Safe Dip
What is it? Safe Dip is a Senior Design project for the Electrical and Computer Sciences Bachelor’s program at Valencia College. The project focuses on designing a low-cost automated system that can pick up metal components, dip them into hot wax, and return them to a conveyor with minimal human interaction.The main purpose of the system is to improve operator safety by reducing direct handling near a heated dipping process.
Avoiding
incidents
Problem Statement
Hot-dipping processes are used in manufacturing to coat, treat, or finish parts. However, manual operation near heated baths can expose workers to safety risks such as burns, repetitive strain, and inconsistent handling.
This project addresses the need for a safer and more controlled way to move metal parts through a dipping process. By automating the pickup, dipping, and unloading sequence, SAFE DIP aims to reduce the amount of time an operator spends near the hot wax bath.
Proposed Solution
The proposed solution is a small automated pick-and-place system designed to move metallic components through a hot wax dipping process.
The system is expected to:
Detect or receive a part from an input area.
Pick up the part using an electromagnet.
Move the part horizontally over the wax container.
Lower the part into the wax using a vertical motion system.
Raise the part after the dipping step.
Move the part to an output area.
Release the part safely.
Stop operation through an emergency stop system when needed.
Project Overview
SAFE DIP is being developed as an automated bench-top machine for hot-dip applications. The system is intended to perform a basic load-dip-unload cycle, where a metal component is detected, picked up, lowered into a hot wax bath, lifted out, and placed back onto an output area or conveyor.
System Design
Basic System Architecture
SAFE DIP can be organized into the following main subsystems:
| Subsystem | Purpose |
|---|---|
| Processing Module | Controls the logic of the system and coordinates sensors, motors, and the electromagnet. |
| Sensing Module | Detects part position, system status, or movement limits. |
| Movement Module | Controls horizontal and vertical motion. |
| Electromagnetic End-Effector | Picks up and releases metallic parts. |
| Power Distribution Module | Supplies power to motors, controller, sensors, and the electromagnet. |
| Communication Module | Allows the system to send or receive information from a computer or interface. |
| Emergency Stop Module | Provides a safety shutdown method during abnormal operation. |
