1. 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

2. 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

3. 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

4. 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

5. Basic Assembly
Components
Completed Assembly

6. Current Process
Assembly Process

7. Proposed Design

21. Ergonomic Analysis 5th percentile female reach = 26.7”
Paddle handles in design = 11”
5th percentile female forearm to forearm breadth = 16.3”
Two-hand tie down push buttons= 12”

22. ANSYS Analysis

23. Material Properties Used - Bottle
Tensile Modulus 35 Ksi.
Poisson’s Ratio 0.38
Density lb/in³.
Yield Tensile Strength 1120 psi

24. Boundary Conditions for current method of assembly

25. Deformation for current method of assembly

26. Max Principal Stress for current method of assembly

27. Boundary Conditions for Proposed Assembly Method

28. Deformation for Proposed Assembly Method

29. Max Principal Stress for Proposed Assembly Method
Max Principal Stress = 159 psi.

30. 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.

31. 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

32. Boundary Conditions Surface are of latch in Y = 6 in
Pressure = F/A = sin 45 * 63 / 6 = 7.425
Surface are of latch in X = 0.5 in
Pressure = F/A = cos 45 * 63 / 0.5 =
Distributed Pressure simulating force of 63 lb transmitted by latch
Fixed Support

33. Total Deformation (in)

34. Von Mises Stress (psi)

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

36. New Boundary for Worst Case using a line pressure of 100 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 =
Distributed Pressure simulating force of 90 lb transmitted by latch
Fixed Support

37. Total Deformation

38. Von Mises Stress

39. Boundary Conditions for Complete Assembly

40. Mesh

41. Von Mises Stress
Max Stress =279 psi

42. Max Von Mises

43. Max Von Mises

44. Pneumatic Diagram

45. Bill of Materials

46. Process Flow

47. Current Layout

49. Future Layout

52. Proposed Layout

55. Senior Design II Schedule