UNIVERSITY OF IDAHO

Project Two
Code Name: Blue Lantern
Group #1
Section 2
5/1/2012

Kris Davis (Project Manager)

Chance Sundquist (Secretary)
Jon Wheless
Adam Bunch
Ali Ameter
Jesus De La Cruz
Brandon Parent

Index
Index-------------------------------------------------------------------------- 1
Opportunity Statement----------------------------------------------------- 3
Stake Holders---------------------------------------------------------------- 4
Customer Needs------------------------------------------------------------- 5
Bill of Materials------------------------------------------------------------- 6
Targets-------------------------------------------------------------------------7
Concept Ideas and Sketches------------------------------------------------8-10
Design Decision Matrix-----------------------------------------------------11
Decision Process-------------------------------------------------------------12
Math Models------------------------------------------------------------------13-17
House of Quality-------------------------------------------------------------18
Component Design-----------------------------------------------------------19-20
Prototype-----------------------------------------------------------------------21
Engineering Drawings-------------------------------------------------------22-26
Final Prototype----------------------------------------------------------------27-8
Circuit Diagram---------------------------------------------------------------29
Testing-------------------------------------------------------------------------30-31
How to Use--------------------------------------------------------------------32
Summary/Reflections--------------------------------------------------------33
Timeline-----------------------------------------------------------------------34
Productivity Sheets----------------------------------------------------------35-38

Opportunity Statement
The purpose of this project is to develop a device that will engrave internal
production codes onto a part such that they are removed by the nal nishing
process in Boeing's Skin and Spar manufacturing facility. This will require being
able to control the depth of the engraving with a high degree of precision.

Stake Holders
Boeing
Laser Manufacturers
Laser Protective Gear Manufacturers
Airplane Manufactures
Precision Manufacturing Companies

Customer Needs
1.
2.
3.
4.

Engraver will be a hand held tool

Patterns needed 1,2,3
Size 1-3 Inches
Patterns must be automatically drawn
5. Time to engrave 4 Seconds

Bill of Materials
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

Item
Cooling Fan
Battery
Digital Servo
Laser
Plastic Cover Plate
Aluminum Angle
Plastic Dowel
Arduino Uno
Perfboard
Pushbutton
Switches
Red LED
Voltage regulator
Diode Heatsink
Focusing Lens
Resisters
Torx Bolts
Nuts
Bolts + Nuts
Bolts + Nuts
Bolts + Nuts
22 and 24 Gauge
wire
Laser Driver
Header + Connector
Mosfet

Description
7cm 12v Computer fan
7.2v NiCad battery pack
HS-5485HB
1.3W 445nm blue
912cm^2 x 0.254cm
1.6m long, 1.3cm x 1.3cm
12cm x 2.5cm
Micro Controller
3.8cm x 3.8

5mm
1m313
Custom machined
445nm AR collimating optics
.5W
6-32 x 5/16in
6-32 _
4-32 x 3/16in
12-24 x 1 1/4in
12-24 x 5/16

1.25A CC Laser driver

IRF510 HEXFET Power Mosfet

Quantity
1
1
2
1

1
1
1
2
1
1
1
1
7
36
32
4
2
4

1
8
1

Targets
1.
2.
3.
4.
5.
6.
7.
8.

Hand held / Portable

Write numbers 1,2,3
Write in less than 4 seconds
Numbers to be 2-3in in size
Cost Under $10 per member
Code simplicity
Safety
Ability to write on 10 different surfaces

Concept Ideas and Sketches

Concept Ideas and Sketches Cont.

Concept Ideas and Sketches Cont.

10

Decision Matrix

Cool Factor

Ease of
Coding

Accuracy

Cost

Size of
Number

Easy to Build

Speed

Draw-ability

Tangent Arm
Lasers
Etch-a-sketch
Polar System 1
Roller Printer
Polar System 2
Double Theta
Stencil Sprayer
Cutting Stamp

