to the Waters server for storage and inspection.

For a detailed view of the automated inspection and connectivity of the machine, please

refer to Siyang Liu's master's thesis: Design and development of an automated inspection system

for vials. Master's thesis [4].

32
Chapter 4

Placement System Design

This chapter describes the design methodologies behind each progression of the prototype

that culminated in the final delineation of the placement system.

The placement system was designed to operate freely without input from the other modules

to increase the ease of prototyping and lead to overall modularity of the machine. During

prototyping, correctly oriented vials were hand loaded into the rake. For final assembly,

collaboration between the placement system and transfer line feeder took place to ensure optimal

mating of both subsystems.

As previously stated, the placement system encompasses oriented vial loading into a tray

in a 10 x 10 matrix. Additionally, the placement system contains a queue for empty trays and

passes loaded trays onto the vision system.

4.1 Design Methodology

A total of 4 prototypes were built before resting on the final design. Each prototype was

created to test a specific set of functions within the placement mechanism. As iterations

progressed, the machine was able to leverage insight from previous prototypes to reach an

optimized delivery point. This section describes the fundamentals behind each of the models with

lessons learned and positive points highlighted for final comparison.

Background Research 4.1.1

Initially, background research occurred to find an existing solution to the presented

problem. Investigation included patent searching, YouTube video viewing, and internet searching

for any automated machine that packaged vials or a similar shaped object. Many videos and

33
companies were found that created machines to orient and linearize a pile of objects. For example,

numerous bowl feeders exist to orient larger bottles. However, none, of the stock mechanisms

nested cylindrical objects in a 10 by 10 matrix within a tray exactly as needed.

Inspiration was drawn from two specific YouTube videos; one displaying the nesting

technique used for bottle packaging by the company Arpac [6], the other showing the insertion of

Crayola crayons into their packages [7]. Figure 4-1 below shows a snapshot of a conveyor

mechanism mated to a linear slide that pushes a line of 8 bottles into rows. The translation of linear

motion in an orthogonal direction by a 'pusher' spurred the development of the rake attachment

used in the final product. Although the bottles in Arpac's machine are not placed inside of a four-

walled tray, their arrangement presented a unique view into a plausible possibility to leverage on

the final prototype.

Figure 4-1: Picture of Arpac's automated bottle stacking mechanism leveraging a solenoid to

push a line of bottles into an 8 by 8 matrix [6]. A) Input line of bottles. B) Bottle pushing

solenoid. C) Nested stack of bottles. D) Direction of input bottle travel. E) Direction of solenoid

34
pusher & nested bottle travel. Note: The orange arrow represents the direction of travel of newly

inserted vials while the blue arrow represents the direction of one stroke length of the solenoid

pushing bottles forward into their nested position.

Crayola's technique for inserting arrayed cylinders (crayons) into packages involved a

similar setup as Arpac's pusher. The main difference was Crayola's use of gravity to feed oriented

vials into the pushing device. Figure 4-2 below displays the crayons lined up and oriented in a

specific direction before they drop into the pushing device. This use of gravity assisted crayon

alignment was mimicked in the vial placement systems technique that allowed vials to freely fall

under the rake mechanism into the tray below.

W79

"" - - *-

'"A0

- 4
,

Figure 4-2: Picture of Crayola's crayon packaging mechanism with gravity fed crayon pusher

mechanism [7]. A) Rows of Crayola crayons. B) Pusher mechanism. Note: Orange arrow

35
 represents the directional force that gravity is placing on the crayons, and thus the direction that

the crayons travel. As stated in the text above, this figure pays tribute to the Crayola packaging

video that lay the foundation of gravity feeding into the packaging machine's design.

Initial Sketches 4.1.2

The first month of design ideation consisted of background research, discussed above, and

brainstorming sketches. The initial concept of loading 10 vials above the tray is highlighted in

Figures 4-3, 4-4, and 4-5. This abstraction presents an opening door concept in which the 10 vials

are aligned above the pallet onto which they will be loaded. A door swings open from the bottom

of the vials, and they are able to fall in place onto the tray. Although the opening door mechanism

was not pursued in the physical prototypes, the structural make-up of these first three sketches

acted as a base-point for the following ideas.

Output

lox

/~'n(OcOC .QQ Tray

Motor
In/Out

Figure 4-3: Sketch of the pallet loading mechanism initial brainstorming idea. Output tube from

top bowl feeder shown on the upper left side of the sketch. Solenoid motor pushing vials into line

36
shown on the middle left side of the sketch. 1Ox vials lined up above tray shown in the middle of

the sketch. Note: This is a modified image of the initial drawing created during the first month of

prototyping. Although the outline of the sketch remains the same, the orange arrows have been

inserted to represent the vial's direction of travel. Furthermore, typeface has been placed on top

of traditional handwriting for the sake of legibility.

/C7/

Opening
Door

Figure 4-4: Isometric sketch of the pallet loading mechanism initial brainstorming idea. Aligned

vials sitting above a partially full tray displayed in the sketch. 30 to 45 degree angle indication

for the slope at which the tray will sit. Opening door sitting beneath aligned vials. Note: This is a

modified image of the initial drawing created during the first month of prototyping. Although the

outline of the sketch remains the same, the blue arrow has been inserted to represent the motion

that an opening door would follow. Furthermore, typeface has been placed on top of traditional

handwriting for the sake of legibility

37
 The second three sets of sketches in Figures 4-5, 4-6, and 4-7 introduced the 'rake' or

'pushing' mechanism that would later be carried through in the physical prototypes. These two

sketches display a solenoid pushing aligned vials off of a platform, forcing them to fall into a tray.

The idea of aligned vials feeding parallel to the surface of the pusher creates stability between the

vial contact surfaces and compactness within the entire machine. The solenoid motor was selected

as an easy-to-program, short-travel, inexpensive mechanism to provide the actuation of the

pushing plate. Here, the mechanism is expected to be angled to keep vials resting on the pusher.

38
 Qspo fV d Lod~) erI(o4 e ~~~

-t- -C-

c ox+y1 elaA-i Tri

V4,a

- -1- I0FWY l-
-

Figure 4-5: Side view preliminary concept sketch of rake mechanism displaying the motion of

the rake moving over the vials as drawn by Diarny Fernandes [5].

39
 Nested Vials
in Tray
p.

I
Pusher
Direction of
Motion 0
Q QQ
L C a
Pusher

Figure 4-6: Top-down view of pushing mechanism (solid black bar) connected to a solenoid

(square with directional) feeding aligned vials into tray below. Note: This is a modified image of

40
 the initial drawing created during the first month of prototyping. Although the outline of the

sketch remains the same, the orange arrows have been inserted to represent the direction that

vials would move to get in front of the pusher and the direction of motion that a pusher would

move the vials into the tray. An orange bar has been placed over the solid black rectangle to

represent the pusher. Furthermore, typeface has been inserted for further clarification of parts.

Pusher

Figure 4-7: Isometric view of pushing mechanism concept displaying aligned vials sitting in

front of pusher on top of a tray with one row of loaded vials. Note: This is a modified image of

the initial drawing created during the first month of prototyping. Although the outline of the

41
 sketch remains the same, the orange arrows have been inserted to represent the direction that

vials would move to get in front of the pusher, the direction of motion that a pusher would move

the vials into the tray, and the trays direction of motion. Furthermore, typeface has been inserted

for further clarification of parts.

Lastly, the three-sided shape of the 'slide' or 'pusher' mechanism was conceived during

the last stage of design sketches. Figures 4-8 and 4-9 display the slider encompassing the top and

both sides of aligned vials. With this setup, when the slide moves forward past the edge of the

floor, the vials have only one direction to fall. The three-sided setup prevents the vials from

tumbling forward when falling. As shown in the drawings, a rail abutment holds a track on which

the slide is supposed to move, preventing any motion other than linear travel in one axis. However,

the physical prototypes neglected to feature this setup due to complexity and presumed stiction

between the slide and track.

Side
Track

Top Top 2.0

Side

Mi

D
E

Rail

Figure 4-8: Sketches of the three-sided slider mechanism connected to a track on which the slider

can move in one axis when actuated by a solenoid. The solenoid is indicated by the letter 'M' for

42
 motor in this picture. Note: This is a modified image of the initial drawing created during the

first month of prototyping. Although the outline of the sketch remains the same, an orange box

has been inserted to represent a vial in traditional rectangular form. Furthermore, typeface has

been placed on top of traditional handwriting for the sake of legibility

ISO

Figure 4-9: Isometric sketch of the three-sided slider connected to the track system with the

solenoid, lettered 'M', sitting behind the slide. Note: This is a modified image of the initial

drawing created during the first month of prototyping. Although the outline of the sketch remains

the same, an orange box has been inserted to represent a vial in traditional rectangular form. The

43
 orange arrow represents the direction of travel of the slide. Furthermore, typeface has been

placed on top of traditional handwriting for the sake of legibility

Prototype I4.1.3

The first physical prototype was created to test the dynamics of aligned vials falling into

place over the vial package. As shown in Figures 4-10 and 4-11, the prototype contained two

pieces, an aluminum U-shaped channel with a piece of duct tape on the end representing the slider

and an aluminum L-bracket with a piece of aluminum bolted onto the top representing the tray

guide. An empty vial tray was able to be placed on the bottom of the L-bracket while aligned vials

could be slid into the slider from the side. When the slider was pushed forward, the vials could

drop into the tray. The entire mechanism was operated by hand, usually requiring a total of three

hands, or two people. The prototype was tilted to different angles, providing the basic intuition for

how different angles related to controlled falls of the vials. In the end, this simple prototype

validated the assumption that the vials could be dropped into their tray with a U-shaped slider

mechanism and provided the groundwork for the slider mechanism and holder in future prototypes.

44
 Figure 4-10: Side view of prototype I including: A) U-shaped slider containing vials with duct

tape on side. B) L-bracket. C) Tray. D) Vials. Prototype verified the ability for vials to be nested

inside of the tray through free fall after being pushed into position by a slider. Note: The vials in

this picture are glass yet have the same dimensions as the plastic vials.

