Team Members and Role:

Abstract:

The General Dynamics Mission Systems (GDMS) plant in Pittsfield MA assembles Missile Interface Boxes (MIBs) for fire control systems in Ohio-class submarines. The MIB is a custom electronics cabinet that weighs 1000 lb and is 6’ tall. Operators install electronic components into the MIB while it is laid flat on its back. Due to bending over the MIB for extended periods of time, operators have reported pain and fatigue, presenting a significant ergonomics issue for the Pittsfield location. Currently, GDMS is able to provide operators with some alleviation by using a gantry crane to place the MIB on a tilting table. The table rotates to improve ergonomics, however the current system has clear limitations: it can only rotate in one direction, only works for one of the plant floor’s cranes, and can’t adjust the height of the MIB to accommodate different operators. This project aims to design a new tilting/rotating mount for GDMS to improve assembly ergonomics. Team 1402 adapted a commercially available car rotisserie with custom manufactured adapters. The MIB is mounted to the rotisserie using a forklift and bolted to the frame, allowing for rotation in both directions as well as providing height adjustment. The team ensured that the new system conformed to ISO Standard 11226:2000, an engineering standard relating to ergonomics. It was determined that operators should not have trunk deflection of 20 degrees or neck bending of 25 degrees for an extended period of time. Based on analysis and testing conducted throughout the design process, the prototype achieved successful mobility, structural, and ergonomic results.