Design and Optimization of a Keycard Encoding Machine Senior Project by Elliott Oberg Department of General Engineering California Polytechnic University San Luis Obispo March 2013 Robert Crockett ‐ Academic Advisor Date Acknowledgments Julie Gibson ‐ Technical Advisor I would like to thank Julie Gibson for her time and patience during the project. Without her support and extensive knowledge of the housing department, this project would not have been possible. Robert Crockett – Academic Advisor I would like to thank Dr. Crockett for allowing me to do a project that I was passionate about. His encouragement motivated me complete the project successfully. Cal Poly Housing and Business Dept. I would like to thank the housing and business department for the time and funds they put into this project along with their commitment to innovation and success. My Family Finally, I would like to thank my family for giving me unconditional support and love throughout my educational journey. They taught me that failure is impossible and that life is limitless. I love you all. 1 | Page Abstract Security on college campuses is a good thing, especially when it comes to your dorm room or apartment building. But due to high initial cost, the Housing and Business Department at Cal Poly, San Luis Obispo, has opted for a proprietary door lock system which requires encoding new keycards manually for every resident, every year. The goal of this project is to offset this labor cost and drain on resources by automating the keycard encoding process. This project will address the design specifications and economic advantages of automation while also exploring and comparing alternative solutions. 2 | Page Table of Contents ACKNOWLEDGMENTS ........................................................................................................................................ 1 ABSTRACT .......................................................................................................................................................... 2 LIST OF FIGURES ................................................................................................................................................. 4 LIST OF TABLES ................................................................................................................................................... 5 INTRODUCTION.................................................................................................................................................. 6 BACKGROUND AND RELEVANT RESEARCH .......................................................................................................... 8 ONITY INTEGRA 5 ELECTRONIC LOCK SYSTEM ....................................................................................................................... 8 ALTERNATIVE SOLUTIONS ............................................................................................................................................... 11 ENVELOPE AND KEYCARD TRANSPORT METHODS ................................................................................................................ 12 PRELIMINARY DESIGN ....................................................................................................................................... 15 DESIGN SPECIFICATIONS ................................................................................................................................................ 15 DESIGN SUMMARY ....................................................................................................................................................... 15 TESTING AND RESULTS .................................................................................................................................................. 18 CONCLUSION ............................................................................................................................................................... 20 EXPERIMENTATION ........................................................................................................................................... 21 THE ENVELOPE FEEDING AND LOADING MECHANISM .......................................................................................................... 21 THE KEYCARD FEEDING SYSTEM ...................................................................................................................................... 22 ................................................................................................................................................................................. 22 THE KEYCARD TRANSPORT SYSTEM .................................................................................................................................. 23 FINAL DESIGN ................................................................................................................................................... 24 DESIGN SPECIFICATIONS ................................................................................................................................................ 24 DESIGN SUMMARY ....................................................................................................................................................... 24 CONCLUSION ............................................................................................................................................................... 26 RESULTS AND DISCUSSION ................................................................................................................................ 27 WORKS CITED ................................................................................................................................................... 28 APPENDIX ......................................................................................................................................................... 29 A‐1: INITIAL DESIGN ..................................................................................................................................................... 29 A‐2: OPTION #1 FOR ENVELOPE FEEDING & INSERTING ...................................................................................................... 30 A‐3: POSSIBLE ENVELOPE CARTRIDGE DESIGN .................................................................................................................... 31 A‐4: CLOSER LOOK AT CARTRIDGE TABS AND TONGUE CONFIGURATION ................................................................................. 32 A‐5: KEYCARD TRANSPORT SYSTEM – CARD REJECTION ....................................................................................................... 33 A‐6: MOTOR AND TRACK SUPPORTS ................................................................................................................................ 34 A‐7: MODIFIED TRACK FOR ROLLER INSERTION .................................................................................................................. 35 A‐8: KEYCARD CARTRIDGE BASE – TECHNICAL DRAWING .................................................................................................... 36 A‐9: KEYCARD CARTRIDGE TRAY – TECHNICAL DRAWING..................................................................................................... 37 A‐10: ENVELOPE CARTRIDGE TRAY – TECHNICAL DRAWING ................................................................................................. 38 A‐11: MOUNTING BRACKET FOR TONGUE ASSEMBLY – TECHNICAL DRAWING ......................................................................... 39 A‐12: ROTATING DISC FOR TONGUE ASSEMBLY – TECHNICAL DRAWING ................................................................................ 40 A‐13: TONGUE FOR ENVELOPE FEEDER ASSEMBLY – TECHNICAL DRAWING ............................................................................. 41 A‐14: KEYCARD CARTRIDGE CLIPS ................................................................................................................................... 42 3 | Page List of Figures Figure 1. Onity Integra5 keycard‐accessed door lock used by Cal Poly Housing Dept. .......................... 6 Figure 2. Onity electronic lock poster. ................................................................................................... 8 Figure 3. Yearly operation cost breakdown as of 2009 (Moir A‐29) .................................................... 10 Figure 4. Yearly operation cost breakdown as of fall 2012. ................................................................. 11 Figure 5. Automated keycard encoding machine specification update 1. ........................................... 11 Figure 6. Typical paper transport using rubber rollers (J. Tamamoto 568). ......................................... 12 Figure 7. Tapered roller paper transport design example (J. Tamamoto 569). .................................. 12 Figure 8. Standard friction pad paper feed mechanism model (Yanabe 18). ...................................... 13 Figure 9. Conventional conveyor belt configuration (Indonesia Belting Solution). ............................. 14 Figure 10. Keycard cartridge system (Moir). ........................................................................................ 16 Figure 11. Envelope cartridge system. 1 ‐ T‐slotted base, 2 ‐ Envelope support lip (Moir). ............... 16 Figure 12. Conveyor belt assembly (Moir). .........................................................................................