45
 A

Figure 4-11: Isometric view of L-bracket on the left with U-shaped channel on the right. Refer to

Figure 4-10 above for a general outline of sizing in comparison to the vials.

Prototype II4.1.4

The second prototype introduced two new concepts: use of a flexure to act as a linear slide

for the rake and a notch in the rake to allow for biasing of the vials. Figures 4-12 and 4-13 display

a top view and a side view of the entire prototype. The prototype contains 3 main parts: an acrylic

flexure acting as the linear slide, an acrylic support structure holding the flexure and rake, and a

Formlabs clear resin 3D printed rake.

46
Figure 4-12: Top view of prototype II. A) Flexure. B) Rake. C) Tray. D) Tray and slider chassis.

Note: Orange outline highlights the shape of the flexure. The large red arrow indicates the

position where force is applied to move the flexure forward and slide the rake.

k#;41
Figure 4-13: Side view of prototype II. A) Flexure. B) Rake. C) Tray. D) Tray and slider chassis.

Note: The yellow box outlines the tray slider chassis body and the orange box outlines an empty

tray.

The idea for using a flexure to act as a linear slide came from a combination of Professor

Slocum's class Fundamentals of Precision Machine Design in which the benefits of flexures are

47
discussed and the 2.72 class Elements of Mechanical Design where a flexure is created to act as a

linear slide on a micro lathe. As shown in Figure 4-14, the flexure created for this prototype is

based off of the geometry of the flexure used in 2.72. The benefit of using a flexure instead of the

rail mechanism's displayed in Figures 4-8 and 4-9 is the flexure's ability to restrict motion in all

but one axis in a simple, clean, easy to manufacture, and maintenance-free manner. The flexure

used in this prototype was made out of acrylic due to ease of fabricating through laser cutting.

However, acrylic is inherently brittle. Therefore, future iterations of the flexure would cycle

through other materials to optimize the flexure's lifespan.

Figure 4-14: Top view of flexure acting as a linear slide on one of the lathes from 2.72. Note:

The orange bars have been inserted on top of the flexure to better reflect the general shape of a

flexure acting as a linear slide. The red arrow represents unconstrained direction of motion the

linear slide flexure can travel.

The second iteration of the rake features a 0.2" notch on the side in which a block can slide

into to assist biasing the vials. The idea of using a block attached to a solenoid to bias the vials

was conceived when meeting with DAPR, an engineering design consultancy group based in

Nashua, NH. Figure 4-15 displays the sketch drawn up during the meeting with DAPR. Figure 4-

16 displays the physical rake prototype with the side cut. The block, which can move in and out,

allows the vials to drop in 2 distinct locations, shifting towards the right side or left side of the

48
package after every other row. This enables the vials to nest in the zig-zag position as shown in

Figure 1-2 above.

Rake

Vc

Vials Tray
Figure 4-15: Front view sketch of a rake holding vials sitting above a tray holding vials. The

back square on the right side represents a pushing block connected to a voice coil. Note: This is a

modified image of the initial drawing created during the first month of prototyping. Although the

outline of the sketch remains the same, an orange box has been inserted to represent a vial in

traditional rectangular form. The red arrow represents the direction of travel of the biasing block.

Furthermore, typeface has been placed on top of traditional handwriting for the sake of legibility

Figure 4-16: Front view of a 3D printed rake with notch for biasing block cut out on the left side.

Note: The orange bars have been inserted on top of the rake to better outline the general shape of

49
 4

the front of the rake. The red arrow represents the position in the notch where the biasing block

will enter.

Both of these design elements, notched-rake and flexure, are carried through to further

iterations of prototypes. When testing the 2nd prototype by hand, vials were able to drop into the

package in a biased manner by pushing on the back of the flexure to move the rake forward.

However, given the imprecision of human interaction to act as actuators for this prototype, a

consistent level of vial dropping and nesting could not be achieved. Therefore, the decision to size

and order motors for the next prototype was made in order to increase the level of precision in part

movement.

As indicated above, laser cutting and 3D printing were the primary methods used to

manufacture this prototype. Their relatively high rate of production with minimal operator input

allowed this prototype to be constructed and tested within one week. The laser cutter was ideal for

constructing 2D parts out of 1/8" and 1/4" acrylic, while the 3D printer could create more complex

geometries. Yet, even given 3D printing's benefits, the choice was made to move away from this

manufacturing method on future prototypes. 3D printing could not be used on the range of

materials we wanted to use in a clean room environment. Furthermore, 3D printing did not produce

a high enough level of precision to create threading strong enough to hold up to the structural

constraints needed in the final prototype. Lastly, the need to produce a design that could easily be

replicated within Water's manufacturing floor bared 3D printing on a Formlabs printer.

Prototype III4.1.5

The third iteration of the prototype focused on the areas of design for manufacturing and

motor selection with integration. The prototype was constructed out of laser cut acrylic and milled

polycarbonate joined by 8-32 machine screws leading to ease of manufacturing and assembly.

50
Three motors were selected, two solenoids and an encoder for pushing the rake, biasing block, and

driving the tray slider. In this prototype, the rake, flexure, tray slider, and chassis were integrated

in their in their penultimate form.

Figures 4-17, 4-18, and 4-19 display the prototype resting on its test platform. As shown,

the rake, flexure assembly, tray slider, and chassis are all novel and made to be assembled with

little more than a hex key and machine screws. The ingenuity put into the layout of this design not

only allowed rapid prototyping but permitted agile reconfiguration of the assembly as

complications arose. As such, parts from prototype III were interchangeable with parts in prototype

IV, decreasing the total amount of fabrication time and material waste needed during the project.

CDE
F G

Figure 4-17: Left side view of prototype III. A) Chassis. B) Tray slider. C) Tray slider lead

screw. D) Biasing motor. E) Rake. F) Flexure. G) Lead screw motor. H) Rake-actuating motor. I)

Test platform. Note: The yellow arrow points to the vial entrance hole in the rake. The orange

arrow indicates the direction of motion of the flexure. The green arrow indicates the direction of

motion of the tray slider.

51
Figure 4-18: Right side view of prototype III. A) Rake-actuating motor. B) Lead screw motor. C)

Flexure. D) Tray slider lead screw bearing block. E) Rake. F) Biasing motor. G) Tray slider lead

screw. H) Test platform. I) Chassis. J) Tray slider. Note: The green arrow represents the

direction of motion of the rake-actuating motor. The orange arrow represents the direction of

motion of the biasing motor. The yellow arrow represents the direction of twist of the lead screw

motor.

52
 E/ F

&"7"

Figure 4-19: Top side view of prototype III. A) Rake- actuating motor. B) Lead screw motor. C)

Chassis. D) Flexure. E) Biasing motor. F) Tray slider lead screw. G) Rake. H) Tray slider.

Prototype III proved useful in validating motor compliance with the mechanical structures.

The first motor to be tested was the flexure-actuating solenoid. The solenoid, rated to output a

force of 144 oz at full extension, was much too violent to be used on the machine. When activated,

the solenoid's rod moved forward at such a great acceleration that the vials within the rake were

jostled. Furthermore, when fully extended in contact with the flexure, the solenoid's rod would

aggressively vibrate at a rate of 60 Hz. The vibration caused the vials to shake while exiting the

rake, preventing their ability fall smoothly into the tray. Therefore, the discovery that a solenoid

would not be able to be used to push the flexure was realized. Using this finding, Diamy Fernandes

deduced the elegant solution of a cam attached to a stepper motor used in prototype IV to push the

flexure.

53
 The second motor to be tested was the vial-biasing solenoid. Given this was a much smaller

motor, providing only 3 oz of force at full extension, the violence experienced in the flexure-

actioning solenoid. The motor was able to provide enough force to hold the vials in place while it

induced an offset. The one unknown was how the motor would perform when interacting with the

transfer line feeding into the rake. However, it was assumed that given the correct calibration, the

transfer line would be able to link well with the rake and biasing mechanism.

The last motor to be tested was the tray-sliding stepper motor. The motor accurately moved

the tray slider up and down throughout the leadscrew's length. Furthermore, the motor provided

enough torque to move the weight of a tray loaded with vials; indication that the motor would be

able to bear the force of multiple queued up trays pushing on the slider.

Finally, minor issues with the fit and finish of the overall assembly were found that needed

to be fixed for the final iteration. As shown in the pictures above, washers were placed between

the sides of the frame and top panel to increase the amount of space needed for the tray slider to

move. More washers were placed under the flexure's mounting assembly to provide the proper

amount of height needed to position the vials within the rake. Furthermore, given that the lead

screw bearing was acting the only point of contact for the tray slider to the frame, the tray slider

was able to wiggle back and forth. All of these snags were able to be identified and corrected for

the final prototype.

Prototype IV 4.1.6

The final prototype adjusted imperfect parts and connections from prototype III as well as

included new sections vital to the system. Parts that were added or adjusted include: a new cam

actuation setup for flexure movement, an offramp for trays to exit, a queue section for trays to

enter, a guide for the tray carriage to follow, mounting brackets with variable angle selection, a

54
backstop to assist with the first row of vial loading, and a gate apparatus to guide vials into the

rake. The new parts integrated in prototype IV can be seen in Figures 4-20 and 4-21 below. These

changes gave the final prototype the ability to accept vials, queue trays, and offload completed

trays as required by Waters.

55
 Figure 4-20: Top side isometric view of prototype IV. A) Tray queue. B) Chassis. C)

Lead screw front. D) Tray. E) Angle bracket mount. F) Vial entrance gate. G) Biasing

56
 mechanism. H) Rake. I) Flexure. J) Tray exit ramp. K) Cam stepper motor. L) Lead screw back.

M) Flexible coupling. N) Lead screw motor. Note: The yellow arrows indicate the tray's

direction of travel within the placement mechanism.

Figure 4-21: Left side isometric view of prototype IV. A) Tray queue. B) Chassis. C)

Angle bracket mount. D) Vial entrance gate. E) Tray. F) Tray slider lead screw. G) Biasing

mechanism. H) Rake. I) Flexure. J) Tray exit ramp. K) Cam mechanism. L) Tray slider lead

screw stepper motor.

