Microsoft Senior Design Project
December 2018 - May 2018
Universal Common Carrier
Microsoft use to use unique manufacturing carriers for each device/model and needed a common manufacturing carrier. Our misson was to create a new universal carrier that: reduces manufacturing costs, reduce environmental impact, unify design philosophies, and reduce fixture lead time.
Rapid "Waterfall" Design
Our team started with independently drawing “napkin” sketches (quick 10 minute ideas) and shared them all with each other for comparison. We rated each design with a Pugh matrix, which highlighted the most important traits defined by Microsoft. The highest scored designs were used to further develop into our next round of designs.
After quick sketches we split into three teams, each with different goals in mind. My was focused on universal parts. We wanted to make a design that could reuse all its parts for any device that way the setup time was fast if the manufacturing line switched from one device to another.
After consolidating a few rounds of designs, our team developed a carrier that could be used for any of their devices and only one part had to be swapped for switching devices. Moving forward, we split into tasking parts to team members. I was tasked to the insert center plate and helped with the outer frame due to another teammate having personal emergency.
Analysis
FEA
I simulated the forces the carrier would undergo moving along the manufacturing line from different processes. I was mainly interested in seeing how much the plate would bend and to verify there would be no plastic deformation.
Thermal
I ran a thermal analysis on the inserts to check for the coefficient of thermal expansion and to validate our pocket in the main frame was large enough for any tolerance stack up.
Testing
Every team member helped with validation testing. We simulated the pressure that would be applied to the adhesive bonding region and measured the amount of flex/bowing within the carrier assembly.
Drafting
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