Technical MemorandumNo. 1 EDSGN100

Date: April 23, 2018

To: Paul MittanLockheed Martin Corporation

From: EDSGN100 Section 00#Design Team 2Tacie TeleskyDaniel ShankCiera McFarlandEric Shaw

Subject: Penn State UniversityEDSGN 100: Introduction to Engineering Design‘Factory of the Future’ InitiativeSpring 2018

Purpose. The purpose of this Memorandum is to discuss a possible solution for a multi-driver for Lockheed Martin. The Memorandum will give specifics about the cost and potential construction options for the design. A specific prototype is not within the scope of this Memorandum. However, schematic diagrams and figures in the Memorandum will explore potential options for creating a prototype of our device.

Background. This year, Lockheed Martin is sponsoring the “Factory of the Future” initiative. The initiative presented us with four different problems that the company is facing. The problem we chose to create a solution for was a multi-driver. Currently at Lockheed Martin, a lot of time and money is being spent on unscrewing hundreds of screws from aircraft units when they fail or have other complications. Our solution in this report will present Lockheed Martin with a more efficient way to unscrew/screw the screws on their aircraft panels. Our solution will save the corporation a substantial amount of time and money. A design for the device was constructed in a CAD program (Fusion 360).

Project Sponsor. Lockheed Martin is a corporation that aims to lead in the advancement of scientific discovery through the branches of aeronautics, missile and fire control, rotary and mission systems, and space systems. Their branches of business range from NASA, to homeland security, to many other intelligence communities. The company has field offices across the United States and other locations in 58 different countries. Their headquarters are located in Bethesda, MD. Lockheed Martin employs over 91,000 employees and has over 49,000 scientists and engineers. The majority of their business sales target aeronautics, where they had over

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$17.8 Billion in sales in 2016. Their total sales in 2016 were around $47.2 Billion. Most of their customer sales went to international operations. The corporation focuses on creating products with a purpose, global support, and local delivery.

Project Requirements. The “Factory of the Future” initiative presented by Lockheed Martin will give engineering students an opportunity to use the engineering process to solve a real issue. The four issues that were presented in the initiative include a need for an organized wire and cable routing formboard (1), a FOD identification and retrieval device (2), a multi-driver tool (3), and a system used for open source tracking in their Innovation Garage (4). Project 1 relates to the building of aircraft harnesses. Each harness requires its own custom formboard and building these custom boards for each harness is incredibly tedious and time consuming. Project 1 must present a solution for a formboard that can be easily adapted and configured to build any unique harness. Project 2 requires a solution for the identification and retrieval of foreign object debris (FOD) in aircraft assemblies. Currently, it takes employees hours to retrieve FOD, and a new device would serve as a time-saver and a stepping stone towards automation and technology insertion. The third design project (discussed in this memorandum), involved the creation of a multi-driver that is capable of unscrewing many screws at once in small spaces. A device capable of this level of adjustability will save Lockheed Martin an incredible amount of money. The last design project, Project 4, will create a concept design that will help the corporation track materials and machines used in their Innovation Garage. A new low-tech system for automated asset management will be able to substitute a previously monotonous manual system.

Project Description. Project 3 from the initiative was the project that we came up with the best concept design for. A multi-driver tool was researched and investigated by all members of the design team, and solutions for the problem were presented by every member. Because of our large selection of design possibilities, our design team chose Project 3. The diversity in our solutions allowed us to combine many ideas to create the best final design.

Problem Statement. With standard tools used for disassembly, only one screw in Lockheed Martin’s aircraft units can be removed at a time. Because there is a high quantity of screws that must be removed every time there is a problem with the aircraft or circuit card, a great deal of time is spent on a monotonous and tedious job.

Design Method. The Engineering Design Process (see Figure 1) allows for the full exploration and analysis of potential options in order to find an optimal solution. This makes it possible to evaluate potential mistakes and improve upon the design until it is safe, efficient, and cost effective.

Step 1: Define the problem. The issue is noted and considered from multiple perspectives. Information on the problem such as relevant parts, customer specifications, and specific features are assembled.

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Step 2. Gather Information. Further information regarding functions of the design, necessary products, availability of those products is compiled to aid in the creation of informed solutions.

Step 3. Generate Multiple Solutions. The primary design is produced, as well as several alternative solutions. Each design must meet the project criteria and be subjected to further testing.

Step 4. Analyze and Select an Optimal Solution. Each potential solution is evaluated based on safety, cost, and effectiveness based on the initial criteria given. The better solutions are tested in greater detail to pick the best design.

Step 5. Test and Implement Solution. A prototype is created and tested for effectiveness. Necessary changes are made until the design is optimized.

Step 6. Share Solution. The final solution is presented to the original requestor. It is approved and implemented to solve the given problem.

