Susana Borrero Valentín Rodolfo Rivera Maldonado University Of Puerto Rico Mechanical Engineering Department Course: Computer Aided Design Dr. Vijay K. Goyal

RTSA RTSA Play Movie Play Movie

Agenda BackgroundBackground Literature SurveyLiterature Survey Problem DescriptionProblem Description Project FlowProject Flow Final DesignFinal Design AnalysisAnalysis CostCost RecommendationsRecommendations ConclusionsConclusions

Background Automobile Industry In-line High Scale Production: In-line High Scale Production: - Over 5 MM Cars/Yr - Over 5 MM Cars/Yr Efficiency: Continuity, Reliability & Speed Efficiency: Continuity, Reliability & Speed Component Assembly Involve: Component Assembly Involve: - Repetitive Task - Repetitive Task Organization of Tools : Constant use Organization of Tools : Constant use Rotary Devices: Rotary Devices: - Electric drills, Wrenches, etc. Project Focus:

Literature Survey Existing Aids – Tool Holders PROS: – Hold – Organized – Keep Tools Identified CONS: – Not handy on the tool – Lack: Fast tool switching – Time consuming: ++ steps Standard Tool belt Drill Bit Set Tool Cabinet

Problem Description There was a need to increase efficiency in repetitive tasks that take place at the high speed production lines of the Automotive IndustryThere was a need to increase efficiency in repetitive tasks that take place at the high speed production lines of the Automotive Industry Being Rotary tools the most frequently used:Being Rotary tools the most frequently used: This was achieved through the Design & Analysis of a universal rotary device adapter, which will carry up to 6 toolbits at a time:This was achieved through the Design & Analysis of a universal rotary device adapter, which will carry up to 6 toolbits at a time: Ready - Fast switching between toolbitsReady - Fast switching between toolbits Reduce- # of steps & timeReduce- # of steps & time Reduce human effort requiredReduce human effort required Overall Line efficiency Individual task performance Rotary Tools efficiency

Project Flow Automobile Industry NEED #1 #2 #3 GENERATE IDEAS FINAL DESIGN #1 Pugh Method +/- Comparison ANALYSIS ANSYS Optimization: Minimize Weight LAGRANGE LAGRANGE StructuralAnalysis A. B. C. $$$ Final Remarks Remarks&Recommendations CONCLUSIONS CostAnalysis

Two different design ideas were considered for the design of the RTSATwo different design ideas were considered for the design of the RTSA Pugh’s Matrix Method was used to make the selectionPugh’s Matrix Method was used to make the selection #1 #2 Idea Selection

Idea 1 Off-Center Rotating Star AdapterOff-Center Rotating Star Adapter

Idea 2 Centered Rotating Star AdapterCentered Rotating Star Adapter

Pugh’s Matrix From Pugh’s Matrix, Idea 1 was selectedFrom Pugh’s Matrix, Idea 1 was selected Criteria% Scale Designs Idea 1Idea 2 ScoreWeightedScoreWeighted Production Cost (1 Unit) Weight Ease of use15001 "Universality" Appearance Visibility10001 Toolbit Switching Time

Selected Idea – Idea # 1 Universal AdapterHigh Visibility Fast Switching Holds Up To 6 Toolbits Adjustable Position Accepts Wide Variety of Toolbits Lower Cost

Optimization Method: LaGrange's Optimization MethodMethod: LaGrange's Optimization Method Focus: Minimize the Weight of the Star-shaped componentFocus: Minimize the Weight of the Star-shaped component Due to the component is symmetry: Analysis of 1 segment Due to the component is symmetry: Analysis of 1 segment SegmentStar-shape component

Optimization Design VariablesDesign Variables All six design variables are the dimensions that define the star’s volume

Optimization Objective Function: W = mg/gc = ρgV = ρg(A T t) f(x) = (A T t)

Inequality Constraints Thickness RangeThickness Range Bending MomentBending Moment Width of ExtremitiesWidth of Extremities Lenght of ExtremitiesLenght of Extremities

Equality Constraints Length “L 2 ”Length “L 2 ” Length “L 1 ”Length “L 1 ” Dimension “a”Dimension “a” Dimension “h”Dimension “h” h 1 (X) = X 3 – R + X 1 cos(30) = 0 h 2 (X) = X 4 – X 3 + X 1 /2 = 0 h 3 (X) = 2X 5 – X 1 + d = 0 h 4 (X) = X 6 – X 1 cos(30) = 0

Optimization Results The dimension obtained from the optimization analysis comply with K-T conditionsThe dimension obtained from the optimization analysis comply with K-T conditions Analysis give us the following results:Analysis give us the following results: f(x) = (A T * t) = Volume = in 3 W = ρgV = ρg(A T t) = Weight= lbs (Feasible Weight) Adapter

ANSYS After optimizing the design, it was verified using an FEM analysis : ANSYSAfter optimizing the design, it was verified using an FEM analysis : ANSYS Geometry and Mesh Force & Restrictions 30 lbs

Stress Plots The maximum stress due to a point load of 30 lbs = psi Note: Does not exceed our yield strength

Stress Plots - Animation

Deflection Plots The maximum deflection is 0.15 in, when 30 lbs are applied at the end 30 lbs Restricted end

Deflection Plots - Animation

Cost Analysis Total Cost: $64 Great cost for such incredible features!

Final Design After all relevant analyses performed:After all relevant analyses performed: Final Design: RTSA Final Design: RTSA

Recommendations In the case the RTSA were to be produced in mass numbers: FEA analysis should be performed on the unit for other conditions:FEA analysis should be performed on the unit for other conditions: - Manufacturing conditions: - Manufacturing conditions: * Thermal & Shear stresses due to casting and others * Thermal & Shear stresses due to casting and others Optimization of other components should be performed to ensure only the best quality product is produced:Optimization of other components should be performed to ensure only the best quality product is produced: - RTSA Cylinder arm - RTSA Cylinder arm - RTSA adjustable ring - RTSA adjustable ring

Conclusions The different studies performed show the RTSA to : Guarantee a reduction of steps and time to your overall processes Excel under harsh machine shop conditions Minimize human effort required to perform repetitive tasks Break the standards in tool-handling products available today Increase Gross Production Volume, and Company's overall savings Provide the perfect opportunity to convert a problem of inefficiency into an extraordinary profitable solution to your Industry$$$

Questions ?