Compactness

Concept:
Importance

0.1

0.2

0.2

0.25

0.1

0.15

0.2

Totals
1.2

4
4
3
5
3
2
4
1
3

x
x
x
x
x
x
x
x
x

4
3
2
3
5
3
3
4
5

5
4
2
2
1
2
3
3
1

x
x
x
x
x
x
x
x
x

5
3
3
4
2
4
5
1
2

2
3
5
3
4
3
3
4
5

1
5
4
3
5
3
3
5
5

4
5
1
2
3
3
4
3
5

4.6
4.6
3.15
3.65
3.75
3.55
4.4
3.5
4.25

11

Decision Process
To start our decision process we first took turns throwing out any ideas we
had while keeping a log of each. After exhausting our individual ideas we moved
on to building upon what we had and coming up with more while working as a
group. Once we felt we had thought of everything we gathered our ideas in a
decision matrix and then came up with a set of targets that we felt were the most
important. After the table was made the group began the voting process with back
and forth reasoning for each target and concept. With the weight of each target
added to the matrix we tallied up the results and began to see the direction the
project was going to go in. In the results it was found that four main concepts
stood out above the rest. From here we used reasoning and our personal interest
levels to decide on a final design. After a lot of thought and talking things through
with each other, we decided our final design was going to be our laser concept.

When making this final decision, there were a couple things that really stood
out and influenced our choice. We were all really excited about the laser concept
and wanted to make it work but at first glance it did not seem plausible. The other
top scoring concepts we knew we could produce a working prototype but we didnt
want to count the laser out yet. With a little research and thought of coding we
found that the laser was going to be easier to implement than first anticipated.
Once we had this solid evidence we chose to go with our laser design.

12

Math Models
Goal: Determine the amount of torque of each servo needed to execute.
Sketch:

X-Z Plane

Equations and Assumptions:

1. Weight of the servo shaft negligible compared to weight of the servos
weight.

13

Calculations:

Reflection:
The torque required for servo one to actuate is very small because all the
weights hangs and rotates perpendicular to gravity.

14

Math model 2
Goal: Determine the stress on the shaft of the each servo.
Sketch:

Equation and Assumption:

1. Neglect inertia due to bracket and brace
Center of mass.

15

Bending moment due to the loads.

Stress concentration due to bending and axial loads.

Moment of inertia of the servo and the laser.

Stress concentration on servo two due to the laser.

16

Calculations:

Reflection:
We can see a big difference between the stress concentrations of the servo 1
shaft versus the servo 2 shaft which is expected since servo 1 experiences bending
and tensile stress and has more load trying to break the component. This will
determine whether we must replace the shaft of the servo to a thicker shaft or a
stronger material.

17

$45.72
anything

10 things

5
1

under $100

1
5

5
5

adjustable

18
9
5

9
9

9
5
1

5
5
1

9
9
5

5
9
1

5
9

Types of Materials to Print On

Planned level satisfaction

Relative importance of need

Cost Efficient

Maximize Amount of Safety

Precautions

Optimal Time to Print

Minimize Coding

Price of the Project

Manufacturing per member

4 seconds

$6.53

under $10

Size of the Numbers

[Dimensions]

fits in the Arduino

adjustable

1-3 inches

Time Needed to Print Each

Number

Dimensions of object

Direction

fits in the Arduino

adjustable

Target

under 4 seconds

Bench Marking
Hand held/ Portable

Qualitative needs
Hand Held
Compact
Automated (Draws
1,2,3)
Draw in 4 seconds or
less
Durable
Numbers must be 2-3
inches in size
Accurate and Percise
Easy to Construct
Cost Efficient
Relatively Easy
Coding
Coolness Factor
Safe to Use

Hand held/ Portable

House of Quality

3
4
3
4

5
5

5
4
3
5
5

9
5

5
4
4
3
5
5
4
3

9
5
4
5
5
4
5
5

Components Decision Process

After our concept was chosen we needed to come up with what components
we were going to use to produce a finished product. Just as in our concept decision,
we made a decision matrix for each component we needed then weighted the target
that went along with it to come up with a final choice.
Frame Work
Enclosed Cube
Enclosed Pyramid
Open Structure

Ease of:

Designing
0.25
5
3
5

Manufacturing
0.25
5
3
5

Assembling
0.25
5
3
5

Safety
0.25
5
5
0

Totals
5
4
3.25

Frame Work: Cube, Pyramid, Open

In this decision the biggest factor was safety from the laser, and ease
of construction. With these, the cube structure was an obvious choice.

Frame Covering
Plexiglass
Sheet Metal
Paper
Wood

Cost
-0.25
0
3
2
3

Availability
0.33
5
3
5
3

Manufacturing
0.33
4
5
3
4

Assembly
0.33
5
5
3
4

Totals
4.62
3.54
3.13
2.88

Covering: Plexiglass, Sheet Metal, Paper, Wood

For the covering assembly difficulty was around the same for each,
but what made plexiglass stand out was the availability. A person on our team had
unused scraps that we used for our covering.

