Machine Design Final

Non‐Contact Thickness Measurement Device
Southern Polytechnic State University

MET 4141 Machine Design

Professor Mir Atiqullah & EXIDE Technologies

By: Ryan Clark, David Guffey, Devon Antoine, and Kevin McCall

Submitted: May 3, 2010

TABLE OF CONTENTS

Page Title

1 Abstract

2 Problem Definition

3 Introduction

4 Customer Requirements

5 Engineering Design/Specs

6 Gantt Chart

7 Initial Design Concepts

8 Design and Analysis

12 Cost Analysis

15 Safety

17 Data Acquisition (LabVIEW)

19 Data Analysis  (MATLAB)

27 Project Status

28 Conclusion

29 Acknowledgements

30 References

Appendix

Author Bio

MET 4141 – Machine Design – Group 5
Spring 2010
Professor Mir Atiqullah

ABSTRACT


EXIDE, a worldwide manufacturer of lead‐acid
batteries, partnered with Southern Polytechnic
State University’s Mechanical Engineering
Technology program to design a device for
measuring the thickness of their lead plates.  Along
with a strict set of customer requirements and
measurement tolerances that needed to be met;
there was no current method to benchmark a
design off of. The engineering group had to start
from complete scratch and come up with an
innovative way to incorporate the device into
EXIDE’S current manufacturing process.

The group, composed of Ryan Clark, Devon Antoine,
David Guffey, and Kevin McCall, took on the task of
engineering the device.

BRAIN STORMING

Brainstorming for the project took almost 2 weeks as the group performed endless amounts of research
to find a benchmark for beginning their design.  A lot of research was put into the measurement device
to locate a suitable method for meeting the customer requirements.

DESIGN

Once the team had gathered enough research, concepting and design of the first models were
produced.  There were 3 separate designs, each for a different location in the space allotted.  A design
matrix was used to weigh out which design was the most suitable.  Once a final concept was chosen, the
detailed assembly was modeled in SolidWorks and revised over time.

ANALYSIS

With a working model in SolidWorks, analysis was done on the table’s ability to withstand the weight of
the lead strip and any other residual weight.  The results showed our design had substantial strength.
SolidWorks was also used to calculate the weight of the table to know exactly how much pressure to
have the gas springs set at.

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Spring 2010

PROBLEM DEFINITION

Our design objective was given to us by EXIDE Battery Company. In their plate manufacturing
process, they did not have any way to measure thickness of their plates when going through the
process. This gave us our problem definition, which is to design a system to provide plate thickness
information as feedback for processes and quality controlling.

The process that EXIDE has for creating these plates started with a large coil of solid lead. Then,
the plates move through a grating machine which punches holes in the plates. Once all the holes are cut,
the plates move to a pasting machine, which adds a lead paste to the top and bottom of the lead strips.
Then the strips move to a cutting machine which cuts six inch section plates. Between the pasting and
cutting machines there is about six feet of clearance where the lead strips sag due to the difference in
speed of the machines. The plates are then sent to a drying machine which hardens the paste on the
plates to a point where they can be handled. Finally, the plates move to a table and they are bundled
into a set of ten where they are measured and weighed.

The area that we were designated to create our device at was after the pasting machine and
before the cutting machine. The issue was that we needed to find a way to measure the thickness
without compromising the paste that had just been freshly applied to the strips. This meant that we
could not come in contact with the paste, or if we had to, the contact had to be minimal. This was a
problem because the “sag” of the strips between the two machines made a thickness measurement
device unreliable if there was completely no contact.

The figures below show the desired area for design:

Pasting Machine Sag in the strips Cutting Machine

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Spring 2010

INTRODUCTION

Exide Technologies is the world’s largest manufacturer of lead‐acid batteries, with operations in over 80
countries and 2009 net sales of over $3.3 billion.  Exide Technologies is a global business organized to
serve customers’ complex stored energy systems needs. Key strengths of the Company are that its
products and services span global markets and geographic borders, melding two significant bases of
experience and technology expertise from its Transportation and Industrial battery divisions.  The
Company shares expertise across business segments.  For example, Exide established a global network of
battery testing centers and design improvement centers in North America, France, Spain, Australia and
the U.K.  This global footprint enables better and faster means of introducing innovations in products and
services, changing the way the world uses and stores electrical energy.

‐www.EXIDE.com

In the fall of 2009, Exide Technologies invited a group of Mechanical Engineering Technology
students from Southern Polytechnic State University to tour their Columbus, Ga. facility and to learn the
process of manufacturing lead‐acid batteries.  To show Exide their appreciation for the tour and to start
a partnership between Exide and the university, Professor Mir Atiqullah offered to have his Machine
Design class work on designing solutions to some of Exide’s engineering problems.

In the spring of 2010, 3 groups were chosen to take on the projects assigned by Exide.  The
scope of each project was laid out to the groups on February 16th at a project “kick off” held at Exide’s
engineering facility in Alpharetta, Ga.  Our group, composed of Ryan Clark, David Guffey, Devon Antoine,
and Kevin McCall, was assigned the task of designing a thickness measurement device for the lead plates
manufactured in Exide’s Bristol, Tennessee plant.

The lead plates in the Bristol, Tennessee plant are manufactured using a proprietary process of
“stretching” the raw lead strip into a grid where it is run through a pasting machine and lead oxide
(PbO2) is pasted into the grid cavities.  The pasted grid is then sent to a cutting machine where they are
cut into individual plates and ran through a drying oven to further harden the paste.

Two of the most crucial aspects of our design were: We could not affect the continuity of the
paste.  Meaning, our device had to have a measurement method that was non‐contact and our
apparatus could not be so invasive to the strip that it caused unnecessary stress to the grid.  The second
aspect was that we were bound by the current floor layout which meant our device had to be designed
to be fully integrated with the current process.

The following report documents the design process our group went through from
brainstorming, to scheduling, to design, and finally completed concept.  All photos and documents
contained herein are property of Exide Technologies and the MET department of Southern Polytechnic
State University.