The first system to be redesigned was actuator required to push the flexure forward. As

learned from prototype III, solenoids do not provide the smooth transfer of force necessary to drop

the vials into the tray accurately. Therefore, another type of motor would need to be used that could

provide enough force with smooth motion. Watching the stepper motor rotate the lead screw on

the previous design provided Diarny Fernandes a thought of brilliance; invert the stepper motor

57
perpendicular to the flexure and insert a cam to the end of the stepper motor to push the flexure.

As shown in Figure 4-22 below, the stepper motor with the cam attached was integrated into the

final system. The stepper motor provides enough torque to be transferred into force pushing the

flexure. Furthermore, the cam designs could be infinitely tuned to dial in on the precise flexure

motion needed to drop the vials into the tray robustly.

Figure 4-22: Isometric view of cam mechanism. A) Flexure. B) Metal contact surface on

flexure. C) Cam. D) Stepper motor. E) Cam mechanism mounting structure. Note: The yellow

58
arrow indicates the cam's direction of twist leading to the actuation of the flexure represented by

the green arrow.

The second system to be added was the offramp on which full trays could exit. This tray

was a constructed of 1/10" sheet of steel with a 20-degree slope. The ramp was specifically

designed to be simple while remaining effective at removing trays from the system. Figure 4-23

below displays the ramp attached to the back end of the system.

Figure 4-23: Offload ramp attached to back of chassis. Note: The green arrows indicate

the tray's direction of travel out of the back of the chassis to the offloading ramp. As shown, the

59
 tray exits perpendicular to its original direction of loading motion. The yellow line indicates the

end point of the chassis before the offload ramp begins.

The third system to be added was the tray queueing assembly on which multiple empty

trays could be loaded. Another simple design, the tray queue extends outward past the main body

of the placement system, providing extra space for the trays to be loaded. This design was made

to hold four empty trays. Yet, the ability to bolt on different lengths of surface allows the tray

queue to be modified once handed off to waters to hold as many trays as they find necessary.

Figure 4-24 below shows the tray queue attached to the front end of the system. Note the placement

of the right wall of the tray system, extending back close to the leadscrew. This placement was

intended to shield empty trays from a moving leadscrew while the tray carriage was near the end

of its stroke offloading a vial.

60
 w

Figure 4-24: Tray queue attached to front of chassis. A) Tray queue. B) Chassis. Note:

The orange boxes represent the placement of four trays within the tray queue.

The fourth system to be added was a guide for the tray carriage to follow. Prototype III

proved that the tray carriage was plagued with inherent wobbling. This is because the carriage was

using the lead screw bearing both as a positioning figure as well as a movement mechanism. As

pointed out by Professor David Hardt, this one point of contact design is considered 'bad

engineering.' Therefore, a groove was cut into the bottom surface of the system where a set screw

connected to the bottom of the tray carriage could rest. Figure 4-25 below shows how the edge of

the groove provides latteral constraint for the lead screw

61
 Figure 4-25: Tray slider sitting on top of guide grooves. A) Tray slider. B) Guide groove

C) Tray slider set screw. Note: The orange box overlays the groove guide and the green squares

denote the location of the tray slider set screws.

The fifth mechanism to be added were mounting brackets with variable angle selection.

The system mount, shown in Figure 4-26 below, featured a modest three bolt connection on which

the outer two bolts could pivot around a central bolt. The mount can angle the placement

mechanism anywhere between 30-degrees to 50-degrees from the ground at 5-degree increments.

Variable angling provides the benefit of selecting the most robust configuration for vial delivery

into the tray.

62
 Figure 4-26: Mounting brackets with variable angle holes. Path of mounting holes

outlined in red. A) Rear pivot mounting hole. B) Mounting bracket. C) Dual front mounting hole.

63
 The penultimate system to be modified was the lip assisting the first row of vials entering

the tray. As noted in prototype III, the first row of trays would not remain biased to the left or the

right once settled on the tray. This is because there was nothing preventing the vials from wiggling

back or forth. All rows after the first are constrained by the edges of the vials before them, but the

first row does not experience this situation. Therefore, as shown in Figure 4-27 below edge of the

lip protrudes out an extra quarter of the inch on the right-hand side to allow the vials to rest against

once in the tray. The right side was chosen for biasing first versus the left side because trays exit

on the left. Keeping the protrusion on the right side allows the trays to exit steadily without being

disturbed by the material.

Figure 4-27: First row assistance edge on back wall of tray slider. A) Tray slider first row

edge. B) First row of vials. C) First row biasing feature on first row edge.

The final system tobe added was agate to guide new vials into the rake. The gate provides

aconnectionpointtothetransfer mechanism inwhichoutputvialscanbeaccepted.Furthermore,

the gate, remaining stationary, is able to act as awall on which the 1 1 th vial in asystem can leverage

off of when pushed out of the rake. Figure 4-28 below displays the gate positioned next to the rake.

64
 Figure 4-28: Gate funneling incoming vials into rake. A) Rake. B) Front side vial gate. C)

Bottom surface on which incoming vials slide. D) Back side vial gate. Note: The yellow arrow

points to the direction of vial insertion.

Lastly main body of the placement mechanism was lengthened to account for the addition

of the tray queue and exit ramp. This meant the prototype gained utilized a foot-long lead screw

and longer sidewalls. All height dimensions remained the same as in the previous prototype.

4.2 System Overview

The as previously stated, the vial placement mechanism performs two primary tasks:

loading the oriented vials into a tray and queueing empty trays to be loaded with vials. five critical

65
components ensure the two tasks are executed properly: flexure, rake, tray transport system, cam

mechanism, and chassis. Two stepper motors and one solenoid actuate these components. Refer to

Figure 4-29 below to see these components and actuators as they are situated in the placement

system.

BI
Figure 4-29: Final vial placement mechanism. A) Cam mechanism. B) Tray slide lead

screw. C) Flexure. D) Rake. E) Tray. F) Angle bracket mount. G) Biasing mechanism. H)

Chassis. I) Tray queue.

Sections 4.3 through 4.9 provide a detailed overview of the design, selection, testing, and

implementation of each of the various components and actuators.

66
4.3 Flexure

The polycarbonate flexure acts as a linear slide constraining motion in all but one axis. As

previously articulated, a flexure was selected to translate motion from the actuator to the rake for

the sake of reliability, part reduction, lack of maintenance, and tunability. Furthermore, the flexure

offers boundless possibilities for calibrating lateral stiffness depending on the part's geometric

layout.

Design of the flexure's geometry was primarily performed in Solidworks with static force

simulations. As shown in Figure 4-30 below, iterations of flexure layout were tested with different

loads to determine the optimal wall thickness of the flexure's components. Tradeoffs were weighed

between walls that were too thin and prone to fracture over walls that were too thick requiring

excessive force to fully move the flexure. Ultimately, a finite range of flexure shapes were chosen

for physical validation within the placement mechanism. The final geometric layout of the flexure

is shown in Figure 4-31 below.

FkS

Figure 4-30: Solidworks static force simulation on flexure.

67
 C)
C)
~t)

C.->

002250
i I

C))

0) (D

6
C20.100
C))

I
00
0.2500 0 2500

Figure 4-31: Technical drawing of flexure geometry.

Material selection for the flexure was first narrowed down between plastics and metals.

Plastics were chosen due to their superior ductility and ability to resist work hardening over

multiple cycles. When looking within the collection of plastics available, five contenders were

considered: acrylic, high density polyethylene, polymethyl methacrylate, polypropylene, and

polycarbonate. Ultimately, polycarbonate was selected because of its high impact resistance,

ductility, chemical inertness in a cleanroom setting, and ability to withstand cycle fatigue.

68
4.4 Rake

The rake was created to accept a line of 10 incoming vials, bias vial offset, and control the

vial descent during their fall into the tray. The rake contains four notable features: a channel for

vials to accumulate, a cutout for the biasing mechanism to enter, an elongated front panel to assist

with vial falling, and a tailstock to assist with incoming vial retention during the movement phase.

The channel for vials to accumulate is 5% wider than the diameter of each vial. This width

difference removes the possibility for vials to bind when entering the channel. Furthermore, the

gate in the injection molding process is placed on the side of each vial. This creates a miniature

protrusion rendering the diameter larger than 12mm in that location. The is long enough to hold

10.35 vials. The extra third of a vial is used when vials are biased towards the right-hand side of

the tray. Because the eleventh vial enters the tray a distance less than half of its diameter, it is able

to be squeezed out by the vial entrance gates shown previously in Figure 4-28.

Once the eleventh vial is squeezed out of the channel, pressure is still exerted on the vial

trying to move it into the void where the channel used to be. The tailstock, shown below in Figure

4-32 acts as a barrier to the eleventh vial. It is only activated when the rake moves forward in the

vial dumping stroke.

69
 Figure 4-32: Left side view of rake depicting: A) Vial entrance gate. B) Chute leading to

interior of rake. C) Tail stock. Note: The yellow arrow indicates the direction the vials flow as

they enter the vial entrance gate.

A cutout on the side of the rake makes room for the vial biasing block to enter from the

vial biasing mechanism. Figure 4-33 below displays the vial biasing block in its extended position

inserted into the rake. When the biaser is extended, the tray length decreases to hold ten vials.

70
 A2

B C

Figure 4-33: Front side view of rake depicting: A) Vial biasing solenoid. B) Vial biasing

block. C) Cutout in rake for vial biasing block. D) Flexure. E) Bottom surface on which

incoming vials rest. F) Bottom of rake's front surface. G) Incoming vial gate. Note: Green

outline highlighting the notched edge of the rake where the vial biasing block fits.

The front of the rake extends downwards past the surface that the accumulated vials sit on,

stopping just short of the tray's upper lip. The extended surface provides more surface to guide the

vials when falling. Because the top of the vials extends past the bottom of this surface when sitting

in a tray, the tray cannot be pushed backwards once a row of vials is loaded.

4.5 Tray Transport System

The tray transport system moves trays from a queue, through the main body of the

placement mechanism, out to an exit ramp. A tray slider carries the trays through the entire system

and provides finite adjustments to accurately position each tray under the rake for vial loading.

