Meet the Team:
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Melissa
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Bob Byrne |
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Eric Dubs |
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Technical
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Project
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Joe Buchak |
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James May |
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Project
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Chief
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Design for Traveling Roll Shuttle Assembly
for
PPG2 Project Overview:
PPG Industries currently runs production lines manufacturing side window glass for automobiles. One specific production line currently utilizes a peripheral ring to transport the glass being shaped into the cooling conveyor. Our goal is to incorporate a modular roll shuttle into the existing system. The roll assembly itself will travel as opposed to the existing fixed roller system. This conversion should increase the throughput of the glass windows. The prototype must be able to accommodate the following:
n
n
n Max width: 30 in.
n Max length: 48 in.
Project Components:
Frame – The design will use a frame within a frame setup, so that various modular frames can be inserted into the fixed frame. The fixed frame will be attached directly to the existing shuttle track. The dimensions for the fixed (outer) frame are restricted by the position of the quench boxes. This frame’s width, length, and height are all subject to limited clearance. The material chosen for the fixed frame is Aluminum tubing, based on its lost cost, light weight, and suitable strength. The inner frame will be constructed of Aluminum, the adjustments on the inner frame will be steel.
Inner Frame
Outer (fixed) Frame
Rollers – The rollers on the modular frame are composed of preformed steel rods and carbon fiber inserts within carbon donuts. The material selected for the rods is steel, based on cost considerations and adequate flexibility. These preformed rods are curved to accommodate a range of window dimensions. Next, based on prior wear and abrasion testing by PPG, carbon fiber was determined as the ideal material for the inserts, because of its compatibility with the steel rods. The carbon fiber inserts are lightweight, making them ideal for a modular frame. The inserts will be fitted into carbon Duratemp brand donuts. In order to lighten the rollers, the Duratemp donuts will only occur on every other insert. Then the rods will be positioned such that the donuts have a staggered pattern. These donuts are necessary to protect the rods from the high temperature of the glass. The inserts and donuts rotate around the stationary rods to achieve the desired roller motion.
Roller Sleeves – The rollers are covered with Kevlar sleeves. The sleeve acts as an insulating layer between the glass and the rollers. The Kevlar sleeves help to maintain the high temperature of the glass during forming. Additionally, the soft sleeves protect the glass from abrasion due to the rough surface of the rollers. The sleeves are inexpensive and also prevent slipping.
Drivetrain – A separate motor will be used to drive timing belts which turn the rollers and control their speed. Timing belts were chosen over chains based on weight consideration. The drivetrain motor will be mounted on the fixed frame, so that it can be used for every modular frame. The ORMEC Servomotor D-series electric motor was chosen because it will supply adequate power, inertia, and torque for the roller rotation.
Source: www.ormec.com
Adjustments – Each modular frame must be adjustable so that it can accommodate various window sizes. Specifically, a vertical slide adjustment will be used for varying the height of each individual pre-formed rod. Also, a separate radius adjustment will be accomplished using a horizontal slide adjustment for each rod. Brass plated will be used for the dovetail slides to prevent wear.
Conceptual Design:
Based on quench box geometry, in order to accommodate the above window ranges, 5 modular units will be necessary. The crossbars on each unit will differ for quench clearance. The preformed steel rods which hold the donuts will be interchangeable. Each unit will weigh approximately 300 lbs.
Links:
ME 415 Mechanical Engineering Systems Design - Fall 2004
Thank you:
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Instructor: |
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Project Sponsor: |
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Sponsor Contact: |
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Dr. H. J. Sommer III |
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PPG Industries, Inc. |
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Mike Fecik |
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