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Some Of The Information Pertaining To This Presentation May Be Hidden To Protect Company Trade Secrets. Such Information Is Intellectual Property Of Velcro Group Corporation And Public Disclosure Is Prohibited.
Problem Statement
A prototype horizontal calendering machine is currently being used by the Innovation and Technology Center (ITC) to develop new fastener products. The machine has been in use for about five years. It requires upgrades to improve the safety, ease of operation, and process development.
Objectives• Design and build a platform and railing
system to allow ease of positioning for both tool change and run conditions.
• Design and build an unwinder with a regulated air brake to be attached to the existing horizontal calender.
• Design and build a laminate guide laminate guide system to feed both laminate and film material to the horizontal calender.
• Design and build an adjustable purge shelf to be connected to the horizontal calender.
• Design and build an idler roll used to strip web from the horizontal calender.
• Design and implement a layout for improved extrusion using two existing ITC extruders.
• Improve wiring and cooling hose layout for ease of use.
• A completed assembly drawing and 3D model are required along with any subassemblies and detailed prints.
Schedule
Platform & Rail SystemFinalized Design
· Rectangular steel tubing with welded joints
· Extension nut welded to legs to accept adjustable leveling feet
· Gray powder coat
· Linear slide rails with hand brakes from PBC Linear.
· Custom designed brackets to mount carriages to table legs
· Hard rubber compression springs mounted to end stops to dampen momentum
· Moveable using a pallet jack
Rail SystemIteration 1 – Preliminary Design
Rail SystemIteration 2 – Preliminary Design
Rail SystemIteration 3 – Preliminary Design
Unwinder SystemFinalized Design
·Nickle plated aluminum rectangular tubing designed to slide within a stainless steel mounting bracket and constrained with click pin. Features include adjustability, removability, and self-alignment.·Sensi-Flex pneumatic tensioner brake from MACHIII·Mounting bracket and sliding cover designed with aluminum sheet metal
UnwinderPreliminary Design
Laminate Guide SystemFinalized Design
·Used to guide film material from new unwinder to the tool.·Constructed using 80/20 aluminum extrusions, a custom fabricated bracket, and removable conveyor rollers.·The bracket was designed with some flexibility in positioning the rollers by adding extra holes.·No-tool shaft collars from Ruland Manufacturing guide the material through the rollers
Purge ShelfFinalized Design
Removable tray designed using 316 stainless steel with supports designed using high capacity drawer slides to be positioned under a plastic extruder for purge or stored against the table frame when not in use. 316 Stainless Steel was chosen as a non-stick surface for purged plastic.
Purge Shelf Iteration 1 – Preliminary Design
Purge ShelfIteration 2 – Preliminary Design
Purge ShelfIteration 3 – Preliminary Design
Idler RollerFinalized Design
·Used to strip hardened plastic from the tool·Designed with both X and Z adjustability to be accurately positioned for the task as well as to be positioned away to have access for a tool change.·Constructed using linear slide rails with PTFE bearings and a locking mechanism. Z adjustability obtained using a precision manual position slide.
Complete AssemblyFinalized Design
Lab Layout &Organization
· The lab setup previously consisted of a prototyping machine, an unwinder, a rewinder, a chiller, and two extruders.
· The unwinder is now integrated into the prototyping setup.
· The lab setup was rearranged for improved extrusion processes using two existing extruders.
· Previously the controls for operating the various machines were on opposite sides, making the operation difficult and time consuming. Moving the controls to the other side of the machine as well as cleaning up the chaotic wiring made the operation much smoother.
· A new chilling system was originally part of the project scope, however, the supervisors decided to integrate a much larger chilling unit to serve all of the machines in the lab.
Budget & Expenditures
Qty Item # Description Supplier Unit Price Line Total
1 Laminate Guide $
454.37
1 Unwinder $
2,630.37
1 Rail System $
2,854.64
1 Purge Shelf $
813.90
1 Idler Roll $
903.32
$
7,656.60
Overall Budget: $8,000
Acknowledgements
• UNH Manchester• Christopher LeBlanc• Sean Tavares
• Velcro Group Corporation• Christopher Libby• Chris Gallant• Mark Clarner• David Fuller• Peter Iannazzi• Greg Kopanski• Andrew Collins• Cynthia Oberg• Jesse Stein• Donna Sorenson
• Fisher Machine, LLC
• Charlie Fisher• Dean Fisher
• Avid Machine Co, Inc.• Phil Hamel
• Custom Sheet Metal Corporation• Dave Bowles