The slider is directed forward and backward through a leadscrew attached to a stepper motor.

Figure 4-34 below displays a bottom view of the transport system.

71
 . ...
.

Figure 4-34: Bottom side view of tray transport system. A) Tray queue section. B) Front

of lead screw. C) Front tip of tray slider. D) Start of chassis section. E) Front end of guide

72
groove. F) Tray slider guide set screw. G) Tray slider bearing block. H) Back wall of tray slider.

I) Back edge of chassis. J) Exit ramp. Note: The yellow arrow indicates the tray's direction of

movement through the transport system and the green arrow represents the lead screw's direction

of twist.

As previously discussed, empty trays enter the system through a tray queue. The current

tray queue can hold four trays but is designed to be swapped out with tray queue sections of

different lengths. The first tray to be placed in the queue drops onto the front surface of the slider

by the force of gravity. Once positioned on the tray slider, a lead screw moves the slider down

under the rake. After the first line of vials are loaded onto the tray, the stepper motor rotates the

leadscrew 5 revolutions to move the tray slider down one vial length. This repeats another eight

times until the tray is full. Lastly, the tray slider moves over the exit ramp to discharge the packaged

tray.

The tray slider mechanism is composed of four pieces of polycarbonate and that act as

control surfaces for the tray, falling vials, and leadscrew bearing. Additionally, two setscrews jut

out of the bottom of the guide arm. Figure 4-35 below displays the key components of the slider

mechanism.

73
 Figure 4-35: Isometric view of tray slider mechanism. A) First row biasing lip. B) Back

panel. C) Side panel. D) Lead screw bearing block. E) Lead screw.

The back panel of the tray slider mechanism acts as a surface to hold the tray. The side

panel constrains lateral motion, wedging the tray between itself and the left wall of the chassis. On

top of the back panel, a first-row guide protrudes over the upper lip of the tray to more accurately

guide the first row of vial into the tray. A bearing block is attached to the side panel to move the

entire tray. Two set screws sit within a groove on the bottom surface of the chassis to constrain

lateral motion of the tray slider mechanism.

4.6 Cam Mechanism

The cam mechanism converts rotary motion to linear motion, providing smooth power

transfer from a stepper motor to the flexure. As previously mentioned, the cam mechanism was

developed after inherent flaws of solenoids were discovered during creation prototype III's testing.

Use of a cam allows a range of designs regarding geometric layout to push the flexure forward at

74
different rates. Figure 4-36 below displays the cam mechanism while Figure 4-37 displays the

geometric layout of the cam.

AV_

-77%
77

BC

Figure 4-36: Cam mechanism connecting to the flexure. A) Cam actuating stepper motor.

B) Cam mechanism mounting structure. C) Cam. D) Cam to flexure contact point. E) Flexure.

Note: The green arrow represents the cam's direction of twist and the orange arrow indicates the

flexure's corresponding direction of motion.

75
 61

0.3750

00 0.-~
CD
If)

C
C

C
00

.4-IV
P0

Figure 4-37: Technical drawing of cam geometry.

An aluminum plate was attached to the back of the flexure where the cam makes contact

to provide a dissimilar material for the cam to rub. Additionally, the cam was constructed out of

acrylic instead of polycarbonate like the rest of the components. This is because acrylic provides

a more wear resistant surface when exposed to prolonged friction. Additionally, acrylic can be

easily laser cut, an important manufacturing method to leverage on such a complex geometry.

4.7 Chassis

One quarter thick sheets of polycarbonate were used to create every piece of the chassis.

As previously discussed, this created an engaging design space where pieces were created in a

two-dimensional fashion and bolted together by 6-32 machine screws to create a three-dimensional

structure. Akin to Ikea's design philosophy, this construction method led to ease of assembly.

76
Furthermore, chassis holds the ability to be constructed out of any rigid material that can be cut

from a quarter inch sheet. This grants Water's the ability to change materials for any reason at

some time in the future if they find the need to do so. Moreover, being constructed out of

polycarbonate adds the benefit of being transparent. This attribute played well when building and

troubleshooting system dynamics.

The main body of the chassis is a rectangular cavity that holds the cam, flexure, rake, and

biaser on top while positioning the tray transport system below. The queuing section sits in front

of the chassis while the exit ramp rests in the back. Mounting brackets are placed to either side of

the chassis and position the structure at the chosen angle. Therefore, the angled chassis imparts the

inherent angle to every mechanism bolted onto its surface.

Beyond providing structural support and angle to every mechanism in the system, the four

sections of the chassis, labeled in Figure 4-38 below, allocate orientation for all mechanisms. The

top section aligns the cam mechanism to the flexure-rake combination and the rake to the biaser.

The right section aligns the lead screw to the stepper motor, inherently translating to the tray slider

placement. The left section aligns the vial accepter gates to the side of the rake. The bottom section

guides the tray slider and positions the left and right sections to align the top section components

over the bottom section. Therefore, precision manufacturing of these sections was crucial to ensure

all components fit together properly.

77
 Figure 4-38: Isometric view of chassis displaying four main sections. A) Chassis top

section. B) Chassis left section. C) Chassis bottom section. D) Chassis right section.

4.8 Actuators

Three actuators provide necessary movement to the placement system: two stepper motors

and one solenoid. The first stepper motor provides rotary force to the leadscrew to linearly move

the tray slider through the system. The second stepper motor provides rotary force to a cam, which

actuates the flexure that pushes the rake forward. The solenoid provides linear force to the biasing

block. All actuators are tethered to a control system that provides power and commands.

The two stepper motors were selected for their ability to provide adequate torque to actuate

the cam and leadscrew under load. Furthermore, the motors fit within the designated budget and

were properly sized to attach onto the placement mechanism. The solenoid was selected for similar

reasons, replacing torque with linear force.

78
 For more information on motor selection and control, refer to Diarny Fernandes' 2019

thesis.

79
Chapter 5

Placement System Performance

This chapter describes the methods that were used to evaluate the placement mechanism's

performance. Results of the evaluations are noted and analyzed to predict how the system will

perform in operation.

5.1 Evaluation Methods

Two tests were conducted to determine the how different attributes of the placement

mechanism managed under prolonged use. The experiments performed included: an accelerated

life failure test of the flexure, and a vial placement robustness test.

It is important to note that, barring notation, all of the trails were performed on the

placement mechanism isolated from the overall packaging machine. Vials were hand packed into

the vial acceptor gates instead of fed through the transfer line feeder. This procedure owes itself to

the fact that the upstream processes were not complete at the time when testing occurred.

Therefore, evaluation results must be explored with an undertone of suspect.

The accelerated life failure test on the flexure transpired first. Once the final material and

form of the flexure was determined and manufactured, a continuous cycle test of one flexure

actuation per second by the cam happened. The flexure lasted for 39,000 cycles before fracturing.

Additionally, a thin black residue built up on the back edge of the flexure where the cam contacted

the metallic plate. Discrepancies between test and standard loading conditions include the

following: the standard flexure actuation rate is 10 times slower at once every 10 seconds, and the

flexure is normally full of vials when actuated whereas it was empty in the test. Given the standard

actuation rate allows more heat to dissipate from the cam contact surface and within the stressed

80
flexure material, it is theorized real life conditions would increase the flexure's life span.

Furthermore, given the excess force from vials loaded in the rake are negligible compared to the

amount of force required to move the unloaded rake, the second discrepancy is not factored into

the performance analysis.

The vial placement robustness test was carried out to find the ratio of correct placements

versus incorrect placements the mechanism could perform. Because there are 10 rows in each tray,

10 placements transpire per full packaging. For the test, approximately 400 placements were

conducted. Each row that correctly landed inside of the tray was counted as a viable placement.

Conversely, rows that did not land correctly were counted as failures. Any time a failure occurred,

the row was emptied and repeated. The ratio of viable to failure placements was 33:1. In the field,

incorrect vial placement events may not result in removal and retrying of the failed row. The full

systems control, and sensor setup was not complete at the time of the test resulting in the strategy

for responding to this scenario not being established. Lastly, over half of all failed placements

occurred during when stacking the first row. As previously stated, the lack of vials acting as

backing for the first row creates a climate of excess instability where vials are more prone to

falling. Proposals on correcting this error can be found in section 6.2.

5.2 Performance

From the two tests performed, the following conclusions are drawn on the performance of

this machine: the machine is able to robustly fill 3 trays on average without error over a month's

period of time. After each month, the flexure, in its current design, should be replaced to prevent

failure. Furthermore, daily cleaning of the cam to flexure contact surface is advised to reduce

particulate buildup.

81
 The number of consecutive correctly filled trays was calculated by dividing the ratio of

viable to failure placements and by the number of rows per tray and rounding down to the nearest

whole number. Similarly, the flexure replacement cadence was determined by dividing the number

of working minutes per month by the number of flexure actuations before failure and rounding

down to the nearest whole number. Lastly, the recommendation for daily cleaning of the flexure

was estimated by the perceived rate of accumulation of residue during the flexure failure test.

Evaluation of the placement mechanism yielded further recommendations to extend flexure

life, decrease particulate accumulation, and increase placement robustness. The proposals can be

found in section 6.2.

82
Chapter 6

Conclusions, Recommendations, and Future Work

This chapter outlines the conclusions that are drawn from the design, development,

manufacturing, and testing of the placement mechanism. Recommendations for improvement are

explored along with a framework for future work.

6.1 Conclusions

This thesis embodied aspects relevant to machine design. From receiving a customer's

problem statement, characterizing it into its requisite objectives and constraints, researching

existing methods, brainstorming potential solutions, designing - fabricating - testing repeatedly,

the team was able to successfully meet the goals laid out in the beginning of the project.

Furthermore, each individual was pressed to work diligently under a strict deadline, with efficient

resource utilization such as budgeting, time management, external consultant leveraging, and

teammate specialties. Undoubtably, these attributes molded the graduate students into more

capable engineers who have proven they can tackle consequential industry problems in a

professional setting.

