capstone senior design project - csu, chico · capstone senior design project large hose cutting...
TRANSCRIPT
![Page 1: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/1.jpg)
Capstone Senior Design Project
Large Hose Cutting Machine
Final Design Presentation
![Page 2: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/2.jpg)
Project Team Members and Advisor
MohsenAlmohammed
Mechanical Engineering
JulioHernandez
Mechanical &MecatronicEngineering
BrettKarr
Mechanical Engineering
Kelly Womack
Mechanical Engineering
Webster Johnson
Mechanical Engineering
![Page 3: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/3.jpg)
Project & Sponsor Background
� Fab-in-house fuel system products
� Local company
� Build 10,000 fuel systems annually
� Use hundreds of thousands of rubber hose per year
![Page 4: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/4.jpg)
Current Machine
Current Hose Cutting Machine
• Works with spooled hose• Cuts smaller diameters
36” Hose Stocks
Continuous Unspooled Hose
![Page 5: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/5.jpg)
Current Problem
Band Saw Debris
�Problem
� Poor edge finish
� Inconsistent Edge Finish
� Permanent Deformation
� Debris
� Time Consuming
� Employee Injury
Hand Shears
![Page 6: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/6.jpg)
Project Specifications
Must Do Should Do Would Be Nice
� Cut ¾-3” diameter hose
� Clean cut- burr size <.15in
� Smooth- frays <1.5mm
� Perpendicular cut- angle ± 5°
� Maintain 2% length accuracy
� No Debris
� Meet OHSA safety standards
� Use Mach 3 G-Code
� Safety Factor >2
�Setup time <5 min
� Drive hose 1
in/sec
�Accommodate All
hose sizes
�Off-the-shelf parts
�No hardware
change
� Indicator light for
system stages
• Magazine Feeder
• Download job
specs
![Page 7: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/7.jpg)
TFI Hose Cutting Work CenterDesign Solution
Drive System2 Stepper Motors1 Pneumatic Actuator
Compression System1 Stepper Motor
Cutting Mechanism1 Pneumatic Actuator
![Page 8: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/8.jpg)
Design Solution
Drive Mechanism• Roller velocity at .5in/s• 2 NEMA 23 motors at 233 in-oz• 1.5” Actuator supplying 21lb force
![Page 9: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/9.jpg)
Design SolutionCutting and Compression• Cutting 4” actuator- ~1200lb Force• Compression NEMA 23 w/ 450 in-oz Torque
![Page 10: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/10.jpg)
Design Solution
Safety Cover
![Page 11: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/11.jpg)
Fabrication
![Page 12: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/12.jpg)
Testing
� Setup Time
� Cutting
� Edge Fray
� Debris
� Perpendicularity
� Length Accuracy
![Page 13: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/13.jpg)
Testing-Setup Time
Specification:Setup Time <5min
Test parameters• Load Program• Enter Data
100% Design Compliance
Specification Met
0
100
200
300
400
500
600
0 20 40 60S
etu
p T
ime (
s)
# Fuel Hoses
Setup Time
![Page 14: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/14.jpg)
Testing-Cutting
Specification:Cut? (yes/no)
Test parameters� Run test fully automated
� All hose types
100% Design Compliance
Specification Met
05
101520253035
ThroughCut
AcceptableCut
No Cut# o
f H
oses
Hoses Cut
![Page 15: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/15.jpg)
Testing-Edge Fraying
0
0.3
0.6
0.9
1.2
1.5
1.8
0 20 40 60Fra
y L
en
gth
(m
m)
# of Hoses
Fray Length
Specification:Fray Edge <1.5mm
Test parameters• Run test fully automated
100% Design Compliance
Specification Met
By Default: Debris Specification Met
![Page 16: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/16.jpg)
Perpendicularity Testing
0
2
4
6
8
0 20 40 60Perp
en
dic
ula
rity
(d
eg
)
# of Hoses
Perpendicularity ≤1” ID
0
2
4
6
8
0 5 10 15 20Perp
en
dic
ula
rity
(d
eg
)
# of Hoses
Perpendicularity >1" ID
Specification:
Angle ± 5°for ≤ 1”Angle ± 2°for >1"
Test parameters• Run test fully automated
Degree of design compliance 96% for hoses ≤1” ID
94% for hoses >1” ID @ ± 5°
16% for hoses >1” ID @ ±2°
Specification Met
![Page 17: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/17.jpg)
Testing- Length Accuracy
Specification:5% length Accuracy ≤3”
(2.85 min and 3.15 max)
Test parameters• Run test fully
automated
97% Design Compliance
Specification Almost Met
0%
2%
4%
6%
8%
10%
0 20 40 60
% L
en
gth
Accu
rac
y
# of Hoses
% Length Accuracy
![Page 18: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/18.jpg)
Reflection and Design Suggestion
Linear slide • Ball screw binding
• Max force 56 lb• Max torque 15 in-oz
• Decreased compression plate size
![Page 19: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/19.jpg)
TFI Project Thanks
Todd LaPant
Director ofEngineering
Joseph Baldi
Mechanical Engineering
John Buss
Mechanical Engineering
Chris McClurg
Research and Development
Ignasio Sucedo
MaintenanceSupervisor
![Page 20: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/20.jpg)
Final Budget ~58,000$
![Page 21: Capstone Senior Design Project - CSU, Chico · Capstone Senior Design Project Large Hose Cutting Machine Final Design Presentation. Project Team Members and Advisor Mohsen Almohammed](https://reader033.vdocument.in/reader033/viewer/2022042308/5ed46f815e2d82034d643ac0/html5/thumbnails/21.jpg)
Conclusion & Questions
This machine is: • Safe
• Versatile
• Repeatable
• Robust
• Modular
• Off-the-shelf
• Fully automated
Specification Spec Met % Compliance
Cut Hose Yes 100%
Fray Length Yes 100%
Burr Size Yes 100%
PerpendicularityAngle ± 5°for <=1” Angle ± 5°for >1”
AlmostAlmost
96%94%
Length % Accuracy Almost 96%
Debris Yes 100%
Setup Time <5min Yes 100%