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CUSTOMER REQUIREMENTS

A list of several requirements was provided by Exide Technology’s representatives for the Thickness
measurement device. Our design was purely based on the list of the requirements, and is included in the
final design. A total of seven customer requirements were given for the group to complete. Also, a
camera device is implemented by our group in addition to the requirements to improve the system.

• Measurement has to be in line
• Measurement resolution should be precise enough to qualify the product based on product
specification
• Data rate: minimum of 8 measurements per second
• Data will be dynamically updated on screen
• Data will be stored in accessible database for statistical analysis
• There will be no “reject” function in this system

Our device, a thickness measurement device must be aligning with the lead paste. Our first two
requirements are that our device is in line with the paste and it does not affect the continuity of the
paste.  This means that the device cannot interfere with the current pasting process by moving
machines. Also the continuity of the paste cannot be disturbed. The wet lead paste is very delicate and
therefore our device must be the least invasive as possible. This means that a “no‐touch” method of
measuring the paste should be used. The best method for measuring in such a way would be to use
lasers to measure the thickness of the paste.  As the paste moves between machines a 6ft gap lies
between the pasting machine and the cutting machine before the paste dries. Due to the gravity, and
speed change between the two machines, a sag in the paste exists.

For the use of lasers to measure the thickness of the paste, eight measurements are to be made per
second.   Also the measurement resolution should be precise enough to qualify the product based on
product specification.  In order to make precise measurements of the lead paste, the lasers must be
perpendicular to the paste. To get accurate measurements along the width of the paste, eight lasers are
to be used. Four lasers above the paste and four below it.

The use of lasers to measure would be beneficial to our device for the next criterion, the data to be
dynamically updated on a screen and be stored in a database for statistical analysis.  Additional software
must be used to adopt the last two customer requirements. Programming such software is not a
requirement because some lasers come with its own software, but we created our own program that
meets those requirements. No reject function would be used during this process but an alarm should
dictate if the paste is out of tolerance. In addition, a ultrasonic camera using ultraviolet rays to detect
flaws within the paste is not a requirement but will improve the device.

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DESIGN SPECIFICATIONS

The following specifications were provided by Exide Technologies about the plates that are to be
measured and the process of how they are made:

• Plate Specifications

• Thickness: range: 0.04 to 0.08 inches

• Tolerance +/‐ 0.003 inches

• Typical size: Individual plate 6 x 4.5 inches

• Line speed: 90 to 140 Ft/Min

• Other Measurements:  6ft between pasting and cutting machine.

• Lead strip enters cutting machine at a height of 31”

The plate size and the other measurements provided determined the overall size of our thickness
measurement device.  The device had to fit into the desired location and also accommodate the
different size plates.

The thickness range of the plates and their tolerances determined the accuracy of the measuring device
to be used.  Also, the line speed determined the number of measurements that need to be made each
second.

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GANTT CHART

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INITIAL DESIGN CONCEPTS

The initial design concepts were based upon the placement of the thickness measurement device. The
design of the device changes depending on the location along the pasting line. There are three locations
where the device could be placed along the lead strip, there are: after the pasting machine, in between
the pasting machine and cutting machine, and in front of the cutting machine. These can be seen in the
figure located below.



The placement of the device was determined by the amount of contact the device would have with the
paste at each location.  A different design concept was made for each location as shown in the figure
below. The figures correspond to the placement located in the figures above. Immediately after the
pasting line, and in the middle of the lead strip creates more pressure along the lead strip due to its
stationary design. The design concept at the location before the cutting machine was the least invasive
of the three due to its ability to lie along the natural “sag” of the lead strip.



The first concept design for in front of the cutting machine introduced the ability to adjust itself
depending on the speed of the paste. The device is made of an aluminum frame and table with PVC
rollers where the paste would lie. Attached perpendicularly to the table is a brace for the lasers, above
and below the table. As the velocity of the lead strip increases, the table would rotate but accurate
measurements would still ensue.  Also, one idea is to have the table adjust in an up or down motion to
compensate for speed adjustment. This design was the building block for the final design.

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DESIGN AND ANALYSIS

Our final design was created to cut down
on cost while still performing the task that was
designated. The design, shown in the figure, uses a set of
aluminum bar stock which creates the frame to hold up
our most crucial part, the table. This table is connected to
our frame by a three evenly distributed hinges which act
as a pivot point to compensate for the sag in the lead
strips. Another crucial part of this design is the gas shocks
that hold up the other end of the table. The shocks are
designed to hold up just the weight of the table so that
any extra weight applied to the table will cause the
shocks to compensate for that weight. Another key part
of our design was the laser measurement system rack.
This rack holds the lasers at a perpendicular axis. This
design is important because it will only make an accurate
reading if the lasers are reading the thickness in a level position.   Final Design



FRAME

The frame of the design is made of 80/20
extruded aluminum shown in the figure labeled
80/20 aluminum. This metal was chosen because
its material properties are strong enough to hold
up the weight of the table. Also the price of the
metal is low in cost, which was an important
design consideration.



                                                                                                                  80‐20 Aluminum





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   SHOCKS

The gas shocks are designed to hold up the weight of the table. This will allow the table to move
with the weight of the lead strip. So if there is any change in angle due to a increase in speed of
the lead strips the shocks will compensate for that angle by adjusting its pressure to equal the
pressure change due to the angle change. The benefit to using these gas shocks over spring
loaded shocks is life expectancy. If the shock needs to be calibrated, it is as easy as adding the
pressure needed. Whereas if a spring loaded shock were used, the replacement costs would be
more expensive and would be more difficult to replace.

       TABLE

The table that we designed has 2 main parts; the 10‐hole joining plates and the polyurethane
idler rollers. The 10‐hole joining plate is used to hold the rollers and the bracket for the lasers.
The costs of these parts were relatively low and they were made of a strong material. The rollers
are used to help the lead strips move freely while still providing a surface to get an accurate
reading by the lasers.  They are made of polyurethane because they have less friction and they
are lighter. This means that the paste that is coming across the rollers will be less likely to stick.
Also, if the designed table is lighter, it is less weight for the gas shocks to hold up. This will
increase the life expectancy in these shocks because they have to do less work when running in
cycles.