Personally, I most enjoyed learning the principals necessary to create a functional three-

dimensional machine using a predominantly two-dimensional framework of sheets bolted

together. As discussed in section 4, this design style drew inspiration from Ikea furniture design.

An increase in prototyping efficiency was enjoyed from leveraging the sundry of manufacturing

methods to create each piece. Furthermore, the ease of assembly and rapid part replacement

validated this design philosophy.

83
 Not only were the aspects of machine design explored, but the traits necessary for

leadership were imbued through completion of the project. I learned to coherently communicate

project status, needs, and barriers to the customer. I perfected my ability to coordinate schedules,

plans, and designs between teammates, laboratory technicians, vendors, and the customer. Lastly,

I recognized the necessity for mutual respect between all parties involved in this project.

The acquirements discussed above led to the assembly of a prototype that theoretically has

the capability of accepting bulk unoriented vials and outputting inspected trays full of 100 vials.

Although the prototype does not match the recommended form for integration into the customer's

factory, it validates that the provided mechanical drawings, when manufactured and assembled to

specification, will perform as needed to fulfil the customer's requirements.

Specifically, the placement mechanism reached its final shape, operation, and performance

to the point where it could be implemented directly within the customer's manufacturing

environment. However, recommendations on alternatives for craftsmanship and placement

mechanism construction before amalgamation with the customer's factory are discussed below.

6.2 Recommendations and Future Work

The placement mechanism succeeded in meeting the functional requirements prescribed

by the team and customer. Yet, in the pursuit of perfection, the following steps are recommended

to optimize the performance of the machine.

First, the bulk material in which the machine was created can be changed from

polycarbonate to aluminum. As mentioned above, polycarbonate was selected as the material of

choice because it was strong, resilient, and most importantly transparent. The transparency aided

in troubleshooting the machines dynamics yet are no longer needed now that the layout of the

machine is solidified. The only part that needs to be kept polycarbonate is the flexure due to the

84
material's mechanical properties that were leveraged in the creation of the device. Aluminum is

recommended as the material of choice because it is a stiffer material than polycarbonate and can

aid in the rigidity of the overall structure. Furthermore, aluminum is relatively inexpensive and

easy to machine compared to other materials.

Second, a rolling contact surface should be designed and implemented in the flexure-cam

interface. This change will lead to both particle reduction and prolonged flexure life. A roller

bearing could be attached on to the back of the flexure as the contact surface to the cam. The

bearing would greatly decrease friction at the interface, which would decrease wear of the cam

and aluminum back plate.

Third, the entrance ramp and exit ramp could be further designed to accept stacked trays

and output packaged trays in a more robust fashion. New trays enter the factory in stacks and must

be removed one by one to be placed on the tray queue by an operator. Developing a mechanism to

automate this step would allow the machine to run continuously without human intervention for a

longer period of time. If the machine is running for a longer period of time without human

intervention, trays will begin to stack up at the end. A more robust exit ramp could funnel the trays

down to a longer queue as they await shipment to the customer.

Fourth, the first tray carriage's first row lip should be optimized to robustly accept the first

row of vials. Grooves representing the shape of a previous row of vials could be drilled into the

lip, providing a similar level of stability that the other rows of vials enjoy.

Beyond the recommendations specific to the current iteration of the placement mechanism,

future work could occur in relation to other products that Waters already packages by hand. For

example, the company currently sells glass vials of the same exterior dimensions. Assuming the

85
glass vials dynamics are similar to that of the plastic vials, they could be packaged by the same

machine to further automate Waters manufacturing operations.

86
Appendix A

Engineering Drawings

A complete catalogue of engineering drawings used to construct the final prototype of the

placement mechanism is displayed in this section.

87
 4 3 2 1

F F

E ','E

4 •

D D

7 8

ITEM NO. PART NUMBER DESCRIPTION QTY.

C C
1 Shell Shell Assembly 1
2 TrayCarriage Tray Carriage Assembly 1
3 FlexureMountRake Flexure Mount Assembly 1
4 6321-2 1/2" 6-32 Machine Screw 4
5 TrayQueueAssy Tray Queue Assembly 1
6 6_32_3-4 3-4" 6-32 Machine Screw 4
1/10" Aluminum 1
B 7 Exit Ramp B
8 6_32_1-4 1/4" 6-32 Machine Screw 2
UNLESS OTHERWISE SPECIFIE: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMEERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE INISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPV'D

A MFG A
Q.A MATERIAL DWGNO

1 OxPlacement
WEIGHT: SCALE:1:20 SHEET 1 OF 1

SOLIDWORKS EducationalProduct.For Instructional1 Only. 2

88
 4 3 2 1

F 17 F
3
166

E E

18

222

26 D

19 ° .- 10

13

C 21 4 C

14 15 24

25 23

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIALDWN
DWGNShellDrawing

A4
WEIGHT: SCALE1:10 SHEET 1 OF 1

4
SOLIDWORKSEdcatinal Product. ForInstructional a.Only, 3

89
 4 3 2 I

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 TopBracetoFlextureM 1/4" Polycarbonate 1
2 Right_Side_Pannel 1/4"Polycarbonate 1
3 Left_Side_Pannel 1/4" Polycarbonate 1
4 Base 1/4" Polycarbonate 1
5 RakeBottom 1/4" Polycarbonate 1
6 ZigZagPlunger Zig-Zag Plunger Assembly 1
7 6_32_1-2 1/2" 6-32 Machine Screw 19
8 6_32_3-8 3/8" 6-32 Machine Screw 4
9 6_32_1-4 1/4" 6-32 Machine Screw 2
10 93255A431 12" Lead Screw 1
11 LeadScrewMountHole 1/4" Polycarbonate 2

12 LeadScrewMountEnd 1/4" Polycarbonate 1

13 6_32_5-8 5/8" 6-32 Machine Screw 8
14 MotorBracketLarge 1/4" Polycarbonate 1
15 MotorBracketSmall 1/4" Polycarbonate 1
16 BottleEjectorSide 1/4" Polycarbonate 2
17 CamAssy Cam Assembly 1
18 6_32_1-2_Sunk 1/2" 6-32 Couter Sunk Screw 8
19 StepperMotor Stepper Motor DC 24V 1
20 MotorScrewTransfer 6061 T6 Aluminum 1
21 8_32_1 1" 8-32 Machine Screw 4
22 8-32-Nut 8-32 Nut 4
23 LeadScrewReinforce 1/4" Polycarbonate 1
24 AngleStand Angle Stand Assembly 1
25 6_32_3-4 3/4" 6-32 Machine Screw 2
26 6208K595 Flexible Shaft Coupling I
NLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAKSHARP DO NOT SCALE DRAWING REVISION
SURFAC FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPV'D

AMFG A
QA MATERIAL: DWG NO.
A4
ShellBOM
WEIGHT: SCALE:1:10 SHEET I OF 1

4 E Product.
SOLIDWORKS Educatioal a3 For instructionalUse.Only. 2

90
 4 3 2 1
3

F F

E E

2
D D

C C

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 70155K661 Linear Solenoid
2 PlungerBlock 3/4" Polycarbonate 1
3 2_56_1-4_Set 1/4" 2-56 Set Screw 1
B B
UNLESS OTHERWISE SPECFIED: FINISH: DERURR AND
DIMENSIONS ARE INMILLMETERS BREAKSHARP DONOT SCALEDRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPV'D

AMFG A
Q.A MATERIAL: DWG NO.

ZigZagPlunger
WEIGHT: SCALE:1:2 SHEET I OF 1

SOLIDWORKS-Educt onal Product. For lnstruction U Only

2 I

91
 6
0

0 0

4
2

8 7
ITEM NO. PART NUMBER DESCRIPTION QTY.

1 MotorBracketSide 1/4" Polycarbonate 2

2 MotorBracketCam 1/4" Polycarbonate 1
3 Cam 1/4" Polycarbonate 1
4 StepperMotor Stepper Motor DC 24V 1
5 CamMotorTransfer 6061 T6 Aluminum 1
6 4_40_1-4_Set 1/4" 4-40 Set Screw 1
7 8_32_1-2 1/2" 8-32 Machine Screw 4
B 8 632_1-2 1/2" 6-32 Machine Screw 8 B
UNLESS ERISE SPECIFIED: FINIH: DEBURRAND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH:
TOLERANCES:
~FNS EDGES . ..
LINEAR:
ANGULAR:

NAME SGAUE DTE TITLE:

RAWN ....

APPVD

"AMFG- A
A TERIAL DWG NO.

Cam Assy
WEIGHT SCAE15 SHEET I OF 1

SOIWG~rdeti %mue~o-nbui ,n, _

92
 4 3 2 I

F
3

BBA

0C>

002

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Angle Bracket 1/4" Polycarbonate 2
2 Bottom Brace 1/4" Polycarbonate 1
3 Back Brace 1/4" Polycarbonate 1
B 4 6_32_3-4 3/4" 6-32 Machine Screw 12 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURAND
DIMENSIONSAEIN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR-

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

A MFG A
Q.A MATERIAL: DWGNO.
A4
AngleStand
WEIGHT: SCALE:1:10 SHEET I OF 1

4 a Product. For Instructional UseOnly.

SOLIDWORKS Educational 3 2 I

93
 4 3 2 1

F F

E E
6

5 8
D D
9 7 10

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 tray Provided 1
2 TraySliderSide 1/4" Polycarbonate 1
3 TraySliderBottom 1/4" Polycarbonate 1
4 TraySliderFirstRow 1/4" Polycarbonate 1
C C
5 632_5-8 5/8" 6-32 Machine Screw 3
6 DriveBearingBlock 3/4" Polycarbonate 1
7 95120A111 932 Bearing Bronze Flange Nut 1
8 6_32_1--1-8 1 1/8" 6-32 Machine Screw 4
9 6_32_3-4 4/3" 6-32 Machine Screw 2
10 6_32_3-4_Set 3/4" 6-32 Set Screw 2
B 11 6_32_1-2_Sunk 1/2" 6-32 Countersunk Screw 2 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURE AND
DIMENSIONS ARE INMILLIMETERS REAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE INISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV*D
AMFG
Q.A MATERIAL: DWGNO.
A
A4
TrayCarriage
WEIGHT: SCALE:1:5 SHEET 1I OF

4
SOLIDWORKS Educatioal ProductFor Instructional se Only. 3 2 I

94
 4 3 2 I

F 8 6 F

E E
O1

D D
3
2

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Flexure_0.6_V3 1/2" Polycarbonate 1
2 FlexureMount 1/4" Polycarbonate 1
C 3 PreloadMount 1/4" Polycarbonate 1
4 Flexure_Shim 1/4" Polycarbonate 2
5 Rake Rake Assembly 1
6 6_32_1-2 1/2" 6-32 Machine Screw 2
7 632_3-8 3/8" 6-32 Machine Screw 2
8 6_32_1 1" 6-32 Machine Screw 4
9 FlexureMetal 0.1" Aluminum 1
B 10 2_56 1-4 1/4" 2-56 Machine Screw 2 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURREAND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPVD-

AMFG
O.A MATERIAL: DWGNO.

