Brazing SaddlesBrazing Saddles

((Team 15)Team 15)Client: Parker-HannifinClient: Parker-Hannifin

Faculty Mentor: Dr. Kevin KochersbergerFaculty Mentor: Dr. Kevin KochersbergerFaculty Coordinator: Dr. Paul StiebitzFaculty Coordinator: Dr. Paul Stiebitz  

Preliminary Design ReportPreliminary Design ReportFebruary 21February 21stst, 2003, 2003

  

Ethan BagleyEthan Bagley

Melissa CurtinMelissa Curtin

Paul DiedrichPaul Diedrich

Charles GulloCharles Gullo

Fulya TezerFulya Tezer

Tom WildTom Wild

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AgendaAgenda

Problem StatementProblem StatementDesign Phase 1Design Phase 1Design Phase 2Design Phase 2Plan of ActionPlan of Action

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Problem StatementProblem Statement

• Current braze Current braze furnace process:furnace process:– Operator loads one Operator loads one

part every six part every six minutesminutes

– Operator must walk Operator must walk 40 feet to opposite 40 feet to opposite end of furnace to end of furnace to retrieve each partretrieve each part

– Part removal system Part removal system currently unreliablecurrently unreliable

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Project GoalsProject Goals

• Design Phase 1: Part removal Design Phase 1: Part removal mechanismmechanism– Key issues:Key issues:

• Part stabilityPart stability• System autonomySystem autonomy

• Design Phase 2: Part Handling Design Phase 2: Part Handling SystemSystem– Analysis of Layout in Brazing AreaAnalysis of Layout in Brazing Area

• FlexibilityFlexibility

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Design Phase 1:Design Phase 1:

Development of Mechanical Development of Mechanical SystemSystem

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Concept DevelopmentConcept Development

• AugerAuger– Rotating coil translates Rotating coil translates

parts from conveyor to parts from conveyor to staging areastaging area

• Swing ArmSwing Arm– Revolving member Revolving member

pushes parts from the pushes parts from the conveyor to the staging conveyor to the staging areaarea

• ForkliftForklift– A lifting device raises the A lifting device raises the

parts off the conveyor parts off the conveyor and a horizontal thruster and a horizontal thruster pushes them to staging pushes them to staging areaarea

Return Conveyor

Furnace # 2Furnace # 1

Motor Housing

Auger Concept - Top View

Slope tables downtoward return belt

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Feasibility AssessmentFeasibility Assessment

Feasibility Assessment

TECH1

TECH2

TECH3

ECON1

ECON2

SCH1SCH2

SCH3

SPEC1

SPEC2

SPEC3

Mod. Fork Lift

Swing Arm

Fork Lift

Ram

Auger

T1 T2 T3 E1 E2 S1 S2 S3 SP1 SP2 SP3Modified Fork Lift 4 5 4 5 5 5 3 4 3 5 5Swing Arm 4 4 4 1 3 4 3 4 1 3 4Auger 4 4 4 1 2 4 3 3 1 2 4Fork Lift 4 4 4 5 5 4 3 4 3 4 5Ram 3 3 3 3 3 3 3 3 3 3 3

Feasibility Assessment

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Further Concept DevelopmentFurther Concept Development

• Original Fork Lift Original Fork Lift ConceptConcept– Interlocking perpendicular Interlocking perpendicular

pairs of forkspairs of forks– First pair raises parts off First pair raises parts off

belt verticallybelt vertically– Second pairs slides into Second pairs slides into

first and reroutes parts first and reroutes parts towards staging areatowards staging area

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Concept Development (cont.)Concept Development (cont.)

• Modified Fork Lift Modified Fork Lift ConceptConcept– Rotating ramp attached Rotating ramp attached

to a small winchto a small winch– Parts are pushed onto Parts are pushed onto

ramp by conveyor ramp by conveyor – Ramp rotates to Ramp rotates to

stabilize partsstabilize parts

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Concept Development (cont.)Concept Development (cont.)

• Final Fork Lift ConceptFinal Fork Lift Concept– Parts are pushed onto Parts are pushed onto

flat plate by conveyorflat plate by conveyor– Vertical thruster raises Vertical thruster raises

part off conveyorpart off conveyor– Horizontal thruster Horizontal thruster

(ram) pushes part (ram) pushes part towards staging areatowards staging area• Thrusters are Thrusters are

pneumatic actuatorspneumatic actuators

• Design requires Design requires uniform part holdersuniform part holders

Conveyor Belt

Flat

Tower

Ram

Conveyor Belt

Ram Housing

Tower

Flat

Stoarge Platform

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Design Details - BoatsDesign Details - Boats

• New boat designed to carry the existing New boat designed to carry the existing part holderspart holders-2 pegs in rear for 2 pegs in rear for stabilitystability