         FINITE ELEMENT ANALYSIS

Being that the table is the most crucial part of the design, it was necessary to do a stress analysis
on it. The figures below show the maximum stress, maximum strain, and the maximum
displacement of the table in the absolute worst condition.

For the analysis, the table is isolated and forces are placed in necessary areas. The table is
fixed at the back to represent the hinges. This helps give us an ultimate condition to see if the
table would yield. On the other end of the table, there are two (15 pound/each) forces pushing
the table parallel to its edge in the upward direction. This represents the forces from the gas
shocks pushing in the direction of the table. Finally, there is a 100 lb. force being applied to the
top of the table to represent the force that the lead strips add to the table.  This force is about
20 times higher than the actual force that would be applied by these strips.

The results of these applied stresses on the table are as follows:

NOTE: the area where there is a color change other than blue is where the there is a change in the
stress, strain, or displacement.

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Maximum Stress

The Maximum Stress= 33MPa; the yield stress of the material is 55 MPa so there is no danger of
the table yielding.

Maximum Strain

The Maximum Strain= 3.5396 x 10‐4

Maximum Displacement

The Maximum Displacement= 0.336 mm

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LASER MEASUREMENT SYSTEM

Acuity Lasers (AR‐700)

One major part of the design is the laser measurement system. The system needed to be able to
read 8 measurements per second, have a high resolution for accurate measurements, and be cost
effective. This laser meets all of those requirements and surpasses them.

The laser measurement system in the figure above, called the AR‐700, is made by the
company, Acuity Laser. There were a lot of comparable laser systems that could have worked as
well, but researching these showed this was the best choice. This laser is able to read up to 9400
measurements/second which is substantially more then what was required, The resolution of the
laser is extremely high, and the cost of the laser is $3495/each which is lower than the cost of
most laser measurement systems.

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MET 4141 – Machine Design
Spring 2010

COST ANALYSIS

Estimated Design Cost

Using an average base salary of $55,000 a year, which is about $27 an hour, with an estimated 680
hours of work, the design cost for the thickness measurement device was $18,360.

Detailed Prototype Cost

The above table is a detailed list of all the parts required for our final design.  The main cost of this
design is the lasers.  We obtained two quotes for laser thickness measurement systems, which include
the lasers, the software to collect and analyze the data, and a computer to display the information.  The
Aquity laser in the table above was the lowest price for everything needed to take and analyze the
thickness of the lead plates.

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T-Slotted Aluminum ($164.40) Welded Steel ($224.38)

What T-Slotted Framing Takes: What Steel Framing Takes:

• Design Time • Design Time • Bill of Materials
• Bill of Materials • Purchase materials • Cut to length
• Purchase Materials • De-burred • Set up fixture
• Assemble Frame Per Design • Weld • Grind Wheels
• Clean weld spatter • Degrease
• Machine for mounting • Primer Coat
• Mask non-paint areas • Paint

T-Slotted Framing Benefits: Welded Steel Expenses:

• No welding - no fighting heat stress or warpage • Band Saw & Clamps
• No priming or painting • Grinder & Sanding Disc
• Lightweight, easy to machine • Welder & Fuel
• Uses standard fractional or metric fasteners • Protective Equipment
• Less engineering time required • Paint Booth
• Easy to fabricate; only simple hand tools required • Skilled Labor
• T-slot technology is industry accepted
• Great aesthetic value
• No expansive fabricationg equipment required
• Easily reconfigured for design changes

T-Slotted Bill of Material: Welded Bill of Material:

Qty Description Cost Qty Description Cost
4 1515-Lt x 18" 32.40
1.5" x 1.5" x 1/8" wall x 18"
4 34.56
4 1515-Lt x 21" 37.80 steel tube
8 #7010 Saw Cut 15.60 1.5" x 1.5" x 1/8" wall x 21"
4 40.32
steel tube
8 #4301 Inside Corner Bracket 34.40
Sandpaper, cleaning
#3320 5/16-18 x 5/8" FBHSCS & N/A 24.50
32 19.20 supplies, tape, paint, ect.
Nut
5 Assembly Labor Time @
30 125.00
Assembly Labor Time 25.00 hrs. 25.00/hr.
Min.
Total Project Cost $224.38
Total Project Cost $164.40

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On the previous page there is a cost comparison between 80/20 T‐Slotted Aluminum and steel tubing
for building a small table.  This was taken from www.8020.net which is the official web site for 80/20.
Due to the fact that using 80/20 aluminum was cheaper and easier to assemble, we decided to use this
material to build the frame of our design.

Since we were not able to build a prototype there was no assembly labor costs involved in this project.
Also, this is a custom design project with no plans of future mass production, so there was no
production cost analysis done.

Including the design costs and the costs of all the parts the total estimated cost of this project is
$52,000.

Description Cost
Design Cost $19,000
Prototype Cost $33,000
Total $52,000

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SAFETY

The following safety information was taken from the Acuity website regarding laser safety and conforms
to OSHA standards.

Acuity’s laser sensors put out about the same power levels as the laser pointers that have become quite common,
but they are still subject to safety regulations. These devices are potentially hazardous only when the beam enters
the eye directly or through optics such as mirrors or focusing lenses. Scattered light or light striking the skin is not
classified as hazardous.

Laser Classes
U.S. regulations presently divide laser devices into “classes” based on the power of the laser, whether it is a visible
or IR laser, and the potential exposure duration. Class I devices are eye‐safe under any circumstances. The
maximum permissible output varies with the laser light frequency and other factors. Class II devices are visible
lasers with output of less than 1 milliwatt. Classifications apply to both pulsed and continuous wave lasers, with
various formulae for determining class.

For cw lasers, Class IIIa lasers are visible lasers with output power of more than 1 mW but less than 5 mW, as
measured through a 7 millimeter aperture. Class IIIb lasers are those with output above 5 mW, or any laser outside
the visible frequency band that is not unconditionally eye safe. Class IIIb extends up to 500 mW output power.