FlexureMountRak#
WEIGHT: SCALE:1:5 SHEET 1 OF 1

SOLIDWORKS Educa4al Product. .o insrtIctinal Use O.

95
 4 3 2 1

F F
6

E E

D D

ITEM NO. PART NUMBER DESCRIPTION QTY.

C 1 RakeFrontFlat 1/8" Polycarbonate 1 C
2 RakeBackHoles 1/4" Polycarbonate 1
3 RakeTopFlat 1/4" Polycarbonate 1
4 6_32_7-8 7/8" Machine Screw 2
5 RakeTail 1/4" Polycarbonate 1
6 6_32_1-1-8 1 1/8" 6-32 Machine Screw 1
7 632_1-2 1/2" 6-32 Machine Screw 1
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURE AND
DIMENSIONSARE INMILLMETERS BREAKSHARP DONOTSCALEDRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKCD
AFPVD,

AMFG A
Q.A MATERIAL: DWGNO.
A4
Rake
WEIGHT: SCALE:1:5 SHEET I OF 1
4 Product.ForInstructionalU"
SOLIDWORKS Educatlioal 3 only. 2 1

96
 4 3 2 1

2
F F
3

E E

D D

C C
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 Queue Base 1/4" Polycarbonate 1
2 QueueLeftWall 1/4" Polycarbonate 1
3 QueueRightWall 1/4" Polycarbonate 1
4 6_32_1-2 1/2" 6-32 Machine Screw 4
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURAND
DIMENSIONS ARE INMILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFAC FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D-

AMFG A
Q.A MATERIAL: WyuNO e

WEIGHT:
Tray-QueueAsSN/ A
SCALE:1:5 SHEET 1 OF 1

4
SOLIDWORKS EductimalProduct. 3
For lnstructional ks.Only 2 1

97
 4 3 2 1

0
F LC) F
o o
o Ln
0 0 0
- L-) L)
c Uf) Ld') 0
Y)0 0 0

5.6000
5.2500
E E

3.5000
2.8000
4+-1 2.1000

C 0.5000
D
0.3000
QC
0.0000
/

~/b~b ~/
n N 0) C0 0) 0
0) 0 U') 0
D0-_ 00) (N 0
NO 0
U') 6) 0

C C

O0

O0

B B
UNLESSOTHERWISESPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE INISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIAL: DWGNO.

PlycarbonateTOpBracetoFlexture A.r r
WEIGHT: SCALE:1:5 SHEET 1 OF 1

SOLIDWORKS Educatisl Product. For Instructional Use Only. 2 1

98
 4 3 2 1

F 0i /0.2500 F
0.1250
0.0000

o0 o 0 0
E 0 0 C LO 0
oN CN 0
C) <>
CC cl)

1.4000
E1 .4000 E
62 32 1.1500
1 .2000 0.2500
0. 1500 43
0.1500
-

0.0000 -0.0000
-

0.2500 C) 0 oN 0000
o O
)

O0 'O
0O Ul 0

(N - -D )o

D 2 D
0.2500

00

0 O OC LC)QC
0' 0'. 0'. O 0
o5 o

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURAND
DIMENSIONS ARE INMILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACEFINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

A MFG A
O.A MATERIAL: DWG NO.

Polycarbonate RightSidePanneA 4
WEIGHT: SCALE:1:5 SHEET I OF I

4 Product. For Instructional 3sOnly.

SOLIDWORKS Educatinal 2 1

99
 4 3 2 1

F F
06-32 0 0.2500
>-0.1250
- 0.0000
00 00

'C4 0
9)
C6) 05 q[1.4000
HR00.18820SX
1.2000 E
11500
0.7000
~ II

+
UC) 0 0
L!) 0D 0
00CI (V) 0
,7 0
rNT 0 0
D 0 0.2500 D
S
I/-I 0.1250
0.0000

0D 00Q
0 C0
0 00
0'

C C
U-
(

B B
UNLESS OTHERWISE SPECIFIED: .FINISH:
IN
DIMENSIONS ARE MILLIMETERS DEBURAND DO NOT SCALE DRAWING REVISION
BREAKSHARP
SURFAC FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

A MFG A
Q.A MATERIAL: DWGNO.

Polycarbonate LeftSidePannel A4
WEIGHT: SCALE:1:2 SHEET 1OF 1
SOLIDWORKS Eductfal Product. ForInstructional I Only. 2 1

100
 4 3 2 1
0.0000 00000
0.2500 - 012500
F 1.1500
1.3750
I--
2.0000 2.0000
2.5000

E
c/
QIA
-+ 4+

9.4500 I 9.4500
9.9500 S

/
10.4500
4 + +4
--

! 11.9500
C
12.7750
13.4500
13.4500 13.5250
13.9500 13.9500
0.2500

00 CD 0 o o 0
00c~ oo Lo Co LC) 0
0 O 'O L() CN CO
0 Loc Co
00
O' CO
B CO
Ljr)

UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND

DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APFV'D

A MFG A
Q.A MATERIAL: DWG NO.
A4
V Polycarbonate Base
WEIGHT: SCALE:1:5 SHEET I OF I

4
SOLIDWORS EducationalPrdut.-frInsructional mOnly-
2 I

101
 4 3 2 1

F (D
F

1.6500
E 1.5250 E
1.2375
I A1 0 ,6_
0.9900
ifi\\. (P.11.--------

-
0.9000
0.6075
0.5000
0.1250
0.0000 e

D QQQ 0 0 I> D
o LO U-) Io IC) o0 LlC)
o 1 o0 LO U') <v.) ICO om
o o o
666S(D

C C

B B
UNLESSOTHERWISE SPECIFIED: FINISH: DEBURAND
DIMENSIONS ARE INMILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN,
CHK'D
APPV'D

A MFG A
Q.A MATERIAL: DWGONO.
A4
Polycarbonate RakeBottom
WEIGHT: SCALE:1:5 SHEET I1 OF

4 3
SOLIDWORKS Educatinal Product.Fr InstructionalU40.Only. 2 I

102
 F F

0,0.3750

11.5000
E 1 1.0000 E

D D

c c

0.3500
0.0000
00.3750
BB
UNLESS OTHERWISE SPECIFIED: FINISH: DESR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DONOTSCALEDRAWINO REVISION
JSURFACE FINISH: EDGES
-

TOLERANCES:
LINEAR:
ANGULAR:

S SIGNATURE DATEITLE

APPV`D ___ fj
MATERIAL: DWGNO.

93255A431 A CME LEAD $CRE'

WEIGH CA SHEET OF

S3LOW..........- vew...,..

103
 4 3 2

F F

1.3000 1.3000
-- 1.1500

E 0.6500 E

-- 0 -
-

-- 40.1500
6 0.0000 w -e n 0000n

.
D o 0 e D
o6 o
NO
o6 CNJ
-Qo
0

C C
(N 0

B 0j B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

A MFG A
Q.A MATERIAL: DWG NO.

VolycarbonatieadScrewMount_Htle
WEIGHT: SCALE:2:1 SHEET 1 OF I

SOLIDWORKS Educat ial Product.ForInstructional Only.

2 I

104
 4 ~~ 3-- 2

&32
F F
1.3000
1.1500

E E
CY)

Iii--40.1500
-0.0000

1.1000

D o 0 LD
(N-

c
0
C

0
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:

i
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

A MFG
MATERIAL:
A
Q.A DWG NO.

PolycarbonateLecidScrew _Mountfhd
WEIGHT SCALE21 SHEET 1 OF 1

4 a ProducL$ornhtruclionalU-Only.
SOLIDWORS Eduicatinal 2 I1

105
 4 3 2 1
oD 0 00
LO o0 Co Q
CNCNC
F 6666' F
J/

0.0000
0.1250
0.2200
0.6500

-
E 1.1500 E

1.7000 /

/50071
2.0800
2.2750

D D

CN~

C C

B B
UNLESSOTHERWISE SPECIFIED: FINISH: DEBURE AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPVD

A MFG
A
Q.A MATERIAL: DWGNO.

PolycarbonateM otorBracketLar
"

WEIGHT: SCALE:1:1 SHEET 1 OF 1

4 Product. ForInstructional Us.Only.

SOLIDWORS Educatioal 3 2 I

106
 4 3 2 1

o- l - CN OC)Cm
F 0 CD
ddd c
eed F

0.0000
0.1250-
0.2200-
0.6500
II K i -q0
E 1.1500- E
MY -,,k
1.7000 -: 5-00
-
T y
2.0800
2.2750

0
D 0 D
(N
0

C 0 C

B B
UNLESS OTHERWISE SPEC FIED: FINISH: DEBURR AND
DIMENSIONS ARE INMILLIETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV*D

AMFG A
G.A MATERIAL: DWG NO.

Polycarbonate Motor_BracketSmdli
WEIGHT: SCALE:I:1 SHEET I OF 1

SOLIDWORKS Educa nel ProductFor instructional a Only.

2 I

107
 4 3 2 1

F 2.2500 2.2500 F

-
cv,

E 14250 +9 /
/ E
-

(5 ~
-~
1.0000

0.6750 '5

0.4250
D D
0.1750
0.0000 0.0000

oao (D
o
q (D
a
o" Lr)
a
loP
oD (o C

C C

0
0
0-
B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIAL: DWG NO.

