Lab Master Multi Testing Platform

Description

The LAB MASTER® multi testing platform was developed for Testing Machines (TMI) to consolidate a diverse range of more than 100 different testing devices into a single module which could be easily configured to perform any of the required tests. A modular system provided many benefits listed below:

Reduce production costs

Provide uniformity across the product line

Consolidate inventory

Improve customer response

Introduce consistent user interface to all products

Improve product branding

Improve overall quality

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Phase 1: Product Line and Market Research

This extensive product line ranged from impact testing devices to tensile machines and thickness gages. Product configurations varied according to specific application and were designed as a unique device. The variety of products over many years of development evolved into a wide range of diverse and very unique products with little to no common attributes. The pictures below represent a small sampling of this vast range of products.

Each product was carefully reviewed based the type of test it performed, its configuration and general construction. Products from TMI’s brochures were documented and categorized. One can readily appreciate the vast range and diversity of products that evolved over many years of adding to an ever growing product line. Each product had its own control panel with a unique display, controls and graphic layout. Size, orientation, footprint, and construction varied from one product to the next. Consolidation of this product line was obviously a major challenge.

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Phase 1: Product Line and Market Research

In addition to documenting every product, our design team also reviewed the manufacturing procedure on the production floor. Assembly operations for numerous products were documented and analyzed based on assembly steps, testing procedures, materials, components and overall construction. This study provided us with critical information affecting the overall design plan and product line modularity.

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Phase 1: Product Line and Market Research

After the product line was completely reviewed, the difficult task of categorizing every product began. This classification process was an essential part of the standardization procedure which was required to streamline the products within a modular platform. Criteria for establishing common parameters were based on the following product attributes:

Physical attributes
Purpose and classification
Specifications
Internal components
General Operation
ASTM test name
Physical sample shape and size
Selling price
Annual production volume

These attributes were quantified for each product which was ultimately grouped into one of four classifications listed below:

Linear based testers (fast and slow)
Dart based testers
Pendulum based testers
Clamp based surface testers

Examples of this study are shown on the following photos.

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During this product classification, our design team began to conceptualize numerous configurations for the module. The primary objective was to define a fundamental testing platform which could cost effectively be configured into anyone of the four basic product classifications and ultimately perform any of the 100 plus tests within the product line. Numerous sketches and brainstorming sessions provided the development team with hundreds of design alternatives. The development teams of TMI and IDS jointly strived to minimize the number of components and parts within the base module. Examples of these ideas are shown in the following slides.

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After the classification process was completed, evaluated, and approved, IDS consolidated the product line by designing a base module that could be configured to emulate the function of any test machine in the product line. The result of hundreds of hours of development concluded with a very elegant design solution which was a computerized base module which would form the common platform for the entire product line. This PC based computer module was housed in a special structural cabinet that could be either vertically or horizontally oriented depending on the testing machine it was to emulate. In addition, the specific test apparatus was to be designed as a plugin unit which would physically be inserted into a standardized open bay within this housing structure. Throughout this process, Testing Machines' management staff provided technical expertise to optimize the modular system while our design team designed the modular system architecture. During the development of this modular system, components were modeled in 3D CAD Numerous assemblies were configured to demonstrate how the system emulate each product.

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The emerging modular system that was developed in CAD was eventually modeled in foamcore. Creation of physical models to physically represent each system concept was very beneficial for TMI’s management who were able to physically interact with the proposed system. Simple physical models were readily appreciated for their size, modularity, feasibility and man-machine interface. Foam core models have proven to be a very cost effective means of quickly translating a 3D CAD model or sketch into a tangible item.

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Phase 2: Concept Development for the Lab Master

After Phase 1 was completed, specific concepts representing the exterior shape of the base module were developed in sketches and eventually in 3D CAD. Developing initial concepts in sketch form provided a rapid method of exploring numerous ideas quickly and spontaneously. These concepts were based on the preliminary sketched layouts of internal components previously completed. This logical progression of the design assured us that the styling alternatives would be consistent with the functional requirements of the product line. Literally hundreds of different design ideas were explored and tested for various products throughout the line.

Other factors affecting design that were considered during this phase also included:

Engineering and performance criteria
Operation sequence for each module
Details for the sample holder
Partial details for each test module layout
Outline for the preferred manufacturing assembly steps and parts
Service issues
Shipping requirements

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Phase 2: Concept Development for the Lab Master

IDS presented renderings for the new modular Lab Master system to TMI. These concepts were were limited to overall physical appearance based on the general specifications stated below:

The enclosure was designed to support all electronic components
Ventilation was integrated into the overall appearance to satisfy thermal requirements.
The enclosure was designed for either horizontal or vertical orientation
The enclosure was designed to permit users to mechanically fasten many test modules to a rail to emulate numerous tests dynamic tests.
A hardened top surface insert was provided to conduct mar and abrasion resistant testing of moving paper.
Our experience with emerging technology at that time convinced our client to replace a membrane keypad and a 2 line LCD with a touch screen display.
The design permitted the electronic module to be oriented either vertically or horizontally, depending upon the testing machine’s requirements.