Regulations for light‐emitting devices are governed by the U.S. Food and Drug Administration (FDA) under 21 CFR
1040.10, PERFORMANCE STANDARDS FOR LIGHT‐EMITTING PRODUCTS .

Classifications of the AR4000 Versions
The AR4000‐RET is a Class I device, meaning that it will not cause damage to skin or eyes. If the target can have
retroreflective tape applied to it, the 4000‐RET is usually the sensor to use.

The AR4000‐LV is a Class IIIa laser device, with a maximum power of less than 5 mW. The aperture cover supplied
with the 4000 LV is required for end user sales in the U.S. OEMs and developers may integrate a separate aperture
cover, so long as it meets Federal requirements.

The AR4000‐LIR and high power LIR are a Class IIIb laser devices. The aperture cover supplied with these sensors is
required for end user sales in the U.S. In addition, complete systems (with power supply) must also include a
keyswitch and power interlock jack. The key must be removable only when the laser is off. The power jack
disconnects power to the laser when it is removed. The AR4000‐LIR power supply includes the keyswitch and
interlock jack. End users providing their own power supplies must include a conforming keyswitch and interlock. A
separate keyswitch/interlock box is available for the 4000‐LIR.

Laser classification becomes even more complex when considering scanned beams. Depending on the speed of the
scan and whether a scan repeats along one line moves in 2 axes, Acuity’s sensors can be made eye safe while
scanning. Regulations require end user scanning systems that are classified as eye safe to include interlocks that
turn the laser off if the beam scanning speed or pattern changes in any way that could cause exposure to
hazardous light levels. Scanning systems may also be classified as Class II, IIIa, or IIIb, but precautions must be
taken to assure that they are used in a safe manner.

The ANSI document Z136.1‐1993, “American National Standard for Safe Use of Lasers” describes the classifications
of lasers and the precautions to be taken for each class. This document may be ordered from ANSI, which has
offices in Hackensack, NJ, and New York, NY. (Phone: 212‐642‐4900)

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EYE PROTECTION

Frame Style: Sperian Milan Wavelength Optical Density
Color: Light Magenta 190 – 380 7 ‐ 7.1
VLT: 45 % 755 – 855 4 ‐ 4.1
Filter #: 104   780 ‐ 840 7 ‐ 7.1
Filter Type: Diode 1

Sperian Part Nbr:   31‐60104

A Class 3B laser is hazardous if the eye is exposed directly, but diffuse reflections such as from paper or
other matte surfaces are not harmful. Continuous lasers in the wavelength range from 315 nm to far
infrared are limited to 0.5 W. For pulsed lasers between 400 and 700 nm, the limit is 30 mJ. Other limits
apply to other wavelengths and to ultrashort pulsed lasers. Protective eyewear is typically required
where direct viewing of a class 3B laser beam may occur. Class‐3B lasers must be equipped with a key
switch and a safety interlock.

KEY SWITCH INTERLOCK

Most international laser safety standards require that laser devices
that emit Class 3B (or higher) radiation must be connected to a safety
interlock. While most users of AR700 sensors intend to integrate them
into a larger system with its own safety interlocks, some sensors will be
stand alone. For these stand‐alone applications, Acuity provides a
special connectivity kit with its own keyswitch interlock.

SAFETY WARNING SIGNS

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DATA ACQUISITION

Software name: LabVIEW 2009

BACKGROUND:

As part of our list of customer requirements, a method for data to be updated dynamically and
displayed on screen for analysis was desired by the engineers at Exide.  Though we had minimal
experience with creating such a program, we decided to tackle the task anyway.  Unfortunately, our
group was unable to acquire a laser system to hook up to a DAQ device, so we were forced to create a
“simulation” for proof of concept.  This simulation uses a Gaussian White Noise VI to generate a random
number given a standard deviation.  These random numbers simulated raw data from the lasers and
controls nested in the front panel allow us to control the numbers to simulate various scenarios (ex, too
thick, too thin).  Below is a screen shot of the front panel and block diagram.

WHITE NOISE VI

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FRONT PANNEL:

LED Indicator for warning Chart with upper and
lower limit bars.

User Inputs

BLOCK DIAGRAM:

LARGER IMAGE LOCATED IN APPENDIX

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THICKNESS MEASUREMENT STATISTICAL ANALYSIS USING MATLAB

Introduction:  This program loads an excel file and plots and X‐Y Plot of time vs. thickness measurement,
along with upper and lower tolerance limits.  It also plots a Histogram to show the central tendencies of
the data.  Also the minimum value, maximum value, mean value, and the standard deviation of the
collected data is calculated.

Program

The MatLab program was written as a Graphical User Interface (GUI) so that the user could
easily interact with the data and more easily see the information displayed instead of using a regular
MatLab function.  First of all this program selects an already existing Excel file, reads the information
contained in the Excel file, loads the data, creates two plots, and finally calculates the maximum and
minimum values, the mean value, and the standard deviation of the data collected.

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Graphs

The first graph plots the time vs thickness measurements (Figure 4) of the data loaded, along with the
upper and lower tolerance limits for the plates.

Figure 4. Time vs Thickness Measurement Graph.

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The second graph plots a histogram (Figure 5)  of the data loaded along with the upper and lower
tolerance limits of the battery plates.  The histogram shows the central tendencies of the data.

Figure 5.  Histogram Plot

Calculations

This program calculates the minimum and maximum values, the mean value, and the standard
deviation of the data loaded.

Mean Value:

Standard Deviation:

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Program Code

function varargout = ThicknessMeasurement(varargin)

%Written by David Guffey
%This program loads an excel file and plots and X-Y Plot of time vs.
%thickness measurement, along with upper and lower tolerance limits.
%It also plots a Histogram to show the central tendencies of the data.
%Also the minimum value, maximum value, mean value, and the
%standard deviation of the collected data is calculated.