Polycarbonate Bottle_Ejector_Sid 4
WEIGHT: SCALE:2:1 SHEET 1 OF 1

SOLIDWORKS Educati~U Product.for Instructional seOnly 2 1

108
 4 3 2 1

F 010-32
1.00 F

-0.50

E E

Q LO v> 0
o o 6

D D

C C

B B
UNLESSOTHERWISESPECIFIED: FINISH: DEBURRAND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
.APPV

A
Q.A MATERIAL: DWGNO.

6061 T6 AluminumM otorSrewTran.f,.r

WEIGHT: SCALE:2:1 SHEET 1 OF I

SOLIDWORKS 4S3O
]Educational Product. For Instructional ai Onlyi 2 1

109
 4 3 2 1

00 )0

F 0- M--

0.0000
0. 1250 TI

0.8750
E

2.7500
D

0.2500
0.1250
0.0000

Lo oD
0 CN No Co ? 1
C 0-a
66o - -Co

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEESRAND
DIMENSIONSAEIN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
*SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

A MFG A
Q.A MATERIAL: DWGNO.

Polycarbona tead _Screw _Reinforde

WEIGHT: SCALE1:1 SHEET 1 OF 1

4 Product. For Instructional Us3Ony,

SOLIDWORKS Educational 2 I

110
 4 3 2 1
4.5000

F 3.5000 + F

0.5000
E 0.0000 E
0000
0oo

0.5000 0 00

D D

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPVD

AMFG A
Q.A MATERIAL: DWGNO.

6061 T6 Aluminum Exit Ramp ^

WEIGHT: SCALE:1:5 SHEET 1 OF I

SOLIDWORKS Educatal Product. For Instructional U83 y Only2

111
 4 3 2 1

F A
F
Cr
*OZS

1.1000 1. 1000

E E

0.6250 0. 6250

40.0000 0. noon
D D
o 0 C o o00
o - o
-0 c o o
oYooo0 C

C C

0i
O

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOTSCA LE DRA WING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD

AFFV
AMFG A
G.A MATERIAL: DWG NO.
A4
Polycarbonate PlungerBlock
WEIGHT: SCALE:2:1 SHEET 1 OF I

SOUDWORKSEducateonal foduct. For Instructional I Only.

2 1

112
 4 3 2 1
ib~

F2.2500T- 2.2500 F

2.0000 + +*)- 2.0000

E E
0

C)
U-)

D I I I D
0.2500 - 0.2500

0.00000 0.0000
1.5000
o0 CDC
ICN
(D-
o66m
666,
C C

B 0 B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPV'D

AMFG A
Q.A MATERIAL: DWGNO.

Polycarbonate MotorBracketSid4 4
WEIGHT: SCALE:2:1 SHEET I OF 1
SOLIDWORKS EducatlmaiProduct. for Instructional Only.
2 1

113
I?
2.6500
2.4000 F
2.2550

13250

E 5 jX~A~-z 0.6500 Ei
0.3950

0.0000
CD0 CD 0 C0 00C
CDLo) LoU- U-) Lo 0
) CN UO (N N
C O
e4- LO <>s -C
c'S C15 C1 0 66
0
D ID

0
01
u')
(NI
61

T!
B
NLESS OTHERWISE SPECIFIE D: FINISH: DEBURRAND
DIMENSIONS ARE IN MILLIM ETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
'S URFACE FINISH: EDGES
OLERANCES:
LINEAR:
ANGULAR:

!R NAME SIGNATURE DATE TITLE:

CHK'D
APPV'D

A MFG IA
Q.A MATERIAL: DWG NO.

PolycrbonateMotorBracketCqrt
WEIGHT: SCALE: 1: 1SHEET I OF

114
 4 3 2 I

0.3750
E
6o
Lf
)

D D

OD

CC 0c
(N
0r

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
BREAK SHARP DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS
SURFACE FINISH: EDGES
-TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

AMFG A
G.A MATERIAL: DWGNO.
A4
Aluminium Cam.2
WEIGHT: SCALE:1:2 SHEET 1 OF 1

SOLIDWORKS Eductional Product. For-instructional Use Only.

2 I

115
 o
1.0
0
0
0
Lo

0
F:

-0.3750

-E 0.0000

-
E JEt
0.3750
I

10.7500
A\
0.6000

nnn

.
o o 0 0 0
0 Lo 0
u')
Lo
CN
0
0
0

B B
iUNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAKSHARP DO NOT SCALE DRA WING REVISION
SURFACE FINISH: EDGES
ITOLERANCES:
LINEAR:
ANGULAR:

NAME .SGNATURE DATE TITLE:

DRAWN
APPV'D

MATEIALA WNO

61 T6AlumnuCO aMotorITransf
WEIGHT SCALE21 SHEET 1 OFI

SoLDVWORKS reuduet insruetien Oy

116
 4 '1 111 -11 -3 2 1

13.7500
F
0*

0 -/

+
++0 11.2500

10.2500
E

8.5000
8.000 8.0000
7.7500
7.2500

4.5000
+

2.7500
C

1.0000 - 1.0000
+

0.1250 i~L
0.0000 ~-_ -7- -- 0.0000
00
C0 C C0 0
Z D 00C 0 0 000
: LC) LO ) 0 L C
e N-o oC
B It| | |D B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE D RAWING RV ISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

CHK'D
APPVD

AMFG A
GA .- MATERIAL: DWGNO.

Polycarbonate Angle Bracke

WEIGHT: SCALE:1:5 SHEET 1OF 1
SOLIDWORKS Educational ProductiorInstructionalU WOnlyr 2

117
 4 327 2

F F
o
0 0 0
o 0 0
40 ON0
03 NO
Lfl

U-) C14 C
0 CN 004- C
E 666

)
E
10.0000 0. 000 0.00001
.0.2500 0.2500

-D 1.5000

- 1-

-
D 3.5000 3.5000 .4 3.50001D
+

5.5000

6.7500 6.75001
'7.0000 7.0000 7.00001
iC
0

5p
0T
0

0
<
B
UNLESSOTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD
APPV'D

Q.A MATERIAL: DWG NO

-~ A4
Polycarbonate Bottom Brace
SCALES SHEET I OF 1

SoL.DwoRrs E....!.2 & r I

118
 F F

C
7.3800
* a-
8.0000 8.0000
7.5000- 7.5000

[I 4.0000
C)
0
0
0
4.0000

+
Dl D

0.50000 0.5000
0.00000 -40.0000

1c Ici
0oCNI
o C
T 0 0D C
oCoo O U-) C
666C Lo) c( C

Bj B
UN OTHERSESPDEBURRAND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DONOTSCALEDRAWING SION
' SURFACE FINISH:, EDGES - --
TOLERANCES:
LINEAR
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
-

JAPPV'D

iA -FG-
Q.A MATERIAL: G NO

Polycarbonate Back Brace

-J BUGHT: SCALE:1: SHEET OP1

souo
so
we~nd.&M!IIAM
WORKS-fiduced6nmi
77 4.& i...11 2
P oducts Pot inshmedo".2,

119
 4 3 2 1

F 00 F

/
~
\(.~
'9+ 1. 3 000
1.3000 0. 8 7 5 0
1.1500 0.5000
0. 1500 0.1250
E E
0.0000 60.0000
00
(NO)
C r- -Q
d
0 66C

2
0.2500
0.1250
D 0.0000 D
0 L) 0 0
0 0 0
0 LO
0)
0 0q
nD

C C

0
0
0

B B
UNLESS OTHERWISE SPECIFIED: PINISH: DEBURR AND
DIMENSIONS ARE INMILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIAL:

Tray-SliderSide A4
WEIGHT: SCALE:I:5 SHEET I OF 1
SOLIDWORKS Educat fal Product. For Instructional U~.Only. 2 I

120
 4 3 2 1

F F

o0 o0 o0 0
o0 o0 o0
0 o0 o- 0
0
0
0
0

E 0.0000 E
0.0250
~0.2500

~o oo
Ln CN CO
C' - o
5.0000

0.0000
0.1250
Dg 0.5000D
0.8750
1.0000

C>

C C

C>

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
'CHK`D
APPVD

A MFG A
-

O.A MATERIAL: DWG NO. 4

-ry d
• B
Polycarbonate TrayQS|derBottor,..
WEIGHT: SCALE:1:2 SHEET 1 OF 1

4 P3
SOLIDWORKS Educational Product.For hatructional UeOnly. 2 1

121
 4 3 2 I

F F

0/00
1-0s
00o
E 0.6000E
0.3500
0.1250
.uuU

0 0 0
Q 0) 0 0
0 0D 0 0D
CO C L(' CO
LQ I4 q
L1C) C)6

D D

01
A
LOI

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS DO NOT SCALE DRAWING REVISION
BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN'
CHrD
AFFV'D

AMFG A
Q.A MATERIAL DWG NO.

Polycarbonate Tray Slider_First_RV

WEIGHT: SCALE:1:2 SHEET 1 OF 1

4 Product. For instructionalUse

SOLIDWORKS Educational 3 Only 2 1

122
 4 3 2 1

F F

E E

1.3000 1.3000 -1.3000

1.1500 -21.1500

D - -+-- o0. 6 5 0 0 D

0.1500 ©© 0.1500
0.0000 / 0.0000 0.0000
0 0 0 00 0 0 D0
00 C 0 0 00 0 00 00 0
CO 0) L o LOD LOo
n-o 000
-o0 0 -0 s>0 -0
6 66 6 666
6666o
C C

to

0,

B I~zpo0 B
UNLESSOTHERWISESPECIFIED: FINISH: DESHR AND
DIMENSIONS ARE IN MILLIMETERS BREAKSHAR DO NOT SCALE DRAWING REVISION
SURFACEFINISH: EDOES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG "A
Q.A MATERIAL: DWGNO.