19

Motor Choice
Servo
Stepper
DC

Compactness
0.25

Difficulty to Code
0.25
5
2
2

Control Accuracy
0.5
5
3
1

Totals
3.75
2
1

Motor: Servo, Stepper, DC

While making a motor choice we looked back on our targets and
decided that accuracy was a big factor. We also believed that ease of coding, for
our case, was important; which lead us to the obvious choice of a servo.

Material to write on
White Paper
Black Paper
Thermal Paper
Wood
Foam/Insulation

Ease of:

Writing
0.25
2
3
2
3
4

Contrast

0.25
1
3
1
3
3

Availability
0.25
5
5
5
5
5

Cost
0.25
1
1
1
2
1

Material: White Paper, Black Paper, Thermal Paper, Wood, Foam/Insulation

The material to be written on was one of the harder decisions we
made. This is because we were limited to what we could get a hold of, budget and
the fact that we were unable to test the material until the laser had arrived. We
used what we knew about light and its properties as well as material and its
properties to brainstorm ideas. We came down to wood and foam/insulation as our
choices but the final choice wasnt made until we could do some testing with the
laser. Once the testing was complete we made a final decision of foam/insulation.

20

2.25
3
2.25
3.25
3.25

Prototype

21

Drawings

22

23

24

25

26

Final Prototype

27

Final Prototype
Our prototype marks whatever it is placed on by use of a 1.3 Watt blue laser. As
described before we decided to use a gimbal system to allow movement in the X and Y
axis. We decided on the 1.3 Watt laser because Jon has previous experience with lasers
and has firsthand knowledge about the power produced to burn or scar surfaces with this
particular type of laser. While testing the servo and laser apparatus, in the case, we
noticed that the heat sink for the laser was getting warm. For the safety of the laser and
the other enclosed components we mounted a fan on the top of the case, which also acts
as an air circulator in the case that any smoke is produced from burning. Our prototype
accomplishes all of the targets set in the House of Quality. We can successfully mark the
numbers 1, 2, 3 within the 4 second time limit. We can also draw the numbers within the
1-3in limit. We also allowed ourselves the capability to increase the dwell time of the
laser, Increase or decrease the size of the numbers, and inputted the coordinates for the
numbers 0-9. The laser can burn or etch almost any surface; however, some surfaces need
a longer dwell time in order to leave an apparent mark. We also added a few safety
features to keep users and bystanders safe. The button used to initiate the laser has a 2
second timer before the system is activated. It also had a pressure switch which let the
Arduino know if the apparatus was set down on a surface. The switch was involved in a
shorting accident during a reassembly and had to be removed.

28

Circuit Diagram

29

Testing

Number 1st time 2nd time 3rd time

1
4
4.2
4.1
2
5.7
4.6
5.7
3
5.6
5.7
5.4

Avg Time
4.10
5.33
5.57

We found that both time and size are within set targets for functionality.

30

Targets
Hand Held
Engrave Time
Size
Cost
Code Simplicity
Safety

Yes, Our prototype can easily be held with one hand and is compact
Yes, Our prototype engraves both 1, 2, and 3 in less than 4 seconds
Yes, our numbers are between 1-3 inches
Yes, Each Member spent less than $10
Yes, just like the prototype itself, our code is small and dense
Yes, we had safety in mind when building the prototype

Materials able
to print on

Yes, our prototype is able to print on almost anything

31

How to Make it Work

When looking at the final product you might ask yourself How do I make go? Its actually
quite simple. Once it has a power source, all you have to do is push the black button for
whatever number you are looking to draw. For example, if you want to draw a three, you
simply press the black button three times.There is a red LED light that blinks whatever number
you are about to draw to confirm your selection. To initiate the laser all you have to do is hold
the red button down two seconds as a safety precaution. Once the laser is about to start, the red
LED will flash again. The next thing you know, the creature is alive.

32

Summary
Time Management Throughout this project we have stayed right at, if not
a little ahead, of schedule. Going into Senior Design, I would like to continue this
trend.

Communication Communication is key in every aspect of life. Having a

group of 7 has tested our communication skills. Some tools we found that facilitate
communication are email, texting, dropbox and consistent meetings. Again, our
group did a very good job of communicating with each other in order to
accomplish this project.

