1. Brazing Saddles ( Team 15) Client: Parker-Hannifin Faculty Mentor: Dr. Kevin Kochersberger Faculty Coordinator: Dr. Paul Stiebitz Preliminary Design Report February 21 st, 2003 Brazing Saddles ( Team 15) Client: Parker-Hannifin Faculty Mentor: Dr. Kevin Kochersberger Faculty Coordinator: Dr. Paul Stiebitz Preliminary Design Report February 21 st, 2003 Ethan Bagley Melissa Curtin Paul Diedrich Charles Gullo Fulya Tezer Tom Wild

2. 2 Agenda  Problem Statement  Design Phase 1  Design Phase 2  Plan of Action

3. 3 Problem Statement Current braze furnace process:Current braze furnace process: –Operator loads one part every six minutes –Operator must walk 40 feet to opposite end of furnace to retrieve each part –Part removal system currently unreliable

4. 4 Project Goals Design Phase 1: Part removal mechanismDesign Phase 1: Part removal mechanism –Key issues: Part stabilityPart stability System autonomySystem autonomy Design Phase 2: Part Handling SystemDesign Phase 2: Part Handling System –Analysis of Layout in Brazing Area FlexibilityFlexibility

5. 5 Design Phase 1: Development of Mechanical System

6. 6 Concept Development AugerAuger –Rotating coil translates parts from conveyor to staging area Swing ArmSwing Arm –Revolving member pushes parts from the conveyor to the staging area ForkliftForklift –A lifting device raises the parts off the conveyor and a horizontal thruster pushes them to staging area

7. 7 Feasibility Assessment

8. 8 Further Concept Development Original Fork Lift ConceptOriginal Fork Lift Concept –Interlocking perpendicular pairs of forks –First pair raises parts off belt vertically –Second pairs slides into first and reroutes parts towards staging area

9. 9 Concept Development (cont.) Modified Fork Lift ConceptModified Fork Lift Concept –Rotating ramp attached to a small winch –Parts are pushed onto ramp by conveyor –Ramp rotates to stabilize parts

10. 10 Concept Development (cont.) Final Fork Lift ConceptFinal Fork Lift Concept –Parts are pushed onto flat plate by conveyor –Vertical thruster raises part off conveyor –Horizontal thruster (ram) pushes part towards staging area Thrusters are pneumatic actuatorsThrusters are pneumatic actuators Design requires uniform part holdersDesign requires uniform part holders

11. 11 Design Details - Boats New boat designed to carry the existing part holdersNew boat designed to carry the existing part holders -2 pegs in rear for stability -Chamfered front edge to ensure loading onto lift -Holes in base to allow circulation -Vertical pegs to retain parts and provide contact surface -Material is Cordierite -2 pegs in rear for stability -Chamfered front edge to ensure loading onto lift -Holes in base to allow circulation -Vertical pegs to retain parts and provide contact surface -Material is Cordierite

12. 12 Design Details - Mounting The new system will be mounted using the existing bolt holes in the end of the furnace tableThe new system will be mounted using the existing bolt holes in the end of the furnace table

13. 13 Design Details - Electrical Electrical Circuit DiagramElectrical Circuit Diagram –Design integrates sensor and activates the mechanism when parts are present

14. 14 Design Details - Pneumatics Pneumatic circuit diagramPneumatic circuit diagram –Design reuses nearly all components of existing system

15. 15 Design Phase 2: Development of Part Handling System

16. 16 Process Flow

17. 17 Concepts Considered Conveyor Concept Table Concept

18. 18 Concept Chosen Cart Concept

19. 19 Time Savings Assumptions:Assumptions: 100% Utilization100% Utilization Three shifts per dayThree shifts per day 250 working days per year250 working days per year Relative Time Savings:Relative Time Savings: –Conveyor system saves 500 hours per year –Cart system saves 450 hours per year –Table system saves 450 hours per year

20. 20 Bill of Materials & Cost

21. 21 Feasibility Questions T1- Enough area to implementT1- Enough area to implement T2- Material handlingT2- Material handling E1- What is the lifetime of this designE1- What is the lifetime of this design E2- Cost to implementE2- Cost to implement E3- Required maintenanceE3- Required maintenance S1- RIT - Time available to implementS1- RIT - Time available to implement S2- Parker -Time available to implementS2- Parker -Time available to implement P1- Time savingsP1- Time savings P2- Interact well with the surrounding operationsP2- Interact well with the surrounding operations P3- Positive effect on the operator's ability to do workP3- Positive effect on the operator's ability to do work

22. 22 Feasibility Analysis

23. 23 Cart Design Ramp will be installed on top shelf of cart to match ramp on tableRamp will be installed on top shelf of cart to match ramp on table Cart is sufficient length to hold 10 partsCart is sufficient length to hold 10 parts Cart will be held against table with a quick release clampCart will be held against table with a quick release clamp

24. 24 Plan of Action Layout & Flow AnalysisLayout & Flow Analysis Ergonomic & Safety AnalysisErgonomic & Safety Analysis Programming of Basic Stamp systemProgramming of Basic Stamp system Fabrication and Installation of Part Removal MechanismFabrication and Installation of Part Removal Mechanism DOE & Statistical AnalysisDOE & Statistical Analysis

25. 25 Questions?