Design Project II: FOD Identification and Removal EDSGN 100; Introduction to Engineering Design; Section 008; Team 2

Submitted By: James Zukowski, Juliette Mitrovich, Alan Hwang, and Jenny Simmons Submitted To: Dr. Xinli Wu ; Spring Semester 2018; Submitted Friday, April 25, 2018

http://personal.psu.edu/awh5579/edsgn100_sp18_section08_team2_dp2.pdf

Abstract: The objective of this project was to design a tool that aids in the detection, identification, and removal of foreign object debris (FOD) in an aircraft. This results in a prototype that is able to retrieve FOD in small, tight, and hard-to-reach spaces. In addition, the prototype is flexible through a multitude of complex scenarios.

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Table of Contents: Abstract (Alan Hwang) ………………………………………………………………….……… ii Table of Contents (Alan Hwang) ……………………………………………………….…...… iii Introduction (Alan Hwang) …………….………………………………………………………. 1 - Problem Statement (Alan Hwang) ………………………………………………………. 1 - Mission Statement (Alan Hwang) ……………………………………………………...... 1 - Design Specifications (Jenny Simmons) ………………………………………………… 1 Design Approach ………………………………………………………………………….…2 - 6 - Gantt Chart (Alan Hwang) ……………………………………………………………..... 2 - Customer Needs Assessment (Alan Hwang) …………………………………………..... 2 - Concept Generation (Jenny Simmons) …………………………………………………....3 - Design Selection Matrices (Juliette Mitrovich) …………………………………………..7 Final Design and Prototype ……………………………………………………………… ...8-12 - Working Drawings (Alan Hwang).............................................................. ………………8 - Prototype (All Members) ………………………………………………………………...11 - Design Features (Jenny Simmons) ……………………………………………………....12 - Operation Instructions (Juliette Mitrovich) ……………………………………………..12 Engineering Analysis …………………………………………………………………………..13 - Working Mechanism (Jenny Simmons) …………………………………………………13 - Cost Analysis (James Zukowski) ………………………………………………………..13 Summary and Conclusions (Juliette Mitrovich) ……….,.................................……………….14 Acknowledgements (James Zukowski) ………………………………………………………...15 References (James Zukowski) ………………………………………………………………….15

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Introduction: Foreign object debris (FOD) creates significant problems at airport facilities -- the intensive process to remove FOD can be an extremely arduous task. Even the smallest piece of debris can pose a significant risk to airport operations. When following safety protocols, it can take up to days to solve the simplest problems -- often leading to a significant loss of time and resources. The aim of this project was to design and prototype a system to improve the efficiency of the FOD removal process. Based on our literature review, desired prototype qualities were prioritized -- such as flexibility, ease-of-use, durability, and price. Five designs were brainstormed -- after a careful analysis of each, the most balanced and efficient design was chosen and presented. Problem Statement: Removing foreign object debris can be a labor-intensive task. On top of the lengthy safety documentation that comes with FOD, the removal of FOD can take up to weeks. Often times, the removal process requires entire aircrafts to be disassembled -- setting operation schedules back a long period of time. Mission Statement: Currently, there are several “situational-driven” FOD removal devices. These devices have a complex design that address extremely specific scenarios -- for example, using a crowbar-shaped device to remove a bolt from the side of an airplane chair. Through a prioritized features list, a prototype is developed to be as flexible as possible. The core of the prototype design is simple and will adjust to as many different FOD removal scenarios as possible. The device will consist of cost-effective components that will keep the price of our product to a minimum without sacrificing quality or durability. Design Specifications:

- Design a tool or instrument that will aid in the detection, identification, and removal of FOD in an aircraft

- The tool or instrument must identify and retrieve FOD in large, small, tight, and/or hard-to-reach spaces

- The design must be compact, user friendly and cost effective - The tool should minimize the need for disassembly of the aircraft

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Design Approach: Gantt Chart:

Table 1: Gantt Chart

Customer Needs Assessment/Literature Review: After analyzing the most and least desired qualities of a removal device, a prioritized “qualities list” was created: 1) Flexibility 2) Ease of Retrieval 3) Ease-of-use 4) Efficiency 5) Size 6) Durability 7) Cost

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Concept Generation: Design A: Remotely Controlled Flying Drone Design

Figure 1: Design A Design A is a compact flying drone designed to fly inside the aircraft to retrieve and identify the FOD. Equipped with two retractable arms and alligator clip claws this drone can reach into almost any area. Although this design is compact and easily accessible, it is not simple and user friendly. The cost to manufacture and repair this device would also be high.

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Design B: Remotely Controlled Rolling Drone Design

Figure 2: Design B

Design B is a remotely controlled drone with rubber wheels designed to climb up walls and rotate 360 degrees. It’s compact design minimizes the need for disassembly of the aircraft and retractable arm meant to reach FOD at a variety of distances. The ball and socket hinge and 3-pronged claw are designed for easy and fast FOD retrieval. This design is not cost effective or easy to use and requires frequent repairs.

