Senior Design I – Project Review P07008 – ArcWorks Wash Bottle Assembly Team Members: Sagar Sheth Team Leader Leonardo Silva Industrial Eng. Stephen Bennice Mechanical Eng. Gabriela Jaramillo Mechanical Eng. Eric Van Hemel Mechanical Eng. Robert Veiders Mechanical Eng. Eng.Faculty Guides: Dr. DeBartolo Dr. Marshall

Project Objective’s Design automated process incorporating all three bottle sizes Reduce human contact with bottle during assembly process Minimize rejected assemblies Apply lean concepts to wash bottle production line

Key Customer Needs Can accommodate different size bottles Should be able to produce large quantities of assemblies Should require minimal force to complete assembly Should create good assemblies The unit should not create additional disabilities for the operators

Key Engineering Metrics Demonstrate that 6 cases of different size bottles can be assembled with average cycle time not exceeding 10 seconds No intervention between the operator and the machine while actual assembly Demonstrate the force required to complete assembly is less than the minimal force required to complete assembly manually for a bottle Produce good assemblies Demonstrate assembly of spout to bottle for at least 2 cases per size

Figure 1b: Figure 1a: Shows the basic components needed for assembly Shows a complete assembly

Figure 2b: Figure 2a: Figure 2c: First step in the assembly process; Spout is inserted into tool Figure 2a: T-shaped tool used to complete assembly Figure 2c: Operator completing assembly by applying force to bottle

Proposed Design

ANSYS Analysis

Finding Maximum Force that can be applied to bottle Same boundary conditions as for Proposed Assembly Method Taking Yield Tensile strength for LDPE as 1120 psi Maximum force found is 175 lb.

Background for Main Block FEA Given a Cylinder constant K = 0. 9 Given a constant air line pressure P = 70 psi Total force applied to latch = K * P = 63 lb Force is applied to latch at 45° angle Assumed force is distributed throughout the latch and then transmitted to main block Latch Main Block

Material Properties Used Aluminum 6061-T6 E= 10 000 ksi V= 0.33 Sy = 40 ksi Su = 45 ksi Max Von Mises stress = 490.622 psi

Boundary Conditions for Worst Case (Line pressure of 90 psi) Surface are of latch in Y = 6 in Pressure = F/A = sin 45 * 90 / 6 = 10.61 Surface are of latch in X = 0.5 in Pressure = F/A = cos 45 * 90 / 0.5 = 127.28 Zero displacement in y Distributed Pressure simulating force of 90 lb transmitted by latch Y Zero displacement in x and z X

Max Deflection (Line pressure of 90 psi)

Von Mises Stress Factor of Safety = Sy/ Max V.M. = 40 000 psi / 986 psi = 40.57

Old Boundary for Worst Case (Line pressure of 90lb) Surface are of latch in Y = 6 in Pressure = F/A = sin 45 * 90 / 6 = 10.61 Surface are of latch in X = 0.5 in Pressure = F/A = cos 45 * 90 / 0.5 = 127.28 Distributed Pressure simulating force of 90 lb transmitted by latch Fixed Support

Total Deformation

Von Mises Stress Factor of Safety = Sy/ Max V.M. = 40 000 psi / 700 psi = 57.14

Two blocks attached by bolts Comparison Table Two blocks attached by bolts One Main Block Factor of Safety 40.57 57.14 Total Displacement 0.000983 in 0.000845 in

Dimensions Used for Bracket

Boundary Conditions Material = AISI 1016 E= 29700 ksi Sy=50.8 ksi Su= 60.9 ksi P=F/A=90/.63 = 142.86 psi Y Z X To simulate 1/8 Screws Zero displacement Y Zero displacement in X and Z

Max Deflection

Max Deformation in Y

Max Von Mises Factor of Safety = Sy / Max V.M = 50800 / 3821 = 12.95

Pneumatic Diagram

Bill of Materials

Manufacturing Plan

Test Plan 1 week (5 days), 18 hours per day (broken into shifts) Goal: 54,000 cycles with no failures 2 cases per size for a total of 6 cases with zero defects and scratches across all bottles Test that all 6 cases are completed with an average cycle time of 10 seconds or less per bottle Test 10 consecutive emergency stop conditions Complete disassembly and reassembly in 2 hours or less Change between bottle sizes in under 10 minutes with ideal time of 5 minutes

Process Flow

Current Layout

Future Layout

Proposed Layout