Resources Knowing all the resources available to a group can play a

valuable role in the success of a project whether it be knowledge, materials or
ability.

Group Members Having 7 group members has made this project seem
much easier from a work load standpoint than 3 members on the last project.
However, with so many in the group, as the leader, I found it difficult to assign
everyone a job during every meeting. It was also much easier for those without an
assignment to slip through the cracks while the rest of us were busy working on
other things. For a group of 7 people we got along great and worked really well
together.

Dont count out any crazy ideas While we were brainstorming we came up with the
idea of using a laser as more of a joke or building block to other ideas. However, the more
we looked into it, the more feasible it became and, when compared to other ideas, it was
actually easier to implement. This is definitely a lesson we will take into Senior Design
with us.

33

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Blue Lantern
Needs and Spec Development
1-Apr
Concept Design
10-Apr

Date
1-Apr
Team Name Group 1

Team Member
Brandon

Major Assignments
Do math modeling/experiments for Stamp Idea

Adam

Do Math modeling/try to find an equation to input into code for Tangent Arm Idea

3-Apr In progress

Ali

Do Math modeling/try to find an equation to input into code for Double Theta Idea

3-Apr In progress

Jon

Do Math modeling/try to find an equation to input into code for Laser idea
Start framework for code
Ask about benchmarking and changing out of parts between numbers
Update Productivity log

New Planned Activities

Kris

Status
Due Date
3-Apr In progress

3-Apr In progress
20-Apr In progress
3-Apr In progress

Accomplishments During Last Period

Team Member
Kris

Action Plan
Brain storm Ideas

Due Date
Owner
1-Apr Complete

Adam

Brain storm Ideas

1-Apr Complete

Chance

Brain storm Ideas

1-Apr Complete

Ali

Brain storm Ideas

1-Apr Complete

Brandon

Brain storm Ideas

1-Apr Complete

Jesus

Brain storm Ideas

1-Apr Complete

Jon

Brain storm Ideas

1-Apr Complete

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Team Member
Jesus
Brandon
Ali
Chance
Jon

Kris

Blue Lantern
Detailed Design
12-Apr
Fabrication and Testing
18-Apr

Date
8-Apr
Team Name Group 1

New Planned Activities

Major Assignments
Get thermal paper for testion
Narrow design selection
Start Solid Works drawing
Narrow design selection
Look for a power supply based on laser and servo needs
Narrow design selection
Plot numbers for code
Narrow design selection
Continue working on code framework
Narrow design selection
Find accurate servos
Get an idea about possible safety issues
Determine wiring needs
Narrow design selection
Update productivity log

Due Date
18-Apr
8-Apr
18-Apr
8-Apr
18-Apr
8-Apr
18-Apr
8-Apr
18-Apr
8-Apr
18-Apr
18-Apr
18-Apr
8-Apr
9-Apr

Status
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress

Accomplishments During Last Period

Team Member
Brandon

Major Assignments
Do math modeling/experiments for Stamp Idea

Adam

Do Math modeling/try to find an equation to input into code for Tangent Arm Idea

3-Apr Complete

Ali

Do Math modeling/try to find an equation to input into code for Double Theta Idea

3-Apr Complete

Jon

Do Math modeling/try to find an equation to input into code for Laser idea
Start framework for code
Ask about benchmarking and changing out of parts between numbers

Kris

Due Date
Status
3-Apr Complete

3-Apr Complete
20-Apr In progress
3-Apr Complete

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Date
15-Apr
Team Name Group 1

Blue Lantern

New Planned Activities

Team Member
Adam
Chance
Kris

Major Assignments

Due Date
Status
17-Apr In progress

Buy Servos
Buy Protective tinting
Start HOQ

10-Apr Inprogress
17-Apr In progress

Jon

Look for free power supply in GJ

Update Productivity log
Title Page
Oportunity Statement
Concepts Considered/Selection
Stake Holders
Preliminary Experiments

Ali

Help adam sketch initial concepts

18-Apr In progress

Team Member
Jesus

Major Assignments
Get thermal paper for testion

Brandon

Start Solid Works drawing

18-Apr Complete

Ali

Look for a power supply based on laser and servo needs

18-Apr Complete

Chance

Plot numbers for code

18-Apr Complete

Jon

Continue working on code framework

Find accurate servos
Start framework for code
Get an idea about possible safety issues
Determine wiring needs
Find protective tinting

