1. Glass Cutting Wire Saw Senior Design Team P16601: Guide Rollers
Team: Ryan Cavanaugh (EE), Samantha Degerick (ME), Evan Ney (ME), Noah Stransky (ME), Quincey Stuck (ISE), Viniamin Tokarchuk (EE), Kenneth Wilkinson (ME)
Faculty Guides: Edward Hanzlik
Customer: Glass Fab of Rochester NY
Problem Statement: Our team is one of three teams that was tasked to create a scaled down, more energy efficient glass wire cutting machine. Our team specifically is the guide roller team, that is responsible for developing the guide roller assembly of the industrial glass cutting wire saw. These guide rollers will rotate back and forth simultaneously, causing a wire to move with very high precision. The two guide rollers must speed up, slow down, and move at constant velocity without causing the wire to stretch and/or break.
Engineering Requirements:
Key Objectives of P16601:
1. Create a wire cutting machine that is efficient for low volume production
2. Design a set of downsized motor powered guide roller to be used in future wire cutting machine
3. Increase operator value-added time
Metric Benchmarking:
Metric
Current Machine
Proposed
Roller Diameter
320 mm
Roller Length
840 mm
420 mm
Roller Weight
130 kg
58 kg
Drive Output
2 x 47 kW
2 x 5.5 kW
Number of Cuts
4100 cuts
cuts
Final Design:
Next Steps:
1. Transfer all acquired knowledge to customer for future improvements/senior design teams
2. Receive quotes for parts that have completed design
3. Begin purchasing custom parts and assemble fixture.
Potential Future Improvements:
1. Remove polycarbonate sheeting and replace with metal screen and door
2. Add water lines around areas that will see high amounts of slurry
Special thanks to Glass Fab Inc., Professor Hanzlik, Machine Shop, Professor Wellin, Tom Bitter, Russ Phelps, Dave Cicero