% THICKNESSMEASUREMENT M-file for ThicknessMeasurement.fig
% THICKNESSMEASUREMENT, by itself, creates a new THICKNESSMEASUREMENT or
raises the existing
% singleton*.
%
% H = THICKNESSMEASUREMENT returns the handle to a new
THICKNESSMEASUREMENT or the handle to
% the existing singleton*.
%
% THICKNESSMEASUREMENT('CALLBACK',hObject,eventData,handles,...) calls
the local
% function named CALLBACK in THICKNESSMEASUREMENT.M with the given input
arguments.
%
% THICKNESSMEASUREMENT('Property','Value',...) creates a new
THICKNESSMEASUREMENT or raises the
% existing singleton*. Starting from the left, property value pairs are
% applied to the GUI before ThicknessMeasurement_OpeningFcn gets called.
An
% unrecognized property name or invalid value makes property application
% stop. All inputs are passed to ThicknessMeasurement_OpeningFcn via
varargin.
%
% *See GUI Options on GUIDE's Tools menu. Choose "GUI allows only one
% instance to run (singleton)".
%
% See also: GUIDE, GUIDATA, GUIHANDLES

% Edit the above text to modify the response to help ThicknessMeasurement

% Last Modified by GUIDE v2.5 26-Apr-2010 06:12:36

% Begin initialization code - DO NOT EDIT
gui_Singleton = 1;
gui_State = struct('gui_Name', mfilename, ...
'gui_Singleton', gui_Singleton, ...
'gui_OpeningFcn', @ThicknessMeasurement_OpeningFcn, ...
'gui_OutputFcn', @ThicknessMeasurement_OutputFcn, ...
'gui_LayoutFcn', [] , ...
'gui_Callback', []);
if nargin && ischar(varargin{1})
gui_State.gui_Callback = str2func(varargin{1});
end

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if nargout
[varargout{1:nargout}] = gui_mainfcn(gui_State, varargin{:});
else
gui_mainfcn(gui_State, varargin{:});
end
% End initialization code - DO NOT EDIT

% --- Executes just before ThicknessMeasurement is made visible.
function ThicknessMeasurement_OpeningFcn(hObject, eventdata, handles,
varargin)
% This function has no output args, see OutputFcn.
% hObject handle to figure
% eventdata reserved - to be defined in a future version of MATLAB
% handles structure with handles and user data (see GUIDATA)
% varargin command line arguments to ThicknessMeasurement (see VARARGIN)

% Choose default command line output for ThicknessMeasurement
handles.output = hObject;

set(hObject,'toolbar','figure');

%Inserts Exide Logo
axes(handles.axes1_ExideLogo);
ExideLogo=importdata('Exide Technologies.jpg');
image(ExideLogo);
axis off

% Update handles structure
guidata(hObject, handles);

% UIWAIT makes ThicknessMeasurement wait for user response (see UIRESUME)
% uiwait(handles.figure1);

% --- Outputs from this function are returned to the command line.
function varargout = ThicknessMeasurement_OutputFcn(hObject, eventdata,
handles)
% varargout cell array for returning output args (see VARARGOUT);
% hObject handle to figure

% Get default command line output from handles structure
varargout{1} = handles.output;

% --- Executes on button press in pushbutton_Reset.
function pushbutton_Reset_Callback(hObject, eventdata, handles)
% hObject handle to pushbutton_Reset (see GCBO)

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%these two lines of code clears both axes
cla(handles.axes2_XYPlot,'reset')
cla(handles.axes3_HistogramPlot,'reset')
cla(handles.text_MinVal,'reset')
cla(handles.text_MaxVal,'reset')
cla(handles.text_MeanVal,'reset')
cla(handles.text_StdVal,'reset')
guidata(hObject, handles); %updates the handles

% --- Executes on button press in pushbutton_Browse.
function pushbutton_Browse_Callback(hObject, eventdata, handles)
% hObject handle to pushbutton_Browse (see GCBO)

[fileName] = uigetfile({'*.xls';'*.xlsx'},'File Selector');

set(handles.edit_fileName,'String',fileName);
guidata(hObject, handles);

% --- Executes during object creation, after setting all properties.
function edit_FileName_CreateFcn(hObject, eventdata, handles)
% hObject handle to edit_FileName (see GCBO)
% handles empty - handles not created until after all CreateFcns called

% Hint: edit controls usually have a white background on Windows.
% See ISPC and COMPUTER.
if ispc && isequal(get(hObject,'BackgroundColor'),
get(0,'defaultUicontrolBackgroundColor'))
set(hObject,'BackgroundColor','white');
end

% --- Executes on button press in pushbutton_LoadData.
function pushbutton_LoadData_Callback(hObject, eventdata, handles)
% hObject handle to pushbutton_LoadData (see GCBO)

%selects axes1 as the current axes, so that
%Matlab knows where to plot the data
axes(handles.axes2_XYPlot)

a=xlsread('random_number.xls');

x =a(:,1);
y =a(:,2);

%upper and lower limits

Page 24 of 30

Spring 2010

y1=0.043;
y2=0.037;

%plots the x and y data
plot(x,y);
hold on
%adds a title, x-axis description, and y-axis description
title('X-Y Scatter Plot');
xlabel('Time');
ylabel('Thickness Measurement');

%plots upper and lower limits
plot(x,y1,'r');
plot(x,y2,'r');

hold off

axes(handles.axes3_HistogramPlot)

x2=0.035:0.0001:0.045;

hist(y,x2)
y3=0:.1:45;
x3=0.037;
x4=0.043;
hold on

%plots upper and lower limits
plot(x3,y3,'r')
plot(x4,y3,'r')

title('Histogram Plot')
xlabel('Thickness Measurement in Inches')
ylabel('Number of Measurements')
hold off

%calculates the min, max, mean, and standard deviation for y values
%and stores them in the appropriate locations on the user interface
MinVal=num2str(min(y),3);
set(handles.text_MinVal,'String',MinVal);

MaxVal=num2str(max(y),3);
set(handles.text_MaxVal,'String',MaxVal);

MeanVal=num2str(mean(y),3);
set(handles.text_MeanVal,'String',MeanVal);