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Design C: Manually Controlled Flexible Arm Design

Figure 3: Design C

As shown in Fig 3, design C has a simple and easy-to-use design that makes it simple to retrieve the FOD. The flexible arm allows this design to get into hard to reach spaces and the 3-pronged claw is attached to a retractable extension to retrieve the FOD from a variety of distances. Although this design is simple and easy to use, the flexible coil arm has a lack of precise control making small FOD retrieval more difficult. Design D: Manually Controlled 3-Pronged Claw Design

Figure 4: Design D

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Design D has a simple and precisely controlled design that aids in FOD retrieval and detection. This design is equipped with a sturdy retractable arm with a ball and socket hinges at each portion of the arm. The joystick and button controls on the handle control arm and claw for easy manual control. Although this model is cost effective and compact, the handle design is not very comfortable for long use. Design E: Manually Controlled Electric Alligator Claw Design

Figure 5: Design E

Design E combines all of the best features from the other four designs in a cost-effective and simple design. The retractable arm and ball and socket joint allows for precise retrieval of the FOD. The alligator clip claw allows for fast and easy pick up and the camera and light on the claw allows the user to see inside the aircraft. The comfortable grip handle and manual button and joystick controls allows for comfortable and exact control.

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Design Selection Matrices:

Design A Design B Design C Design D Design E

Selection Criteria Efficiency Ease of Retrieval Cost Ease-of-use Durability Size Flexibility

0 0 - - 0 + 0

0 0 - - - 0 0

- - - + + 0 0

+ 0 + + 0 0 0

+ + + + 0 0 0

Sum +s Sum 0s Sum -s

1 4 2

0 3 3

2 1 3

3 4 0

4 3 0

Net Score Rank

-1 3

-3 5

-1 3

+3 2

+4 1

Continue? no no no yes yes

Design D Design D Design E Design E

Selection Criteria Weight (%) Rate Score Rate Score

Efficiency 20 3 .6 4 .8

Ease of Retrieval 20 3 .6 3 .6

Flexibility 15 3 .45 3 .45

Durability 15 2 .3 3 .45

Ease-of-use 10 2 .2 3 .3

Size 10 3 .3 3.5 .35

Cost 10 3 .3 3 .3

Total Score Rank

2.75 2

3.25 1

Continue? no develop

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Final Design and Prototype Working Drawings: 1) Grip

Figure 5: Grip Working Drawing

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2) Link

Figure 6: Link Working Drawing

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3) Socket

Figure 7: Socket Working Drawing

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Prototype Images: Scale: 1 : 1

Figure 8: Prototype Working Drawing

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Figure 9: Prototype Isometric View and 3D Printed Prototype

Design Features: This design focuses on making the FOD retrieval device compact, user friendly and cost effective. The simple, manually controlled electrical claw minimizes the need for disassembly of the aircraft while retrieving the FOD. The tool is designed to work in large, small, tight, and/or hard-to-reach spaces and assist in the removal process. The joystick and button controls featured in the handle allow the operator to control the device with ease. The overall process is simple, easy to use and created to assist users of all skill levels. Operation Instructions: Once you find the location of the FOD, find a location to place the electric claw so it can reach the FOD (make sure the clamp is shut so it can fit in save space). Once it is placed accordingly, open the clamp using the trigger button on the handle. Using the joystick on the handle, move the arm of the claw to locate the FOD. Once it is found, push the “up arrow” on the claw handle to extend the arm to reach the FOD. Once it is in position to grab the FOD, click the trigger button to close the clamp and capture the FOD. Once it is secure, push the “down arrow” to retract the claw arm and pull out the FOD.

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Engineering Analysis: Working Mechanism: To begin the FOD retrieval process, start by identifying the FOD and its location. Next, decide which side of the aircraft will be easiest to retrieve the FOD from, insert the the retrieval device. The joystick and button controls operate the camera and light to locate the FOD inside the aircraft. The arm extends or retracts to position in front of the FOD. The controls to operate the ball and socket joint and the FOD can be secured in the alligator clip claw. Then the arm retracts back out of the aircraft and retrieves the FOD. The small and compact design will allow the device to fit in a hole small enough for a standard size screw. This process should be fast and simple for users of all skill levels. Cost Analysis: This product will be 3D printed using polylactic acid. The plastic is strong, durable, and cost efficient. According to 3D Hubs and Monster Steel, the price of each individual part will be as follows:

● Ring: $0.16 ● Link: $2.78 ● Alligator Clip: $0.24 ● Ball and Socket Joint: $1.36 ● Base Tier of Arm: $5.85 ● Second Tier of Arm: $3.61 ● Grip: $21.92 ● Rubber for Grip: $2.99 ● DC Motor: $20

Total Cost = $58.91 *Note that this product would be mass produced and therefore would reduce the overall price.

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Conclusion: In conclusion, the goal of creating a FOD retrieval device that addressed the concerns of Lockheed Martin, as well as the design specifications, was met. The manually controlled electric claw is able to retrieve FOD in small, tight, and hard-to-reach spaces. In addition, the claw is flexible through a multitude of complex scenarios.

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Acknowledgements: Team two would like to thank Lockheed Martin for providing us with their resources and assistance. In addition, Team two would like to Dr. Xinli Wu and Mike Gillett for their assistance in the design process and the making of the product. References:

“Browse Online 3D Printing Services.” 3D Hubs, www.3dhubs.com/. “Gorilla Grip Silicone Rubber Tattoo Grip Cover Classic Style.” Monstersteel,

www.monstersteel.com/products/gorilla-grip-silicone-rubber-tattoo-grip-cover-classic-ste “MetalMiner Prices: Stainless Steel Prices.” Steel, Aluminum, Copper, Stainless, Rare Earth,

Metal Prices, Forecasting | MetalMiner, agmetalminer.com/metal-prices/stainless-steel/.

Brochure:

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