1. AGITATOR REDESIGN FOR CORROSIVE ENVIRONMENT Kate Karauda Luigi Abbate Will Fritzinger Peter Torab

2. Project Overview  Sponsored by Coating Technology Inc.  Goal is to redesign the agitator system for greater corrosion resistance and longer life

3. Current Tank Layout

4. Current Cam System

5. Failed Hardware Analysis

10.  First impressions:  Worm gear not suitable for this application  Current process puts severe load on motor/gearbox  Many wear points  Failed motor did not appear to be affected by corrosion Will conduct more detailed motor analysis

11. System Requirements

13. Solutions 123456 Sub Functions 1 Create flow over entire surface High pressure sprayLow pressure mist Move fluid via propeller Move parts linearlyMove parts radially Ultrasonic vibration 2 Create flow through capillaries High pressure spray Move fluid via propeller Move parts vertically Move parts horizontally Move parts radially Ultrasonic vibration 3 Minimize chemical bath degradation Decrease cycle time Limit contaminates above/around tank Cover tank Stabilize bath temperature and properties 4Maintain bath temperature Use current systems, address if needed Heater 5 Maintain homogeneous mixture Keep solution agitated Circulate via pump 6 Reduce corrosive environment exposure of system Move system away from tank vapors Install vapor hood system Corrosive vapor shielding Forced air 7 Increase corrosion resistance of materials Select corrosion resistant materials Apply corrosion resistance coating to materials 8Operating instructionsPrepare handbookPrepare videoMaintenance tablePowerpointGraphics on system 9Cover moving partsShielding Reduce number of joints and pinch points Controls in safe spot 10Limit exposure to chemicals Move system away from tank vapors Install vapor hood system Personal respiration devices (PPE) Increased ventilationCover tank Morphological Chart

14. Datum1234 Sub Function s 1 Create flow over entire surface Move parts vertically High pressure spray Move fluid via propeller Move parts radiallyUltrasonic vibration 2 Create flow through capillaries Move parts vertically High pressure spray Move fluid via propeller Move parts radiallyUltrasonic vibration 3 Minimize chemical bath degradation N/A Recollect fluid, seal system No Change Covered tank, less fluid used 4 Maintain bath temperature Current system Use current systems, address if needed Included Heater 5 Maintain homogeneous mixture Keep solution agitated N/A 6 Reduce corrosive environment exposure of system Cover over tankN/A Move system away from tank vapors N/A 7 Increase corrosion resistance of materials N/A Select corrosion resistant materials 8 Operating instructions Word of mouthPrepare handbook 9 Cover moving parts N/A Protective bars over propeller Cover shaftN/A 10 Limit operator exposure to chemicals Cover over tankEnclosed tankCover over tank Enclosed tank Pugh Chart

15. SprayPropellerRotationalUltrasound CriteriaDatum1234Criteria A DATUM -S+-ACost B+ +++BOperating costs C-+++CEase of use D-+-+DAvailability ES+++EMaintenance F++++F Corrosion resistance G++++GFatigue H++++HLifetime I++++IAesthetics J+S++JPerformance KS+++KSafety LS+++LErgonomics +61011 Score-3011 S3200 Pugh Chart

16. System Design 1 - Rotational  Vertical Axis Rotary Motion  ‘Carousel’ with part mounts  Corrosive resistant materials  Motor and gearbox moved away from vapors

17. System Design 1 - Rotational  Can utilize current tank framework  Limited corrosion exposure  Fewer moving parts than current system  Increased motor/ gearbox lifetime  Difficult to accommodate different size dies  Need new die fixtures  May be difficult to access parts  More custom parts ProsCons

18. System Design 2 - Ultrasound  Off-the-shelf ultrasonic cleaning unit  Built-in temperature control  Small unit can accommodate 1-3 dies

19. System Design 2 - Ultrasound  Significantly decreased cycle time  Built-in heater  Smaller batches of fluid used  No minimum number of parts to run/batch  Versatile  High initial cost for commercially available systems  Completely replace current system  Repairs may be through an outside company ProsCons

20. Design Areas Not Yet Complete  Rotational motion vs. Ultrasonic  Complete capillary force calculations  Corrosion testing and process validation  Off-shelf part selection  Detailed component design

21. Corrosion Testing  Polarization Cell  Measured current is proportional to the rate of metal stripping  Stripping rate will be proportional to bath decomposition rate.  Variable Corrosion Testing  https://edge.rit.edu/edge/P13656/public/WorkingDo cuments/Review%20material/Variable%20corrosion% 20Chart.pdf

22. Project Schedule  Current Action Items:  Pick a design to satisfy customer needs  Defining test conditions for the prototype design  Document and investigate previous failure modes  Invite the customer for Systems Decomposition Review