Std=num2str(std(y),2);
set(handles.text_StdVal,'String',Std);

guidata(hObject, handles); %updates the handles

Page 25 of 30

Spring 2010

function edit_fileName_Callback(hObject, eventdata, handles)
% hObject handle to edit_fileName (see GCBO)

% Hints: get(hObject,'String') returns contents of edit_fileName as text
% str2double(get(hObject,'String')) returns contents of edit_fileName
as a double

% --- Executes during object creation, after setting all properties.
function edit_fileName_CreateFcn(hObject, eventdata, handles)
% hObject handle to edit_fileName (see GCBO)
% handles empty - handles not created until after all CreateFcns called

% Hint: edit controls usually have a white background on Windows.
% See ISPC and COMPUTER.
if ispc && isequal(get(hObject,'BackgroundColor'),
get(0,'defaultUicontrolBackgroundColor'))
set(hObject,'BackgroundColor','white');
end

Page 26 of 30

Spring 2010

PROJECT STATUS

Our initial plan was to build a working prototype to give to Exide Technologies at the end of our project.
Due to expenses of the lasers and long lead times on the lasers we were not able to build a prototype of
our final design.  Due to this reason we focused on the real time information display and the data
storage and analysis part of this project, instead of putting our efforts into building a partial prototype
that could not be tested.

We are satisfied with our final design and feel that we have come up with a feasible solution to the
problem that we were given.  If Exide Technologies agrees, we would like to pass this project along to a
machine design group for next semester.  Ideally the next group would continue the project and build a
working prototype to hand over to Exide Technologies.

Page 27 of 30

Spring 2010

CONCLUSION

Each of the customer requirements provided by Exide Technology was completed within the time
allotted by our Machine Design I course at Southern Polytechnic State University.  The final design for
the thickness measurement device is capable of measuring the thickness of paste to the correct
specifications outlined by the customer requirements. The device is designed to measure the thickness
of the paste accurately with non‐contact lasers and table with minimum invasiveness.

The device was not built due to the time frame of receiving actual Acuity lasers before the April 26th due
date, and due to the cost of each laser. With more time and funding a prototype of the device could be
built and tested for functionality. This is unfortunate, but next semesters Machine design 1 class may
have the opportunity to build a working model of the thickness measurement device and have it placed
at the Exide factory located in Chattanooga Tennessee.

As a group we were able to put our engineering knowledge and skills together and come up with a
quality design. It was a learning process to encounter design challenges and overcome them. This design
project gives insight into our future as mechanical engineers solving problems in a team environment. It
was a great opportunity for us students to work with the Exide battery company, for it adds value to us
and Southern Polytechnic State University MET department that we as a student body are capable of
completing such challenges.

After presenting the design for the device Erika Olausen sent an email to us about our design, she wrote:

“Hongbo and I wanted to thank you all for an outstanding effort on the plate thickness in‐line
measurement project.  It was apparent that you all put a significant amount of time and consideration
into your project.  I am a programming geek myself, so I was really excited to see your GUI for the
operator interface and the Matlab analysis tool for the output data.  The amount of effort you all put
into your project really showed clearly.  While other groups might have stopped at identifying a working
laser kit, you all continued to work to integrate the process with a system that is easy to use for the
operators as well as the data analyzers at the plant level.”

Page 28 of 30

Spring 2010

FINAL CONCEPT PHOTOS

Spring 2010

Spring 2010

ACKNOWLEDGEMENTS

The Thickness Measurement design team would like to thank:

• Professor Atiqullah for the opportunity to work with EXIDE Battery Company on our project.

• Hongbo Zhang and Erika Olausen from EXIDE for giving us our machine design project.

• Also, a special thanks to Professor Kenton Fleming and Professor Gregory Conrey for their help
on the Finite Element Analysis.

• Finally, we would also like to thank Professor Simin Nasseri for her help with our MATLAB
program.

Page 29 of 30

Spring 2010

REFERENCES

1. Solid works, used for computer aided engineering.
Link: http://www.solidworks.com/

2. Matlab, used for statistical analysis
Link: http://www.mathworks.com/

3. LabVIEW, used for thickness measurement
Link: http://www.ni.com/labview/

4. 80‐20, provided a material to base our design on
Link: http://www.8020.net/

5. Matweb, Material properties were found for our design
Link: http://www.matweb.com/

6. Measure It All, Quote for a thickness measurement system
Link: http://www.measureitall.com/

7. Acuity, The company used for the lasers on the design
Link: http://www.acuitylaser.com/AR700/sensor‐technical‐data.shtml

8. Rockwell Laser Industries, Provided safety information on Lasers
Link: http://www.rli.com/

9. Occupational Safety & Health Administration, offers more safety information on Lasers
Link: http://www.osha.gov/SLTC/laserhazards/index.html

10. Salary.com, Provides information on average paid salaries (used for cost analysis)
http://www.salary.com/

11. Microsoft Office Excel, Used to produce the gantt chart, program for storing thickness
measurements, etc.
Link: http://www.microsoft.com/en/us/default.aspx

12. Textbook: “Fundamentals of Machine Elements, Second Edition.”

Page 30 of 30

APPENDIX

Page Title

A1 Machine Drawings

B1 Customer Correspondences

C1 Acuity Laser Documents

D1 Data Acquisition (Block Diagram and Front Panel)

E1 Gantt Chart

F1 Power Point (Final Presentation)

35.000

1530X35
DR. BY: GROUP 5 SHEET NO.

