Lightnin SPX Test Stand Aditya - Oriana - Don - Jesse - Ron - Dana - Geoff

2 Team Members Aditya Sanghi, IE Project Leader Geoffrey Cusano, ME Dana Harris, IE Ron Mendolera, EE Oriana Starr, ME Don Strong, ME Jesse Warner, EE

3 Project Overview Sponsor: Lightnin SPX Manufacture: pumps, mixers, valves, fittings, mills, heat exchangers, and process systems Gear reducer production moved to Rochester, NY from Wytheville, VA

4 Project Overview, cont. Six-month project: evaluate process inefficiencies & propose solutions  Constraints: time, cost, footprint & height  Avoid bottlenecks and hazardous workstations

5 700/800 Series Mixer Gear reducer

6 Process Flow Distance ~ 500 ft

7 Assembly Stand Side Front

8 Spin Test & Assembly Area

9 Torque Stand Side Front

10 Project Mission Statement The mission of the project with Lightnin SPX is to substantially improve the current cycle time of testing reducers while efficiently accommodating reducers of various sizes and configurations within the current assembly space available.

11 Needs Assessment Order Qualifiers & Winners  Cost to build SHALL NOT exceed $200,000  Return On Investment  Labor savings  Design software to be used: Inventor  Utilize existing equipment Scope  2-3 detailed concepts

12 Concept Development Level 0: Station setup Three Stations Two Stations One Station

13 Concept Development Transportation  Rail system, wheels, rotary arm, trolley, etc. Slave unit  Pump, two gears, electric generator, etc. Attachment of test unit to stand  Clamps, magnets, pins, bolts, etc.

14 Feasibility Assessment Level 0: Station Setups

15 Feasibility Assessment Level 1: Feasibility of station designs  Compare five designs based on the two best setup options  Included transportation options  Pugh’s Method resulted in 3 Feasible Preliminary Designs

16 Analysis - Option 1 Two Station Design Features  Assembly  Spin  Transport  Torque Advantages Disadvantages

17 Analysis - Option 2 All-in-One Lift and Rotate Features  Assembly  Spin  Transport Lift Forklift  Torque Advantages Disadvantages

18 Analysis - Option 2 All-in-One Lift and Rotate Features  Assembly  Spin  Transport Lift Forklift  Torque Advantages Disadvantages

19 Analysis – Option 3 All-in-One Assembly on Rails Features  Assembly  Spin  Transport  Torque Advantages Disadvantages

20 Future Plans - Senior Design II Analysis  FEMA  Time studies Software Analysis  FEA: ANSYS  Simulation: Arena  Ergonomics: 3DSSPP

21 Project Plan – Senior Design II

Questions ?