Semi-Automated System for Quality Assurance of the CRV7 Bridge Filter Circuit
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Date
2013-12-02
Authors
Buist, Glenn
Hnatiuk, Clark
Matthews, Curtis
Nixon, Johnathon
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Abstract
This report describes the process undertaken and results obtained by Bristel Consulting (hereinafter “the team”) in analyzing and redesigning the Bridge Filter Circuit (BFC) testing process currently in use at Magellan Aerospace, Winnipeg (hereinafter “the client”). To complete this project, the team communicated closely with the client to identify needs, constraints, and the project objectives. This information was used throughout the entire design process. The BFC is a component of the electronic ignition system contained within C15 and C17 rocket motors produced by the client. Dangerous inadvertent rocket firings due to electromagnetic interference are prevented by the BFC. For proper function of the BFC, the resistance values of four coiled wires must be within a specified range. Quality assurance of the rockets requires that each BFC must be tested for proper resistances before assembly into the rocket. Currently, the testing process is performed by an operator stripping eight wires individually in a machine, attaching multimeter test leads to four pairs of wires, typing the multimeter reading into a spreadsheet, applying a masking tape label marked with a hand written serial number, and storing the BFC in a bag to await the next assembly process. The problem with the current process is that it is both overly time consuming and labour intensive. To meet the client’s needs of a faster and less labour intensive BFC testing process, the team set out to design a new process. Design was constrained to the existing work area, and costs were limited to not exceeding that of the current process. During the conceptual design phase of the project, these constraints and limitations were used to screen out a fully automated BFC testing process. Results of the concept selection process showed that the optimal solution to the client’s problem is a semi-automated system using a hand lever actuated fixture for connecting BFC wires to the multimeter, a custom computer program written to upload resistance measurements automatically from the multimeter, and a tray for organizing the storage of tested BFCs. All of these system components were incorporated into the final design of the new process with […]