team air liquide senior design project 2007 process improvement of resin application system phase iv...
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![Page 1: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/1.jpg)
Team Air LiquideSenior Design Project 2007
Process Improvement of Resin Application System
Phase IV Group Presentation
Pete John
Adam Willoughby-Knox
Kevin Malik
Laura Shultz
![Page 2: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/2.jpg)
Who is Air Liquide MEDAL?
Products–Hollow fiber membranes for N2 generation, CO2 removal, and H2 purification
Applications–Oil & Gas, Laboratories, & Aerospace Industries
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Our Project:
Create an automated process to coat fibers with epoxy for filter end caps
Epoxy end caps
Process Improvement of Resin Application System
![Page 4: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/4.jpg)
Motivation
• 60 bundles lost last year– Average $25,000 per bundle– $1,500,000 loss
• Adverse Product Performance– Defects & Poor Recovery Rate
• Labor Allocation Issues– Second technician needed
![Page 5: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/5.jpg)
Current Process
technician paints ends with the special epoxy and a plain paintbrush.
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Problem Definition:
How to automate resin application?
How to create a good epoxy infiltration?
Current Process Issues:•Gas leaks•Resin wicks down the length of the fibers•Effects the efficiency of purification.•Number of Machine Operators•Resin Waste/Mess•Resin very viscous hard to work with•Variability results in loss of bundles.
![Page 7: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/7.jpg)
Problem Definition
• What characteristics define good resin application?
• What system constraints exist?– Resin material properties
– Resin dispenser
– Loom feed rate & layup process
– Multiple products must be produced on the same machine
– Factory setup
– Wicking effects & porosity
![Page 8: Team Air Liquide Senior Design Project 2007 Process Improvement of Resin Application System Phase IV Group Presentation Pete John Adam Willoughby-Knox](https://reader030.vdocument.in/reader030/viewer/2022032714/56649d4e5503460f94a2d643/html5/thumbnails/8.jpg)
1. Prevent gas leaks
2. Consistency in quality
3. Reduce amount Machine Operators
4. Reduction of Resin Waste
1. Minimal voids in resin
2. 4 in band width
3. 1 operator
4. Directly supply resin onto loom
Initial Metrics & Target Values
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Initial Design Path
Resin Applicator
Resin Application
Band
Fiber Filter SpoolResin
Infiltrator
2 Components
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Resin Application System
Liquid Control Systems
•Continuous feed pump
•Specified nozzle for initial dispense width
•Control system accommodating different sized bundles
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Infiltration System
Initial Flow Front
Conveyer MotionInfiltrated Fibers
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Design Parameters
• Flow Rate
• Initial Dispense Width
• Roller Material
• Roller Pressure on Loom
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Flow RateCup # Weight before use Weight after use Resin amount used
1 802.6 49.7 752.92 794.8 46.6 748.23 793.7 656.4 137.3
Total Resin used 1638.4
Cup # Weight before use Weight after use Resin amount used1 792.3 47.1 745.22 798.9 193 605.93 - - -
Total Resin used 1351.1
Left Side
Right Side
l
mVm
Recorded Mass
(m)
V = feed rate of loom
l = length of total bundle sheet
Recorded Mass
(m)
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Roller Material Defined
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Roller Material Tested
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Roller Material Selection
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Parameters Defined
• Flow Rate
• Initial Dispense Width– Same bandwidth (4 inches)
• Roller Material– Epoxy Glide Roller by Wooster (R232-4)
• Roller Pressure on Loom– Adjusted before motion initiated
s
gm 03.217
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Updated Performance Requirements
Updated Target Values1 No significant voids2 One technician to oversee3 No break of roller contact4 200-230 g/min flow rate5 Resin at 40 degrees C
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Prototype Description
Loom Machine
Fibers
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Prototype Description
Store-Bought Store-Bought Roller FramesRoller Frames
Adjustable Primary Arm
RotatableRotatableSecondary ArmSecondary Arm
Pivot Point
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Prototype Description
Resin GunResin Gun
Adjustable Primary Arm
RotatableRotatableSecondary ArmSecondary Arm
Store-Bought Store-Bought Roller FramesRoller Frames
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Prototype Testing
Adjustable Primary Arm
RotatableRotatableSecondary ArmSecondary Arm
Resin GunResin GunResin Resin GunGun
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Post Treatment Processes
• Resin cure
• Ends machined
• Clean cut to open fiber ends
• Chemical Post-Treatment
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Testing Analysis
Evaluation Techniques
•Wicking•Hardness•Optical Photographs•Leak Test
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Wicking
Prototype
Operator-Painted
Variable Wicking
Operator-Painted
Even Wicking
Prototype
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Prototype Operator
70.75 70.05
70.50 70.00
66 58
76 78
6.51 25.00
2.55 5.00
Average
Median
Minimum
Maximum
Variance
Standard Deviation
Hardness Test
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Magnified Images 100x
Ideal SurfaceMicro-VoidInterface Void
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Leakage Test
Glass beads used to detect leaks in the bundle
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Continued Analysis
• Post-Production Process– Post-Production Testing
• Nitrogen Recover Rate• Final Leak Test → Success• End-Cap Dissection
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Updated Requirements and Final Solution
• Liquid Control Systems– Automated Flow Rate– Heated Resin Lines– Ratio Monitoring
• Fixed Frame– 80\20 Aluminum– Adjustable– Stable & Rigid
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Final ImplementationResin application system provided by Liquid Controls
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Final Implementation
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Future Considerations
• Fastener Maintenance– Important for secondary applicator
• Immobile Joints– Preventative maintenance
• Agitator to further infiltrate fibers– Mechanical, pneumatic, ultrasonic– Maintenance issues
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0
2
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08/29/07 09/05/07 09/12/07 09/19/07 09/26/07 10/03/07 10/10/0710/17/07
10/24/0710/31/07
11/07/0711/14/07
11/21/0711/28/07
12/05/07
Ti
me
(
h)
Date
Labor Tracking (08/29/07 - 12/06/07)
Design & Analysis Labor Project Management LaborFabrication Labor Test & Evaluation Labor
Cost Analysis
$400.62 Materials CostLess than $1,500 Developmental Budget
$24,350 Labor
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Potential Savings
• 60 bundles lost last year– Average $25,000 per bundle– $1,500,000 loss
• $112,000 solution cost– $109,866 Liquid Controls, $1,500-$2,000 for frames
• Potential first year savings+ $1,388,000 - $1,588,000
• Eventual savings per year+ $1,588,000 - $1,788,000
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Questions
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Appendices