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Hydraulic Press Loading SystemDesign

Hydraulic Press Loading SystemDesign

Ben Snyder

Jeff Rogers

Jina Miller

Ali Saeed

ME 462 Capstone Design

May 5, 2005

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Moving the Press in a New DirectionMoving the Press in a New Direction

Existing presses

Large force ranges

Difficult to control

and operate Not bi-directional

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Main RequirementsMain Requirements

Precise bi-directional operationUse of Bishop-manufactured rack and

pinion assembly

12-15 Ton loading capacity

Cost

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Scope of DesignScope of Design

Control System

Hydraulics

System Interfaces

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Control System DesignControl System Design

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Pinion AssemblyPinion Assembly

Pre Existing

Modeled in Pro-E to help determine otherdimensions

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Rack & Pinion Support ComponentsRack & Pinion Support Components

Housing Block

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Rack & Pinion Support ComponentsRack & Pinion Support Components

Housing Block Clamp

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Rack & Pinion Support ComponentsRack & Pinion Support Components

Bearing Housing

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Rack & Pinion Support ComponentsRack & Pinion Support Components

Rack Guide

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Rack & Pinion Support ComponentsRack & Pinion Support Components

Base Plate

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HydraulicsHydraulics

Power Pack

Cylinder

Hoses and Fittings

Maximum Shaft Diameter for

Various Cylinder Bores

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

4.0 5.0 6.0 7.0 8.0 9.0

Cylinder Bore (In)

MaximumS

haft

Diameter(In)

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InterfacesInterfaces

Grounding the Control System

Control System to Hydraulics

Control System to Operator

Bishop I to Bishop II

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InterfacesInterfaces

Grounding theControl System

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InterfacesInterfaces

Control System toHydraulics

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InterfacesInterfaces

Control System toOperator

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InterfacesInterfaces

Bishop 1 to Bishop 2

Attachment of Cylinder

Location of Steering Wheel

Clearance to Back PlateAttachment of Power Pack

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Final AssemblyFinal Assembly

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Hydraulic Press EvaluationHydraulic Press Evaluation

Based on Engineering Targets

Some were unable to be verified

Three parts:

FEA

Physical TestingCost Analysis

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Finite Element AnalysisFinite Element Analysis

To ease machining and reduce corrosion,aluminum was desired.

FEA was performed to prove it was up to thejob.

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TestingTesting

Designed to test engineering targets

A test procedure for the remaining

portions can be found in the report.

Testing consists of various operationsusing a load cell, stop watch, etc.

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Engineering Target VerificationEngineering Target Verification

Maximum Pressure: 12.37 tons

Number of Applications: 2

Stroke Time: 5.7 cycles per minute

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CostCost

Initially, price was desired to be $1500 to

$1800.Prototype: $2922

Mass Produced: $1834 (est.)

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Other ConsiderationsOther Considerations

Due to time constraints, an unloadingvalve was not installed

Until performance of extended test,maintenance estimates cannot be done.

No physical testing can be performed.

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PerformancePerformance

Safety

Watch fingers!

Environmental issues

No impact

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RecommendationsRecommendations

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ConclusionConclusion

Meets requirements

Accurate

Efficient

Marketable

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Questions & CommentsQuestions & Comments