Daimler Chrysler Car Transport Upgrade Team #3 John Barr Aladrian Crowder Hilary Goldman Matt Reber

Background Information Daimler-Chrysler Newark Assembly Plant Assembly Process: 3 phases of production Paint Shop: workings and history Transport System: difference from plant norm Phosphate and E-coat Process Accumulation Lines: unique conveyor system

Accumulation Lines Skids go into holding pattern when production is down 5 accumulation lines, each 200 feet long Motor driven chain with high rollers

Accumulation Line Video

Problem Definition Destructive nature of friction and wear from accumulation chains has caused severe damage to skids used in paint shop. Worn skids must be replaced and system must be modified to decrease effects of friction and wear.

Other Effects to System Cast iron rollers showing same wear pattern as skids. Worn skids fall off rollers – leads to down time and lost money

Life of System Components A new fleet of approximately 80 skids are going to replace the current model, after 6 years of use. Drive motors for accumulation chains are being over-worked. All 826 cast iron rollers and bearings are being replaced.

Mission Statement To develop a concept and working design that will significantly decrease the wear experienced by the skids.

Wants/Metrics Wants Cost Performance System Compatibility Metrics Price Wear Rate

Wear Model Primary material property affecting wear rate is hardness. Wear rate is inversely related to material hardness by Archard’s Equation: V=volume, K=wear rate, F=force, L=sliding distance, H=hardness

Concept Development Initial Brainstorming Increase wear resistance Eliminate wear Increase Wear Resistance Alter hardness of current material Add sacrificial wear material Eliminate wear Break contact between skid and chain

Increase Wear Resistance Alter Hardness of Current Material Flame or Induction Hardening Suitable for 1045 steel Other properties of material do not change Wear-resistant coating Bottom of skid directly hardened

Increase Wear Resistance Addition of Sacrificial Wear Material Plastics Good wear characteristics Easily machined Metals Attach to skids quickly Used in similar applications in industry Wear pad Skid

Eliminate Wear Break Contact Between Skid and Chain Mechanically lift skid off accumulation chain Reduces power drawn by motor to drive chain Change to system is localized

Concept Comparison Wear pads Plastic Pad Fails due to PV limit Cost far greater than other concepts Metal Pad Industrial norm Inverse effect on other components of system Hardening Effects only a minimal depth Similar effects of metal wear pad Lifter One time application requiring periodic maintenance More complicated solution

Concept Selection MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids MECHANICAL ENGINEERING CONCEPT MATERIAL ENGINEERING CONCPET Reduce Wear Lifting skids off the accumulation chain will eliminate contact of skid bottoms and chain rollers Hardening bottom surface of the skids will reduce the wear rate on bottom of skids

Support for Skid Lifter Eliminates wear on skids Increases life of accumulation chain Saves energy Reduces drive motor work-load Has no effect on other system components

Skid Lifter Components Skid Lifter Geometry Lifting Power Structural Design

Geometry Design of lifter limited by space Must remain contained in existing accumulation line area Goal – minimize volume of lifter

Lifting Power Mechanical Screw jack Hydraulic Oil Large forces Pneumatic Air Clean

Pneumatic Power Used extensively in paint shop Clean Low maintenance and reliable Last for 1,000 miles of rod travel Seals need replaced once every two years Valves good for 1,000,000 cycles

Structural(mechanical?) Design Simple machines implemented to provide lift Inclined plane and wheel Greater distance needed, but less energy Down Position Up Position

Structural Design Basic design repeated every 10 feet

Space To keep the accumulation area structurally sound, and the design of the lifter small, it was decided to be contained within area shown.

Skid Lifter Design Pneumatic cylinder will provide force Simple machines implemented to provide lift Inclined plane and wheel

Video clip of lifter

Testing

Gantt Chart TBD

Handoff Plan Complete design specifications Individual component design Sub-assembly design Assembly instructions Controls and Safety Logic Company procedure

Questions