October-November 2018, TRENTO (IT) Info: proto-challenge ......PROSIZE Sizing machines for natural...
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October-November 2018, TRENTO (IT) Info: [email protected]
Transcript of October-November 2018, TRENTO (IT) Info: proto-challenge ......PROSIZE Sizing machines for natural...
October-November 2018, TRENTO (IT)Info: [email protected]
Example of submitted
PROBLEM
The company
PROSIZESizing machines for natural fibres
FILSIZESizing machines for synthetic fibres
PRODYEIndigo dyeing machines for denim
All these machines share one common component: the BEAMING MACHINE (headstock):
Karl Mayer Rotal (Mezzolombardo, IT)Member of B.U. Warp Preparation
In the beaming machine the yarnis rolled onto a «beam», which is a large bobbin. The following process is weaving on a loom.
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
The productBEAM ADAPTER (hub): Interface between the machine and customer‘s beam
BEAMING MACHINE ADAPTER BEAM
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
The challenge
Operators must lift it by hand and insert in the beam
Each adapter weighs about 10 kg or more
PURPOSE OF THE CHALLENGE:Re-design the adapter in order to make it lighter, without affecting the mechanical characteristics
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Product features
Beam adapters must withstand heavy solicitations
Torque (up to 5000 Nm) Shear (up to 25 kN) Fatigue (up to 150 rpm)
Today such adapters are made of cast iron and are machined at lathe
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
SOLUTION
Initial conditions
P= 250 Mpa
F = 25 KN
F = 25 KN
Remote displacement Pressure Spindle’s weight Contact lever force
Working Loading
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
FE analysis
Stress distribution - Working Stress distribution - Loading
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Topological optimization
optimized
F = 25 KN
P= 250 Mpa
F = 25 KN
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
FE analysis
Stress distribution - Working Stress distribution - Loading
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Optimized component
Mass: from 9.5 kg to 4.5 kg (-47%)Material: from Gray cast iron to steel (tougher)Size: same, thinner
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Smaller alternative
Size: from 212mm to 160 mm external diameter
Topological optimization
FE analysis
Re-designed in InventorFE
M
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Optimized final component
3.5 kg (-66%)4.5 kg (-47%) 9.5 kg > >
© Copyright 2018 Karl Mayer Rotal. All rights reserved.
Credits
Matteo Bettinelli Alberto Comoretto
Mechatronics Engineering Department,University of Trento
Stefano AldegheriKarl Mayer Rotal
Info: [email protected]
