ITT Technical Institute Industrial Automation Engineering

Technology
Capstone Project

Pinewood Derby Car Manufacturing

Project Plan

Project Presented By:

Rita Johnson
Jason Evoniuk
Josh Jones
Nathan Merrell
Arsham Orami
Carl Wickstrom

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Technology
Capstone Project
Table of Contents

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ITT Technical Institute Industrial Automation Engineering
Technology
Capstone Project
1. Project Summary
Our class has a simple vision. We want to make an automated pinewood derby
manufacturing system. This project will use the Mitsubishi robot, a CNC mill and a
conveyor belt.

2. Project Details

2.1. Purpose.
The main purpose of this project is to clearly demonstrate what students in the
Industrial Automation Engineering Technology (IAET) program at ITT are capable of.
This project is a reflection of the skills we have learned during the past four years.

We want the opportunity to show the world what IAET students can do.

This project will showcase the following skills:

• Project Design – Identifying a problem and the envisioning a desired goal
• Process Management – Creating a plan, scheduling the project, making a
budget, accounting of funds, managing the project
• Technical Writing – Clearly explaining the project throughout its development
and creating a thorough report upon completion
• Computer Aided Drafting (CAD) – Designing parts and fixtures
• Computer Numerical Controls (CNC) – Implementing CAD drawings to create
needed fixtures for the project, manufacturing the from blanks
• Robotic Motion – Moving work pieces from place to place
• Programmable Logic Controllers (PLC) – Controlling timing of the processes
and monitoring safety
• Electronics – Wiring sensors and relays, as needed to provide a safe work
environment and network the different devices together

2.2. Overview.
The IAET class will create a manufacturing process using a variety of tools. The
body of the car will be machined using the CNC machine. In addition to moving
parts from place to place, the robot will be responsible for assembling the vehicles.
In the end this project will produce pinewood derby cars without any human
intervention.

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Technology
Capstone Project

2.3. Basic Description of the Project

• Pinewood derby car blanks will be presented by a feeder for the robot to load
into the CNC mill.
• The CNC program will begin operation; the general shape of the car will be
cut.
• The robot will remove the part from the CNC machine, rotate the part 90
degrees then load it back into the CNC mill for finish milling.
• The robot will place the finished body of the car onto the conveyor.
o There will be four regions on the conveyor belt.
 The first region is the location where the robot will place the
machined parts.
 The second region is a mock painting chamber.
 The third region is a mock drying chamber.
 The fourth region is where the robot will pick up the parts for
additional processing.
• The robot will continuously load blanks into the CNC and place the finished
parts on the conveyor belt.
• The conveyor will advance one unit after a part has been placed on the belt
by the robot.
• When the robot is idle from its duties with CNC operations, it will take wheels
from a feeder and place them in a wheel mounting fixture as needed.
• After the body of the car has exited the drying chamber the robot will pick it
up and install wheels on both sides of the vehicle.
• The robot will arrange the cars neatly after the wheels have been attached.

The IAET class will design and machine all of the required fixtures for the project. The
class will design the work cell, program all the machines and controllers to make this
project work. Upon completion of this project, the manufacturing system will
manufacture at least 5 vehicles without human intervention.

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Capstone Project
3. Project Organization & Responsibilities
Our team has had the opportunity to work with each other for the past 7 quarters of
school. During this time we have seen where we excel, and just how effective we
are when we work as a team.

3.1. Organization
Responsibilities Team Leader
Project Management N/A
CAD Design Josh Jones
Fixture Designs Josh Jones/Arsham Orami
Mechanical Jason Evoniuk
Electrical Nathan Merrell
Robotic Programmer Carl Wickstrom
CNC Programming Josh Jones
PLC Programmer Arsham Orami
Safety Nathan Merrell
Accounting Rita Johnson
Presentations Carl Wickstrom/Jason Evoniuk
• We have decided to make project management a responsibility of the entire
team.
• At the beginning of each day we will meet to discuss the project.
• The meetings will allow us to properly allocate our labor resources so we can
accomplish a complicated task or a specific milestone.
• We want our teams to shift dynamically; when someone needs help we can
lend a hand.

3.2. Safety.
The people listed as team leaders have proven in previous projects that they are
experts in their specific area. They will be responsible for the safety of their
equipment within the work cell.

• Safety should always be designed into a product or system.

• It is assumed that during the course of this project we will encounter
some safety hazards within our work cell.
• It is the team’s responsibility to notify the person in charge of safety
regarding any hazards in the work cell.
• If a safety hazard cannot be removed though a design change, a sensor
will be designed to address the problem

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Capstone Project
4. Milestones and Schedule.

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5. Materials and pricing.

Part Description Size Quantity Units Price Total
Materials for Cars
Pinewood Derby Car (Blank) 7" x 1.25" x 1.75" 35 each $ 2.80 $ 98.00
Wheel/Axel Kits (4/kit) 1.25" round x .2 20 kit $ 3.50 $ 70.00
Work Cell Construction
2x4 Wood Struts 2" x 4" x 8' 10 each $ 1.55 $ 15.50
Brackets Varies 30 each $ 1.00 $ 30.00
Wood Screws 2.5" 1 box $ 5.00 $ 5.00
Acrylic Sheet 0.093" x 2' x 4' 1 sheet $ 14.99 $ 14.99
Safety Sensors $ 30.00 $ 30.00
CNC Machining
¼" Mill Dia. x 1-3/4"
Extra Long Length Milling Bits 2 each $ 20.00 $ 40.00
LOC
4 piece center Milling Drill Set Varies 1 each $ 19.97 $ 19.97
Fixtures
Medium Density Fiberboard (MDF) 1/2" x 2' x 4' 3 sheet $ 8.16 $ 24.48
Wood Screws 1 1/4" 1 box $ 4.74 $ 4.74
Aluminum 1/2" x 8"x 8" 1 each $ 28.91 $ 28.91
Miscellaneous Expenses
Pizza $ 80.00 $ 80.00
Unbudgeted Expenses $ 38.41 $ 38.41
Total $ 500.00

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