DATE: 5/2/2010 SCALE: 1:3
1
OF 15

20.000

1530X20

DATE: 5/2/2010 SCALE: 1:2
2
OF 15

30.000

15030X30

DATE: 5/2/2010 SCALE: 1:3
3
OF 15

3.00
.25
.75
10X .38
.75

1.50 6.00

1.50

1.50
.75

.75 1.50 1.50

6.00

10-HOLE JOINING PLATE

DATE: 5/2/2010 SCALE: 1:3
4
OF 15

.150
.750

.835 2X .375

1.000
3.000

R.200 R.200

.750 .150
3.000
1.500

CORNER BRACKET

DATE: 5/2/2010 SCALE: 1:1
5
OF 15

3.000

.250

R.125

3XR.164 R.750

.750

1.500

.500
.250 1.500 .750

PIVOT ARM

DATE: 5/2/2010 SCALE: 1:1
6
OF 15

16.000
8X .350 2.200
.125

2.125
1.500

1.125 1.000
8.000

ARCHITECTUAL ANGLE

DATE: 5/2/2010 SCALE: 1:2
7
OF 15

2.080 10.838
.125 .211 2X .236

1.125 .789

1.125
8.000

15.000

ARCHITECTUAL AL ANGLE

DATE: 5/2/2010 SCALE: 1:2
8
OF 15

1.900 .098 16.250 .098
.709
.315

.394 .394

REXROTH ROLLER

DATE: 5/2/2010 SCALE: 1:2
9
OF 15

.500 .064

1.000 .064

21.000

DETAIL A
SCALE 2 : 3

A

6.000
5.000

1.000

LASER ARM

DATE: 5/2/2010 SCALE: 1:2
10
OF 15

.500 15.000

ADJUSTMENT BAR

DATE: 5/2/2010 SCALE: 1:2
11
OF 15

.750

.125
12.000

R.171 .375
.314

.236
.341

SHOCK PISTON

DATE: 5/2/2010 SCALE: 1:2
12
OF 15

R.100

.708

12.624

.314 .236 .375
.341

R.171 .125

SHOCK CYLINDER

DATE: 5/2/2010 SCALE: 1:2
13
OF 15

ITEM NO. PART DESCRIPTION QTY
4 NUMBER
8 1 4001 1530 X 35 2
2 4002 1515 X 20 3
15
3 4003 1515 X 30 4
4 4004 1515 X 10 1
5 4005 ELECTRICAL CABINET 1
6 4006 90 DEGREE JOINING PLATE 4
1 7 4007 4-HOLE CORNER BRACKET 10
8 4008 HINGE 3
11 4009 PIVOT ARM 2
12 4010 ARCHITECTURAL ANGLE 1X1 2
13 4011 SHOCK CYLINDER 2
6 14 4012 SHOCK PISTON 2
15 4013 ARCHITECTURAL ANGLE - R 1
16 21 17 16 4014 ARCHITECTURAL ANGLE - L 1
17 4015 ROLLER 6
2
18 4016 LASER ARM 2
14 19 4017 ADJUSTMENT BAR 1
20 4018 ADJUSTMENT NUT 4
21 4019 AR700 COMPACT LASER 8
15

18
5
19

20

7
11

THICKNESS DEVICE
13 3

DATE: 5/2/2010 SCALE: 1:3
1
OF 15

ITEM NO. PART DESCRIPTION without
NUMBER belt/QTY.
1 4001 1530 X 35 2
8 9 18 21
2 4002 1515 X 20 3
3 4003 1515 X 30 4
4 4004 1515 X 10 1
5 4005 ELECTRICAL CABINET 1
6 4006 90 DEGREE JOINING PLATE 4
7 4007 4-HOLE CORNER BRACKET 10
8 4008 HINGE 3
11 4009 PIVOT ARM 2
12 4010 ARCHITECTURAL ANGLE 1X1 2
17
13 4011 SHOCK CYLINDER 2
14 4012 SHOCK PISTON 2
10 20
15 4013 ARCHITECTURAL ANGLE-R 1
16 4014 ARCHITECTURAL ANGLE-L 1
19
17 4015 ROLLER 6
18 4016 LASER ARM 2
15 19 4017 ADJUSTMENT BAR 1
20 4018 ADJUSTMENT NUT 4
1 21 4019 AR700 COMPACT LASER 8
12

16 7

4 11

5 14

6

3

2 13
1530X35

DATE: 5/2/2010 SCALE: 1:3
15
OF 15

Ryan Clark
From: David Guffey [dguffey@spsu.edu]
Sent: Sunday, May 02, 2010 6:48 PM
To: Ryan Clark
Subject: Fwd: follow-up to down load of 80/20 information
Attachments: South linecard.pdf

‐‐‐‐‐ Forwarded Message ‐‐‐‐‐
From: "Mark Layburn" <MLayburn@sunsrce.com>
To: dguffey@spsu.edu
Sent: Tuesday, April 13, 2010 4:57:05 PM GMT ‐05:00 US/Canada Eastern
Subject: follow‐up to down load of 80/20 information

Thank you for your interest in the 80/20 line of products.

SunSource is a local distributor of 80/20 and would be happy to answer any additional questions you might have.

I have also attached a SunSource line card.

CLICK HERE TO VIEW OUR LINE CARD

Mark Layburn

SunSource

Customer Service Representitive

ph# 800‐207‐7126

fax# 770‐414‐9827

www.sun‐source.com

1

Ryan Clark
To: Ryan Clark
Subject: Fwd: Initial contact

From: "Bill Burns" <bburns@cfcsite.com>
To: dguffey@spsu.edu
Sent: Monday, April 12, 2010 10:08:16 AM GMT ‐05:00 US/Canada Eastern
Subject: Initial contact

Good morning David,

My name is Bill Burns and I am with a company called CFC. We are an 80/20 distributor here in GA.

80/20 contacted me with your contact information as I am the local territory manager.

Please give me a call/email at your convenience to arrange a time we can meet. At CFC we have two full time 80/20
designer specialists to assist with projects. We will provide a BOM, drawings and quote for your needs.

I am looking forward to hearing from you.

Bill Burns

CFC – GA

Territory Manager

678‐234‐7382 cell

bburns@cfcsite.com

The information contained in and transmitted with this e‐mail is confidential and may be privileged. It is intended only
for the individual or entity so designated above. You are hereby notified that any dissemination, distribution, copying, or
the use of or reliance upon the information contained in and transmitted with this e‐mail by or to anyone other than the
recipient(s) designated above or the employee or agent responsible for delivering the transmittal to the intended
recipient is unauthorized and strictly prohibited.
If you have received this e‐mail in error, please notify the sender by replying to this email and delete the email from your
computer.

