IVALution Project Website

Project Title: Redesign of an Automated Hot-Wire Foam Cutter

Project Team: IVALution (Joe Rebilas, John Proctor, Mike Voit, Dan Vresilovic, Matt Smith)

Date: Spring 2002

Faculty Coach: Dr. Martin Trethewey

Sponsor: Dr. Timothy Simpson - IVALO Lighting

IVALO Lighting is a newly established company that specializes in the production of overhead lighting fixtures. Currently, IVALO Lighting only produces 5 ft. and 6 ft. overhead lighting fixtures, but they plan to expand their line of products to make different size lighting fixtures for desk lamps, conference rooms, etc… They have provided IVALution with the task of redesigning various components of their automated hot-wire foam cutter that was created by Dr. Timothy Simpson and a few of his graduate students. The automated hot-wire cutter is used to produce foam molds and prototypes of light fixtures. The following points describe the problems posed by Dr. Simpson and the details of how each has been enhanced by IVALution:

The hot-wire clamping mechanisms were the first components addressed. They were inadequate in their design because they melted at normal operating temperatures. In the end the clamps were machined from aluminum, extending their overall "reach". This not only moved the wire away from the plastic that was melting, but also made it possible to achieve the desired 1.0" cutting diameter.
The guide mechanisms were the second item that was addressed. Their solution and results were the same as was mentioned above for the clamping mechanisms.
The next problem encountered was the way in which the machine was "zeroed" before prototype cutting could commence. Returning the motors to their zeroed positions took upwards of 15 minutes. IVALution's remedy consisted of "quick return" mechanisms attached to each of the 6 moving blocks on the lead screws. The mechanism relied on threads that could be disengaged. The blocks can now be moved to their zeroed positions in seconds, rather than minutes.
The next part altered was the foam advancing bed. The previous design was constructed hastily out of pine wood. IVALution's design was similar in its function, but overall, it was lighter in weight, simpler, and more practical.
A unique idea for making the zeroing process simpler was to create calibration semicircles that would be used to automatically set the hot wire's cutting diameter. This ingenious idea was added to the project deliverables mid-semester, and was a successful addition to the rest of the tasks.
A new power supply was to be purchased that would replace the one that was on loan from the PSU MNE department. A power supply with more than enough voltage supply and ample current capacity was purchased for much less than was originally budgeted for.
The last problem that IVALution addressed was that of the machine's wiring. In its previous state, it was crude and at times, unsafe. All components on the machine were appropriately grounded and insulated for safety, and the machine more smoothly than ever.

Ultimately, IVALution successfully completed the ME 415W IVALO Lighting student project that was presented to them at the start of the semester. All of the specified deliverables, and even a few extras, have been fulfilled, and all of the project's objectives have been successfully completed on time and under budget. The project overall was a complete success for IVALution.

The guide mechanisms were the second item that was addressed. Their solution and results were the same as was mentioned above for the clamping mechanisms.

The next part altered was the foam advancing bed. The previous design was constructed hastily out of pine wood. IVALution's design was similar in its function, but overall, it was lighter in weight, simpler, and more practical.

A unique idea for making the zeroing process simpler was to create calibration semicircles that would be used to automatically set the hot wire's cutting diameter. This ingenious idea was added to the project deliverables mid-semester, and was a successful addition to the rest of the tasks.

A new power supply was to be purchased that would replace the one that was on loan from the PSU MNE department. A power supply with more than enough voltage supply and ample current capacity was purchased for much less than was originally budgeted for.

The last problem that IVALution addressed was that of the machine's wiring. In its previous state, it was crude and at times, unsafe. All components on the machine were appropriately grounded and insulated for safety, and the machine more smoothly than ever.