-Chamfered front edge Chamfered front edge to ensure loading onto to ensure loading onto lift lift

-Holes in base to allow Holes in base to allow circulationcirculation

-Vertical pegs to retain Vertical pegs to retain parts and provide parts and provide contact surfacecontact surface

-Material is CordieriteMaterial is Cordierite

-2 pegs in rear for 2 pegs in rear for stabilitystability

-Chamfered front edge Chamfered front edge to ensure loading onto to ensure loading onto lift lift

-Holes in base to allow Holes in base to allow circulationcirculation

-Vertical pegs to retain Vertical pegs to retain parts and provide parts and provide contact surfacecontact surface

-Material is CordieriteMaterial is Cordierite

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Design Details - MountingDesign Details - Mounting

• The new system will be mounted using the existing bolt The new system will be mounted using the existing bolt holes in the end of the furnace tableholes in the end of the furnace table

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Design Details - ElectricalDesign Details - Electrical

• Electrical Circuit Electrical Circuit DiagramDiagram– Design integrates Design integrates

sensor and sensor and activates the activates the mechanism when mechanism when parts are presentparts are present

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Design Details - PneumaticsDesign Details - Pneumatics

• Pneumatic circuit diagram Pneumatic circuit diagram – Design reuses nearly all components of existing systemDesign reuses nearly all components of existing system

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Design Phase 2:Design Phase 2:

Development of Part Handling Development of Part Handling SystemSystem

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Process FlowProcess Flow

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Concepts ConsideredConcepts Considered

Conveyor ConceptConveyor ConceptConveyor ConceptConveyor Concept

Table ConceptTable ConceptTable ConceptTable Concept

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Concept ChosenConcept Chosen

Cart ConceptCart ConceptCart ConceptCart Concept

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Time SavingsTime Savings

• Assumptions:Assumptions:• 100% Utilization100% Utilization• Three shifts per dayThree shifts per day• 250 working days per year250 working days per year

• Relative Time Savings:Relative Time Savings:– Conveyor system saves 500 hours per Conveyor system saves 500 hours per

yearyear– Cart system saves 450 hours per yearCart system saves 450 hours per year– Table system saves 450 hours per yearTable system saves 450 hours per year

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Bill of Materials & CostBill of Materials & Cost

Conveyor by the WallPart Name Qty Cost

Conveyor 1 1,770.00$ Chute 1 140.00$ Landing Table 1 200.00$

Total 2,110.00$

Landing CartsPart Name Qty Cost

Chute 1 140.00$ Cart 2 400.00$ Ramp 1 160.00$ Sides on the cart 60.00$

Total 760.00$

Sharing Landing TablePart Name Qty Cost

Chute from -80 1 140.00$ Chute from CFM 1 140.00$ Table 1 300.00$ Sides on table 2 60.00$ Change Furnace Direction

Total 640.00$

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Feasibility QuestionsFeasibility Questions

• T1- Enough area to implement T1- Enough area to implement • T2- Material handlingT2- Material handling• E1- What is the lifetime of this designE1- What is the lifetime of this design• E2- Cost to implementE2- Cost to implement• E3- Required maintenance E3- Required maintenance • S1- RIT - Time available to implement S1- RIT - Time available to implement • S2- Parker -Time available to implementS2- Parker -Time available to implement• P1- Time savingsP1- Time savings• P2- Interact well with the surrounding operationsP2- Interact well with the surrounding operations• P3- Positive effect on the operator's ability to do workP3- Positive effect on the operator's ability to do work

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Feasibility AnalysisFeasibility Analysis

0

1

2

3T1

T2

E1

E2

E3

S1

S2

P1

P2

P3

Conveyor

Carts

Table

Baseline

T1 T2 E1 E2 E3 S1 S2 P1 P2 P3 Total

Conveyor 1 3 1 3 1 2 2 3 2 3 21Carts 2 3 2 3 2 3 3 2 2 3 25Table 1 3 2 3 2 3 3 2 1 3 23Baseline 2 2 2 2 2 2 2 2 2 2 20

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Cart Design Cart Design

• Ramp will be installed on top shelf of cart to match ramp on tableRamp will be installed on top shelf of cart to match ramp on table

• Cart is sufficient length to hold 10 partsCart is sufficient length to hold 10 parts

• Cart will be held against table with a quick release clampCart will be held against table with a quick release clamp

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Plan of ActionPlan of Action

• Layout & Flow AnalysisLayout & Flow Analysis

• Ergonomic & Safety AnalysisErgonomic & Safety Analysis

• Programming of Basic Stamp systemProgramming of Basic Stamp system

• Fabrication and Installation of Part Fabrication and Installation of Part Removal MechanismRemoval Mechanism

• DOE & Statistical AnalysisDOE & Statistical Analysis

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Questions?Questions?