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. Figure 1b: Figure 1a: Shows the basic components needed for assembly
Shows a complete assembly

6. Figure 2b: Figure 2a: Figure 2c:
First step in the assembly process; Spout is inserted into tool
Figure 2a:
T-shaped tool used to complete assembly
Figure 2c:
Operator completing assembly by applying force to bottle

7. Proposed Design

25. ANSYS Analysis

26. 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.

27. 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

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

29. Boundary Conditions for Worst Case (Line pressure of 90 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 =
Zero displacement in y
Distributed Pressure simulating force of 90 lb transmitted by latch Y
Zero displacement in x and z X

30. Max Deflection (Line pressure of 90 psi)

31. Von Mises Stress
Factor of Safety = Sy/ Max V.M. = psi / 986 psi = 40.57

32. Old Boundary for Worst Case (Line pressure of 90lb)
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

33. Total Deformation

34. Von Mises Stress
Factor of Safety = Sy/ Max V.M. = psi / 700 psi = 57.14

35. Two blocks attached by bolts
Comparison Table
Two blocks attached by bolts
One Main Block
Factor of Safety
40.57
57.14
Total Displacement in in

36. Dimensions Used for Bracket

37. Boundary Conditions Material = AISI 1016 E= 29700 ksi Sy=50.8 ksi
Su= 60.9 ksi
P=F/A=90/.63 = psi Y Z X
To simulate 1/8 Screws
Zero displacement Y
Zero displacement in X and Z

38. Max Deflection

39. Max Deformation in Y

40. Max Von Mises
Factor of Safety = Sy / Max V.M = / 3821 = 12.95

41. Pneumatic Diagram

42. Bill of Materials

43. Manufacturing Plan

44. Test Plan 1 week (5 days), 18 hours per day (broken into shifts)
Goal: 54,000 cycles with no failures
2 cases per size for a total of 6 cases with zero defects and scratches across all bottles
Test that all 6 cases are completed with an average cycle time of 10 seconds or less per bottle
Test 10 consecutive emergency stop conditions
Complete disassembly and reassembly in 2 hours or less
Change between bottle sizes in under 10 minutes with ideal time of 5 minutes

45. Process Flow

46. Current Layout

48. Future Layout

50. Proposed Layout