Polycarbonate DriveBearing_Block'
WEIGHT: SCALE:2:1 SHEET 1 OF 1

SOLIDWORIS Educatieon IProduct.fornstructiona Ony,

2 I

123
 4 3 2 I

F F

E E

00. 1440 TH RU X2,

D D

LS1

0
C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE INMILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG
Q.A MATERIAL DWGNO

95120AI11 BRONZE GENERAL PURPOSE4 AC

WEIGHT: SCALE-1:1 SHEET 1 OF 1

SOLIDWORKS Educatial Productfor structional Only,

2 I

124
 ., ____ ________
-~ -------~ -.- ~~.-~---- ------ -~

01,
01
\o.0000 NI

f 0.25000
E- 0D
0 Ei
CD) 0
2 250000

0025050250

Dn

0.1000 E

CN y

C C1

i0.2500
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DONOTSCALEDRAWING REVISION
'SURFACE FINSH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

D1RAWN
-

CHKD

Q.A - MATERIAL: DWGNO

___ Polycarbonate Flexure_0.6_V3

.- SCALE1 SHEETIOF1

socIDwoRn~us aim predfeariter klirect..I oeny, - - -------.-- -

-

125
 4 3 2T

0D Lf) CQJ
(nN (Nl 0D
F . . F

2.6000
2.4750
A4 2.1000
A 40

1.5000

0.5000

-0.0000
00 0( 0 00 C
DD' (Z 0 '0 0ZD
DO
r-'uO D
O
1_ C

C C
00

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHKD'

AMMFG
GA MATERIAL DWG NO.
A4
Polycarbonate FlexureMount
WEIGHT SCALE1l2 SHEET 1 OF 1

SOLIDWORKS Educational Product.or Instructional U Only.

126
 4 3 2 1

F -- __
- ----- - 0.7500 F

--- 40.2000

10.0000
E O E
O C C C
O CD O U-) CD CD
'O) U-)
0O O6
0
CD
OD

0.2500
0.1250
-'0.0000
D D
oo O O (D
O
o O C) O
(N CD
C) C

c c

(D©

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

A MFG A
Q.A MATERIAL: DWGNO.

Polycarbonate Preload_MountA4
WEIGHT: SCALE:2:1 SHEET 1 OF 1

4 Product-Forfnstructional Ls.eOnly,
SOLIDWORK Educatioal 3 2 I

127
 4 3 2 1

F F

.0.2500

/-
2.0000

1.5000- -
E E

/-

0.5000

0.0000e-

D 0 0
D D 0 0 D
D CO LC)
0 0~
-

C C
00C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DO NOT SCALE DRAWING REVISION
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

AMFG A
Q.A MA TERIA L: DWG NO

Polycarbonate FlexureShim A4
WEIGHT: SCALE:1:I1 SHEET 1 OF 1

SOLIDWORKS Educational Product.For-Instructional UseOnly.

2 I

128
 4 3 2 1

F F
2090

0.5000

- 0.2500

E 0.0000 E

00
(D0C 0
00
0 0- 66C

C- C)0

D D

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIAL: DWG NOl
A4
6061 T6 Aluminum FlexureMetal
WEIGHT: SCALE:2:1 SHEET 1 OF I

4 Produt For Intuctonal kse

SOLIDWORKS Eucatinal 3 Only. 2

129
 4 3 2 1

f)|

F F

0/ 0 0.0000
0 r1C 0 0

0001.000 E
Cl __2.0000
X4- + 1.8750
1.4000

0.00

C C

B 'i B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

AMFG N
Q.A MATERIAnL:a DWG NO.

Polycarbonate Rake_Front_FlatA^4
WEIGHT- SCALE:1:2 SHEET 1 OF I

SOLIDWORS Educatil
3 Only.
4 Product. ForInstructional Use 2 1

130
 4 3 2

F c F

1.5000
1.3750
E 0.9000 E
0.8750

0.3750
0.0000

000 0DCD 0 0
DD DC D( DnC

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

AMFG A
Q.A MATERIAL DWGNO.

Polycarbonate Rake Back HolesA.

WEIGHT: SCALE:12 SHEET I OF 1
4OIWOK 3 2 1
SOLUDWORKS Educational Product, For intructional UeOy

131
 4 3 2 1

F 0D F

E E
0.2500
0
.1 2 5 0
Tz 0.0000

0 00 0
OU 0OO O0
O
0 0
O -N.O0 O
Osr~- t L0
0
D 0 0 D

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

AMFG A
Q.A MATERIAL: DWGNO.

Polycarbonate RakeIopFlat ^
WEIGHT: SCALE:1:2 SHEET 1 OF 1

SOLIDWORKS Educatinal Product. For instructional Use Only.

2 I

132
 4 3 2 I

F F
0.3000

1.2500
1.1250-

E E

0.1250 - %0
-

0.00004

D D D
N '-r)
O)
CD LO
C -C
D

C C

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMFG A
Q.A MATERIAL: DWGNO.
A4
Polycarbonate RakeTail
WEIGHT: SCALE:2:1 SHEET1IOF 1

4 ProductFor nstructional Ui3 Only.

SOLIDWORKS Educatinal
2

133
 4 3 2 1

F F

4
0.25
-8.0000

E 7.5000 E

D D

0.5000
0
C C
i-I

'O LO O
LO N4 CN 0
0o (D
0
0' u,
O6 0

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

-DRAWN
CHK'D
APPV'D

A MFG A
O.A MATERIAL: DWG NO.
A4
Polycarbonate Queue Base
WEIGHT: SCALE:1:5 SHEET 1 OF 1
4
SOLIDWORKS Educatinal Product or Instructional us. Only. 3 2 I

134
 4 3 2 1

F F

9.5000
0 6-32 T 0.5 X 4
9.0000
E E

C)
(D
CD
Ln
01-
D D

2.0000

4 1.2500

C 4 0.3500 C
0.0000'
1.0000
0.25

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS BREAK SHARP DO NOT SCALE DRAWING REVISION
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPV'D

AMF G k
Q.A MATERIAL: DWG NO.

Polycar bonate Queue_LeftWall ^A

WEIGHT: SCALE:1:5 SHEET 1OF 1

SOLIDWORKS Educatinal Product.ForInstructionalUs Only.

2 1

135
 4 3 2 I

F F

11.0000
06-32 T 0.5 X4 10.5000

E E

-D

D D

13.5000
C)1
2.7500

C C
-40.5000
025 0.0000
0.25
1.0000

B B
UNLESS OTHERWISE SPECIFIED: FINISH: DEBURR AND
DIMENSIONS ARE IN MILLIMETERS DO NOT SCALE DRAWING REVISION
BREAK SHARP
SURFACE FINISH: EDGES
TOLERANCES:
LINEAR:
ANGULAR:

NAME SIGNATURE DATE TITLE:

DRAWN
CHK'D
APPVD

A MFG A
Q.A MATERIAL: DWG NO.

Polycarbonate QueueRightWI!
WEIGHT: SCALE:5 SHEET I OF 1

4 Produ. For lnstuc

SOLIDWORKS Educntonl onal se Only.
2 1

136
Appendix B

Bill of Materials

A complete catalogue of all parts and materials purchased for prototyping the placement
mechanism can be found found in the bill of materials below.

137
Item Quantity Link
Raw Materials
1/8" Polycarbonate 6x12" 1 NA
1/4" Polycarbonate 48x48" 1 NA
1/2" Polycarbonate 6x12" 1 NA
1/2" Diam. 6061 T6
Aluminum Rod 12" Length 1 NA
1/10" 6061 T6 Aluminum
6x12" I NA
Screws/ Nuts
1/4" 2-56 Set Screw 1 NA
1/4" 4-40 Set Screw 1 NA
3/4" 6-32 Set Screw 2 NA
1/2" 6-32 Countersunk
Screw 10 NA
1/4" 2-56 Machine Screw 2 NA
1/4" 6-32 Machine Screw 4 NA
3/8" 6-32 Machine Screw 6 NA
1/2" 6-32 Machine Screw 38 NA
5/8" 6-32 Machine Screw 11 NA
3/4" 6-32 Machine Screw 20 NA
7/8" 6-32 Machine Screw 2 NA
1" 6-32 Machine Screw 4 NA
11/8" 6-32 Machine Screw 5 NA
1/2" 8-32 Machine Screw 4 NA
1" 8-32 Machine Screw 4 NA
8-32 Nut 4 NA
Motors & Misc

https://www.amazon.com/Stepper-Motor-Leads-Channels-
Single/dp/B07DSGFZHF/ref=ascdfB07D5GFHF/?tag=hyprod-
20&linkCode=dfO&hvadid=242041198988&hvpos=1o17&hvnetw
=g&hvrand=8949379198700410282&hvpone=&hvptwo=&hvqmt
=&hvdevc&hvdvcmdl=&hvlocint=&hvlocphy=1018145&hvtargid
Stepper Motor 2 =nia-4A7420Sna22%ansc=1
Solenoid Motor 1 https://www.mcmaster.com/70155k661
12" Lead Screw 1 https://www.mcmaster.com/98941a735
Lead Screw Nut 1 https://www.mcmaster.com/95120a111
Clamping Flexible Shaft
Coupling 1 https://www.mcmaster.com/6208k595

138
Bibliography
[1] Linkedin. "Waters Corporation". https://www.linkedin.com/company/waters/ Accessed

25 June 2019.

[2] Z. Zhang. Design and development of an automated sorting and orienting machine for

vials. Master's thesis, Massachusetts Institute of Technology, 2019

[3] E. Moskofidis. Design and development of a transfer system for an automated vial

packaging machine. Master's thesis, Massachusetts Institute of Technology, 2019

[4] S. Liu. Design and development of an automated inspection system for vials. Master's

thesis, Massachusetts Institute of Technology, 2019

[5] D. Fernandes. Design and development of a precision packing stage and master control

system for an automated vial packaging machine. Master's thesis, Massachusetts Institute

of Technology, 2019

[6] Youtube. "108-44 Bottles".

https://www.youtube.com/watch?timecontinue=271&v=pZIJgT7rVic Accessed 10 May

2019.

[7] YouTube. "How It's Made Crayola Crayons".

https://www.youtube.com/watch?v=3vtJgZFIqpc&t=242s Accessed 10 May 2019.

139