A few of the concepts presented during this phase are shown in the following slides.

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Phase 2: Concept Development for the Lab Master

In addition sketches and renderings describing possible design alternatives for the new Lab Master, IDS also team assisted TMI in identifying purchased components, manufactured items, and modified subassemblies for all components affecting the module design. Another task completed during Phase 2 was a preliminary cost estimate based on the proposed modular design concept. The objective of this study was to provide TMI with projected tooling investments and reoccurring unit costs based on various manufacturing methods. This study included selecting a concept and sketching each part with sufficient detail to obtain a reasonable estimated price. Sketches provided an efficient means of illustrating each part based on a specific manufacturing process. Estimated weights and sizes were also included in the bid package. The following sketches illustrate the information that was transferred to perspective fabricators.

After the concepts and costs were evaluated by TMI, a design direction was established and selected for further development throughout the remainder of the program.

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Phase 3: Production Design Detailing

TMI and IDS agreed upon the most suitable design and manufacturing process based on numerous considerations. It was decided that the selected concept was to be developed as a pressure formed product with a very structural internal sheet metal chassis to provide adequate rigidity to any plugin test module. The selected design was completely detailed into a set of production ready parts and subassemblies to satisfy all product requirements. Every manufactured part and specified hardware required to manufacture the enclosure was included within a Pro-E 3D solid model assembly. Parts were designed in accordance with the selected manufacturing process and detailed in a 3D assembly which was eventually used to generate a complete set of production drawings. All molded or cast parts were detailed with appropriate draft angles, tolerances, and hardware suited to the specific manufacturing process. Sheet metal parts were designed with appropriate bend radii, tolerances, and mounting hardware.

Close communication with TMI’s engineering and management staff was maintained through every critical stage of development. Communication was maintained with data sharing. e-mails and real time web meetings. This well managed program eliminated misinterpretation, undesirable design details, and program delays since TMI was continually appraised of the developing design.

At the end of Phase 3, TMI received one set of 3D solid geometry files for the electronics enclosure, operator interface module and covers for a testing linear module. Cad data was transferred to TMI in IGES and Pro-E format.

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Phase 4: Functional Prototype and Design Revisions

After the production design was completed in Phase 3, our staff sent drawings to specific vendors to construct a pre-production prototype based on the CAD file. IDS obtained bids from a minimum of three vendors specializing in each manufacturing process including rapid prototyping, sheet metal and machined parts. During the prototyping process our team interfaced with these facilities to answer questions and provide technical support. We also provided TMI with technical assistance during the assembly of the first prototype. Minor design modifications were made to the design and preliminary production control drawings after the prototype was evaluated and finalized by TMI. Phase 4 was completed after the prototype and minor design revisions were included in the 3D assembly.

The manufacturing processes included in this design are listed below:

Metal investment casters
Plastic casters and stereolithography prototype shops
Aluminum extruders
Machine shops
Sheet metal shops
Thermoformers

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Phase 5: Production Part Drawings

After the design was prototyped and approved by TMI, a set of production drawings based on the final production design were completed by our design team. Production control drawings were created for purchased parts or modified parts. Drawings included critical tolerances, surface finish, draft and all other pertinent information required to fabricate each part. All 3D models and associated 2D part drawings were modified to comply with TMI’s final design specifications. Production documentation included geometrically toleranced part drawings to assure production consistency in critical areas.

The final documentation package included assembly drawings, subassemblies, cast drawings, and machine detail drawings. Material specifications, tolerances, finish, color, draft and other pertinent information were called out on every part drawing. Plastic molds were machined directly from 3D CAD files developed by our design team.

Phase 5 was completed after all part drawings were reviewed and TMI received a 3D IGES file of all parts as well as a complete set of production part drawings in DXF or DWG format. Also included were assembly drawings, a bill of material and a set of Pro-E files.

Vendor Liaison and Production Follow-up

During production tooling and startup IDS provided TMI with technical by answering questions pertaining to tolerances, surface finish, design modifications, or any other issues, which typically arise when parts are manufactured or assembled.

Since its introduction the Lab Master® product line has grown into a significant portion of Testing Machines’ product line. Below are a few of the many different Lab Master configurations offered by TMI in its current product line.

ZDT Tester is a precision PC Controlled testing instrument which automatically determines internal bond strength according to TAPPI T 541. All testing parameters such as test speed, dwell time and compression force are selectable in an easy to use, intuitive software program supplied with the instrument.

PRECISION TESTING

Peak Force is measured to a maximum capacity of 1100 N (250 Lbs) with a 0.04 N (0.01Lbs) resolution and accuracy of ±0.5% of reading. Position is measured and controlled with 0.1μm resolution and 0.2 μm repeatability. Peak force is measured by applying a force in the z-direction until ply separation occurs.

Lab Master Z-Directional Tensile Tester photo 2.

APPLICATIONS

ZDT measurements are an effective tool for monitoring a variety of strength properties which aid in improving printing and coating applications, bonding strength of paper cores, delamination strength, intrinsic fiber bond strength, paperboard and combined board strength and fiber-to-fiber bond strength.

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