18-Apr
18-Apr
20-Apr
18-Apr

Brandon
Adam

18-Apr
18-Apr
18-Apr
18-Apr
18-Apr

In progress
In progress
In progress
In progress
In progress

Accomplishments During Last Period

Kris
Adam

Due Date
Status
18-Apr Complete

Complete
Complete
In progress
Complete

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Blue Lantern
Between Design and Fabrication
21-Apr
Fabrication
23-Feb

Team Member
Jesus

Major Assignments
Make graphic of circuit diagram
Math Model
Engineering Drawings

Date
21-Apr
Team Name Group 1

New Planned Activities

Brandon
Chance
Adam
Jon
All
Kris
Ali

Due Date
Status
29-Apr In progress
29-Apr In progress
24-Apr In progress

HOQ
Target Rational
Testing

29-Apr In progress
In progress
23-Apr In progress

Testing
Prototyping
Prototyping Documentation
Project Management
Prototyping
Testing

23-Apr
22-Apr
29-Apr
29-Apr
22-Apr
23-Apr

In progress
In progress
In progress
In progress
In progress
In progress

Accomplishments During Last Period

Team Member
Adam
Chance
Kris

Action Plan
Buy Servos
Buy Protective tinting
Start HOQ

Due Date
Owner
17-Apr In progress
10-Apr Inprogress
17-Apr In progress

Jon

Look for free power supply in GJ

Update Productivity log
Title Page
Oportunity Statement
Concepts Considered/Selection
Stake Holders
Preliminary Experiments

Ali

Help adam sketch initial concepts

18-Apr In progress

Brandon
Adam

18-Apr
18-Apr
18-Apr
18-Apr
18-Apr

In progress
In progress
In progress
In progress
In progress

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Blue Lantern
Fabrication
24-Apr
Presentation
1-May

Date
4/29-5/1
Team Name Group 1

Team Member
Chance

Jon

Major Assignments
Gather info needed for presentation
Assembling Presentation
Assembling Portfolio
Summary
Project Report
Status Report
Assembling Portfolio
Update productivity log
Tweaking code

Brandon

Tweaking CAD drawing

1-May In progress

Adam

Sketching original design choices

1-May In progress

Ali

Sketching original design choices

1-May In progress

Team Member
Jesus

Major Assignments
Make graphic of circuit diagram
Math Model
Engineering Drawings

New Planned Activities

Kris

Due Date
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr

Status
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress
In progress

Accomplishments During Last Period

Brandon
Chance
Adam
Jon
All
Kris
Ali

Due Date
Status
29-Apr In progress
29-Apr In progress
24-Apr In progress

HOQ
Target Rational
Testing

29-Apr In progress
In progress
23-Apr Completed

Testing
Prototyping
Prototyping Documentation
Project Management
Prototyping
Testing
Prototyping

23-Apr
22-Apr
29-Apr
29-Apr
22-Apr
23-Apr
22-Apr

Completed
In progress
In progress
In progress
In progress
In progress
Completed

Project Title
Project Phase
Phase Start Date
Next Mileston
Next Mileston Date

Blue Lantern
Presentation
1-May

Date
1-May
Team Name Group 1

Team Member
Chance

Jon

Action Plan
Gather info needed for presentation
Assembling Presentation
Assembling Portfolio
Summary
Project Report
Status Report
Assembling Portfolio
Update productivity log
Tweaking code

Brandon

Tweaking CAD drawing

1-May Completed

Adam

Sketching original design choices

1-May Completed

Ali

Sketching original design choices

1-May Completed

Jesus

Make graphic of circuit diagram

Math Model
Engineering Drawings

29-Apr Completed
29-Apr Completed
24-Apr Completed

HOQ
Target Rational
Testing

29-Apr Completed
Completed
23-Apr Completed

Testing
Prototyping
Prototyping Documentation
Project Management
Prototyping
Testing
Prototyping

23-Apr
22-Apr
29-Apr
29-Apr
22-Apr
23-Apr
22-Apr

Accomplishments During Last Period

Kris

Brandon
Chance
Adam
Jon
All
Kris
Ali

Due Date
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr
29-Apr

Owner
Completed
Completed
Completed
Completed
Completed
Completed
Completed
Completed
Completed

Completed
Completed
Completed
Completed
Completed
Completed
Completed