Criteria for Success. The success of the device was determined based on six chosen characteristics. These were Easy to Use, Flexible Design, Cost Effective, Maneuverability in Tight Spaces, FOD Minimizing Design, and Visually Appealing. The value of each quality was considered in the making of the design. This ranking is seen in Table 1.

Procedures. Based on the project description, the primary design was focused on flexibility and maneuverability. The general setup (see Figure 2) featured four rails and sixteen motors, which could be reconfigured into multiple rectangular shapes (see Figure 3). An Autodesk Fusion 360 CAD model was created to provide a visual representation of the design. The design can incorporate a variety of screwheads (see Figure 4) and it can be tailored to fit many avionics boxes (see Figure 5).

The drills will be powered by three 12V batteries that are mounted to one corner of the rails. The motors can be mounted to the linear rail blocks using 3D printed mounts and self-tapping screws for plastic. Throughout the design process, we aimed to design the multi-driver using mostly existing parts that can be ordered online. The motors, gearboxes, and interchangeable drill bit holders can be taken from Black and Decker Electronic Screwdrivers. The linear rails and blocks can be ordered from Hiwin Corporation. The 12V drill batteries can be purchased from DeWalt. We then designed mounts that can be 3D printed to connect the parts, such as the mounts that connect the motors to the blocks on the linear rails.

Results and Discussion. An issue noted early in the process was how the size of the motors limited how close together two adjacent screws could be and still be unscrewed simultaneously by the device. Multiple motors were considered to reduce the effects of this limitation until the final version was chosen (see Figure 6). Potential costs of parts were evaluated (see Table 2). The final design cost was compared to the labor costs of current technology to demonstrate the cost effectiveness of the solution (see Table 3). Costs could be reduced by 3-D printing the device as opposed to purchasing the parts. However, the design requires a level of high

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precision that is better achieved with less 3-D printing. The design has advantages over the current technology in use because it can unscrew multiple screws at once and be reconfigured to fit the situation.

Conclusions and Recommendations. The final design has the potential to be an efficient solution based on the given specifications and the team Criteria for Success. While a working model could not be made, careful analysis of the digital model was considered in the creation of the final design. The team would be happy to provide additional services in the future if desired. Any questions can be directed to Daniel Shank at dss5493@psu.edu. We would like to thank Paul Mittan and Lockheed Martin cooperation for this opportunity.

References.

PSUFreshmanDesign2018Final.pdf

LMCorp_RMSOverview_24JAN2018-PSUFreshmanKickoffSpring2018.pdf

Engineering Design Process_Seyyed Khandani.pdf

https://www.homegardencyprus.com/en/catalogue-shop/power-tools/drills-drivers/cordless-drivers/cordless-screwdriver-lithium-ion-bosch-psr-select-detail

http://archive.cotsjournalonline.com/articles/view/101408

https://www.indeed.com/salaries/Electrical-Engineer-Salaries-at-Lockheed-Martin

https://www.indeed.com/salaries/Aircraft-Mechanic-Salaries-at-Lockheed-Martin

https://www.indeed.com/salaries/Avionics-Engineer-Salaries-at-Lockheed-Martin

Attachments. Tables 1, 2, and 3 and Figures 1, 2, 3, 4, 5, and 6 attached.

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TABLE 1Preliminary Criteria for Success

Criteria No.

Project Success Criteria

Critera Importance

Ranked 1 (Most) thru 6 (Least)

1 Easy to Use 1

2 Flexible Design 2

3 Cost Effective 4

4 Manueverability in Tight Spaces 3

5 FOD Minimizing Design 5

6 Visually Appealing 6

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TABLE 2Cost of Parts: Purchased Parts vs. 3D Printing

CostPart Cost QuantityHIWIN Linear Rails $50.00 4HIWIN Block $14.00 20Screwdriver for motor $10.85 12Batteries $32.00 4TOTAL: $738.20

3D Printed option Cost Quantity 3D Printed Linear Rails and Blocks $40.00

4 Rails 20 Blocks

Screwdriver for motor $10.85 12Batteries $32.00 4TOTAL: $298.20

Disclaimer: These are estimates and actual prices may vary

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TABLE 3Cost of Product vs. Labor Costs

Salary vs Cost

JobSalary/Hour

Hours to offset cost

Aircraft Mechanic $26 28.0

11.33D Printed Option

Electrical Engineer $39 18.9

7.63D Printed Option

Avionics Engineer $52 14.2

5.83D Printed Option

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Figure 1. Engineering design process used to develop an optimal solution for the selected project for the ‘Factory of the Future’ initiative

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Figure 2. General view of the proposed device

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Figure 3. The device can be reconfigured into a variety of arrangements

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Figure 4. Different types of screwheads can be used

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Figure 5. The solution should be applicable with multiple avionics boxes

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Figure 6. The final motor selected for the design

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