Many engineering students are focused on theoretical coursework and some structured laboratory experiments. However, troubleshooting of equipment and complex machines are not given sufficient attentions during the engineering course of studies. In order to familiarize student s with troubleshooting and identifying the failed section, a relatively complex and non-functional milling machine is selected as a senior design project. The objectives of this project is to identify the different sub-systems of the machine, isolate each sub-system, test and document the result. Repair the failed sub-system and integrated the overall machine and perform a final test on the completed machine. A procedure will be developed to teach the future students following similar methodology in identifying the failed components of a complex machine and finding solution to fix it.
The existing machine under consideration comprised of mechanical moving parts, motor and gear, electrical relays and contactors, power supply, electronic control circuit. A separate electronic circuit connecting a computer to the machine for transferring data. The data is using a G-code numerical programming language to the machine for operation. The new repaired and retrofitted machine will have Beagle Bone control with communication link for interfacing. Implementing Beagle Bone controller will allow direct communication link via Ethernet port. Understanding and repairing of such a machine requires background information about all the sub-systems.
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