Failsafe Sensor Configuration for MiTek Vertical Stackers
Failsafe Sensor Configuration for MiTek Vertical Stackers
Embedded Files
Course or Client
MiTek Internship
Completion Date
Summer 2024
Skills
3D modeling, PDM, Communication with Vendors, Logic Design
Challenge: Design failsafe rotation limit sensing for MiTek Vertical stacker machines
Challenge: Design failsafe rotation limit sensing for MiTek Vertical stacker machines
Who MiTek is
Who MiTek is
MiTek is aiming to change the way the world builds houses. They strive to do so by making houses stronger and easier to build through offsite construction; which means building components such as floor and roof trusses in a factory and then transporting them to the build site to then be assembled. MiTek enables offsite construction by producing engineered connectors and automated equipment for assembling trusses in factories.
For my internship, I worked on the Automation Core Platform Support (CPS) team in St. Louis, MO. This team of electrical and mechanical engineers works to support the existing catalog of over a dozen machines that MiTek sells in the US by continuously improving their functionality and manufacturability with feedback from customers and the manufacturing team. My office was located in St. Louis and was connected to the manufacturing floor, allowing for easy access to see the physical machines being designed and ask welders and assemblers questions.
Defining the Needs and Requirements
Defining the Needs and Requirements
The Peak-up Stacker is a machine used in material handling to stack assembled trusses vertically for easier unloading by forklifts. A video of the Peak-up Stacker in operation can be seen to the right. This machine is most commonly used outside and is exposed to the elements and rough use by customers, so its durability and reliability are paramount. An issue discovered by a customer is that the limit switches used to define the limits of rotation of the lifting shaft could bend easily, which in the best case would reduce the effectiveness of lifting the trusses and in the worst case would cause the machine to overrotate until it broke and possibly hurt someone.
For this project, I was assigned to determine how to prevent such a failure from happening by implementing a more robust sensor and modifying the logic. I worked with electrical engineer intern Austin Mays for specific sensor selection and vendor communication.
Limit switch sensor
Existing Design
Existing Design
2 physical limit switches that require calibration and break easily (shown in red in the figure on the right)
Toggle logic (stops when sensor is pressed)
Existing operation
Proximity switch example
New Design
New Design
2 contactless Proximity switches (shown in red in the figure on the right)
Push button logic (Moves until sensor is uncovered and no longer detects arc flag, then reverses)
Proposed failsafe operation
Note: I am unable to show the complete 3D models and designs I produced during my internship, so presented here is a basic ideas that convey the core concepts
Conclusions and learnings
Conclusions and learnings
One lesson I learned from this project was how it is incredibly valuable to find a subject matter expert early in solving a problem. I experienced this by talking to the customer repair staff getting to hear how the failure occurred firsthand and hearing their experience of other ways the machines have failed that were not clearly documented.
I also learned how companies can interact with vendors, gaining an appreciation for the communication and time required for sourcing a product affordably and reliably.
Me and Austin Mays in front of the MiTek office
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