1

Ryan Clark
To: Ryan Clark
Subject: Fwd: Laser Measurement System
Attachments: SPSU AS 200-025 Dual 7710.PDF

From: "Larry_F / MIA" <larry@measureitall.com>
To: "David Guffey" <dguffey@spsu.edu>
Sent: Thursday, March 18, 2010 3:52:41 PM GMT ‐05:00 US/Canada Eastern
Subject: Re: Laser Measurement System

Hi David,

Attached is the quotation you requested. Please don't hesitate to contact me if you should have any questions.

Sincerely,

Larry Forszen
www.measureitall.com
Tel 704.895.2548
Fax 866.407.5325

*** Have you seen our new RS232 data capture software... check it out at http://www.prowedge.com

NOTICE: This facsimile transmission is intended only for the person(s) named above and may contain information that is
privileged and confidential. If the reader of this message is not the intended recipient, you are hereby notified that any
other distribution, copying or disclosure is strictly prohibited. If you receive this facsimile transmission in error, notify
the sender immediately by return e‐mail and destroy the initial transmission without making a copy. Our standard terms
and conditions apply to all sales. Warning: Although this message has been checked for viruses using antivirus software,
it is the responsibility of the recipient to check that the document(s) and/or attachment(s) is/are virus‐free and the
sender accepts no responsibility or liability for any loss, injury, damage, cost, or expense arising in any way from the
receipt or use thereof by the recipient. All documents transmitted by sender, including this email, are not intended to be
binding until a hard copy has been manually signed by all parties. EXPORT CONTROL NOTICE: This email may contain
technical data whose export, transfer, and/or disclosure may be controlled by the US International Traffic and Arms
Regulation (ITAR) 22 CFR part 120‐130 or the Export Administration Regulations Commerce.

On Wed, 17 Mar 2010 12:03:57 ‐0400 (EDT), David Guffey wrote:
> Can you send me a quote for two AcuSpec200‐025 lasers and all of the necessary connectors and the software.
>
> Thanks,
> David Guffey
1

> dguffey@spsu.edu
> 770‐861‐5773
>
> ‐‐‐‐‐ Original Message ‐‐‐‐‐
> From: "Larry_F / MIA" <larry@measureitall.com>
> To: "David Guffey" <dguffey@spsu.edu>
> Sent: Wednesday, March 17, 2010 11:54:13 AM GMT ‐05:00 US/Canada
> Eastern
> Subject: Re: Laser Measurement System
>
>
> Hi David,
>
> Yes, the software can take in 2 sensors and display the net thickness of the material.
>
> Warmest regards,
>
> Larry Forszen
> www.measureitall.com
> Tel 704.895.2548
> Fax 866.407.5325
>
> *** Have you seen our new RS232 data capture software... check it out
> at http://www.prowedge.com
>
> NOTICE: This facsimile transmission is intended only for the person(s) named above and may contain information that
is privileged and confidential. If the reader of this message is not the intended recipient, you are hereby notified that any
>
>
>
>
>
>
> On Wed, 17 Mar 2010 09:51:06 ‐0400 (EDT), David Guffey wrote:
>> Mr. Forszen,
>>
>> Thank you for your response, We are working with a battery company and measuring the thickness of the lead plates
used inside the battery, after the plates have been pasted with lead oxide. Where we are measuring, the line of plates is
suspended so we are thinking we will need two lasers for one measurement, one on top and one on the bottom, and I
was wondering if the software can use two lasers to make one measurement.
>>
>> Thanks,
>>

2

>> David Guffey
>> dguffey@spsu.edu
>> 770‐861‐5773
>>
>>
>> ‐‐‐‐‐ Original Message ‐‐‐‐‐
>> From: "Larry_F / MIA" <larry@measureitall.com>
>> To: "David Guffey" <dguffey@spsu.edu>
>> Sent: Thursday, March 11, 2010 12:09:26 PM GMT ‐05:00 US/Canada
>> Eastern
>> Subject: Re: Laser Measurement System
>>
>>
>> Dear David,
>>
>> Please advise what you are trying to measure and the surface finish. I have attached information on one of our lasers
that can likely do what you want.
>>
>> The pricing is as follows...
>>
>> Single AcuSpec200‐025 $4,995 / price includes:
>>
>> (1) AcuSpec200‐025 Sensor
>> (1) DB9 serial connector
>> (1) Power supply
>> (1) Sensor set‐up/configuration
>> (1) Software (single site/single user license)
>>
>>
>> Software: AcuSpec Laser PC Software (included) Features...
>> Accepts one or two AcuSpec laser sensors Display and plot thickness
>> Calibrate single laser On‐screen alarms Auto Zero feature Inches or
>> mm display Record measurements to file if desired.
>> Windows 2000, XP, XP Pro.
>> Single site/single user license
>>
>> Please don't hesitate to contact me at 704.895.2548, or reply by email if there is anything else we can do for you. We
are grateful for your interest in our equipment and look forward to being of service to you.
>>
>> Warmest regards,
>>
>> Larry Forszen
>> www.measureitall.com
>> Tel 704.895.2548
>> Fax 866.407.5325
>>
>> *** Have you seen our new RS232 data capture software... check it out
>> at http://www.prowedge.com
>>
>> NOTICE: This facsimile transmission is intended only for the person(s) named above and may contain information that
is privileged and confidential. If the reader of this message is not the intended recipient, you are hereby notified that any

3

>>
>>
>> On Wed, 10 Mar 2010 14:48:37 ‐0500 (EST), David Guffey wrote:
>>> I am working on a laser measurement project.
>>>
>>> Project Specs.
>>> No‐contact measurement
>>> Thickness range: 0.04 +/‐ 0.003 inches to 0.08 +/‐ 0.003 inches
>>> 10 measurements per second
>>>
>>> I am also interested in software to display dynamic data and also store data for statistical analysis.
>>>
>>> I would appreciate suggestions on what to use for this project and pricing information.
>>>
>>> Thank You,
>>>
>>> David Guffey
>>> dguffey@spsu.edu
>>> 770‐861‐5773

4

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