Improved Honeycomb Expander

Levi GordyKarl GrabczewskiAndy OlenderskiStephanie Swain

Team Alcore

Overview• What is Alcore?• Process of Interest• Current Problems• Alcore Wants• Metrics• Our Concept• Subsystem Development• Cost Analysis• Value to Sponsor• Path Forward

What is Alcore?• Located in Edgewood, MD

• Produces and Processes Aluminum Honeycomb Core

• Product applications in Aerospace, Marine, and Construction Industries

• Used in Commercial Airlines and Military Hardware

Process of Interest

•Aluminum Core Expansion (7 steps)

Transfer Cart Holding Table

Nailing Station

Finished Stack

Expander Holding Table

Cutting Station

Process of Interest (Graphically)

Expansion Phase

Aluminum Core

Module Module

Aluminum Core

Current Problems•Unnecessary Handling

–Transfer between stations

•Labor intensive–Nailing, loading, unloading, resetting

•Inconsistent Process

– Human error causes delays

– Higher variability in timing

Alcore Wants•Driving Wants

–Reduced Handling–Reduce cycle times

•Varying Cores Require Adaptability

•Other wants result from driving wants

• Training Time• Manageable Weight• Improved Safety

Transfer Cart

Cutting Station

Finished Stack

Expander

Metrics

•We can improve many aspects of the process•Further improvement not possible in all areas

Metric Current Value Target ValueNailing Time 150 sec 10 sec

Loading Time 60 sec 30 sec

Expansion Time 60 sec 30 sec

Quality Check Time 160 sec 130 sec

Unloading Time 80 sec 60 sec

Operators Needed 2 to 4 2

Cores per Expansion 1 to 2 2 to 4

Cycle Time 8.5 min 4.3 min

Current Expansion Table

1

2

3

4

Our Concept…

Incorporate an automatic gripping system

Critical Subsystems

•Five critical design components

Overhead Press

Gripping Module

Slide Rail

Resetting Mechanism

Linear Actuators

Support Frame

•Examined Alternatives for each subsystem

Sliding Module Considerations

• Needs to support insertion forces

• Resist binding from expansion forces

• Minimal deflection along guide rail

• Mating modules can’t obstruct one another

Sliding Module

F

Nylon Lined Plain-Bearing System

•Static Load Capacity of 2240 lbs

• F = 400 Newtons ≈ 90 lbs

• Approx 20 Modules along width of table

•≈2000 lbs Cumulative Load

•Cumulative Load < Rated Load Capacity

Sliding Module Components

1. Guide Rail2. Guide Block 3. Gripping Nail4. Retaining Plate5. Eyelet Screw

1

2

34

5

Return Mechanism

1

2

•1 – 3/32” Aluminum Cable Ferrules•2 – 25ft x 3/32” coated cable•Winch pulls cable taught

Actuator Considerations

• Small profile to easily attach to frame • Suitable for high cycles: Raising and

lowering slide rail and modules • Produces required forces to puncture 12 lb

core ( 8000 N / actuator assuming 10 ft width)

• Lightweight

Actuators

• Rod screw actuator with In-line motor– Low profile (8.6’’ x 3.8’’)

• High Cycles Time to Fatigue– (90% reliable to 10^6

inches)

• Meets required forces– Max force ~4300 lb (~16000

N)

• Low added weight (14.2 lb)• Can operates at 25 in/sec • Multiple Mounting Options

– Foot mount and Externally threaded screw

Support Frame•Utilize Existing Mobile Gantry

•Proven in this application

•Eliminates cost of producing new frame

Cost Analysis (Full Scale System)Part Price

Guide Rail 900.00

Guide Block 4141.92

Nitride Ejector Pin 118.08

Retaining Plate 1920.00

Retaining Screw 16.18

Eyelet Screw 620.16

Cable 19.90

Cable ferrules 94.08

Winch 69.99

Linear Actuator 31595.16

 Total Cost 39,495.47

Benefits

Estimated Profit per

annum

Reduced Operators $49000

More Cores per cycle $500,000

Faster Cycle time $500,000

Total New Earnings (est.)

$1,049,000

Our PrototypeOverhead Press Concept proved to be the best

Prototype to Simulate one section

Proves insertion times, removal times, resetting times.

Completed Prototype

Testing and Validation• Prototype crosshead mounted into

Instron• Single module on guide rail to test

insertion quality and time

Testing Video• Video_Core Insertion.MOV

Testing and Validation• Used same speed

as linear actuator to insert nail into 1 to 5 cores– At most Alcore

currently expands only 2 cores at a time

• Nail was inserted cleanly and quickly– Nailing, loading, and

unloading currently take 290 sec at Alcore

– Our prototype reduces time to 100 sec

Testing and Validation

• Our resetting mechanism resets the modules in 1 second

Testing Video• Video_Resetting.MOV

Results vs. Target Values

Improvement Criteria

Target Value Results

Nailing Time 10 sec 10 sec

Loading Time 30 sec 30 sec

Expansion Time 40 sec untested

Quality Check Time 130 sec untested

Resetting Time 40 sec 1 sec

Cores per Expansion 4 5

Operators Needed 2 2

Time saved per cycle ≈

3.5 min

Time Charts Comparing Old vs New Process

0

100

200

300

400

500

600

700

Old Average Worst Case (Old) Estimated New Averages Worst Case (New)

Process

Tim

e (s

eco

nd

s)

Unloading Time

Quality CheckTime

Expansion Time

Loading Time

Nailing Time

Value to Sponsor

• Reduces handling time/labor intensiveness– Happier work force

• Reduces # of operators needed– Operators used more effectively elsewhere

• Increased number of cores per cycle– Higher Productivity

Path Forward• Determine max number of cores

subject to expansion force constraint

• Prepare transition/full scale implementation package

• • Validate expansion time on full scale

system

Questions?

Supplementary Information

Dimension Distance (mm)

A 70

B 36

B1 31

D 57

G 23

Side View

Dimension

Distance (mm)

C 96

E 45

F M8 x 24.8

G 23

H 21.5

J 60

K 40*

M 10

N M6

P 6

Resisting Bind-up of Module• Guide Blocks are rigid• Designed for much higher

loads than will be experienced

• Prototype testing could further validate

• Ball Bearing Modules much more costly

Cable/Module Reset•Winch

–Portable–12 V DC–2000 lb capacity–$69.99–Cable goes through eyebolts on modules–Master Lock Model# 2953AT

Slide Rail

• Slide Rail available in 1 m sections• Support Beam used to mate

sections/add rigidity

1m 1m 1m