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Improved Honeycomb Expander
Levi GordyKarl GrabczewskiAndy OlenderskiStephanie Swain
Team Alcore
Overview• What is Alcore?• Process of Interest• Current Problems• Alcore Wants• Metrics• Our Concept• Subsystem Development• Cost Analysis• Value to Sponsor• Path Forward
What is Alcore?• Located in Edgewood, MD
• Produces and Processes Aluminum Honeycomb Core
• Product applications in Aerospace, Marine, and Construction Industries
• Used in Commercial Airlines and Military Hardware
Process of Interest
•Aluminum Core Expansion (7 steps)
Transfer Cart Holding Table
Nailing Station
Finished Stack
Expander Holding Table
Cutting Station
Process of Interest (Graphically)
Expansion Phase
Aluminum Core
Module Module
Aluminum Core
Current Problems•Unnecessary Handling
–Transfer between stations
•Labor intensive–Nailing, loading, unloading, resetting
•Inconsistent Process
– Human error causes delays
– Higher variability in timing
Alcore Wants•Driving Wants
–Reduced Handling–Reduce cycle times
•Varying Cores Require Adaptability
•Other wants result from driving wants
• Training Time• Manageable Weight• Improved Safety
Transfer Cart
Cutting Station
Finished Stack
Expander
Metrics
•We can improve many aspects of the process•Further improvement not possible in all areas
Metric Current Value Target ValueNailing Time 150 sec 10 sec
Loading Time 60 sec 30 sec
Expansion Time 60 sec 30 sec
Quality Check Time 160 sec 130 sec
Unloading Time 80 sec 60 sec
Operators Needed 2 to 4 2
Cores per Expansion 1 to 2 2 to 4
Cycle Time 8.5 min 4.3 min
Current Expansion Table
1
2
3
4
Our Concept…
Incorporate an automatic gripping system
Critical Subsystems
•Five critical design components
Overhead Press
Gripping Module
Slide Rail
Resetting Mechanism
Linear Actuators
Support Frame
•Examined Alternatives for each subsystem
Sliding Module Considerations
• Needs to support insertion forces
• Resist binding from expansion forces
• Minimal deflection along guide rail
• Mating modules can’t obstruct one another
Sliding Module
F
Nylon Lined Plain-Bearing System
•Static Load Capacity of 2240 lbs
• F = 400 Newtons ≈ 90 lbs
• Approx 20 Modules along width of table
•≈2000 lbs Cumulative Load
•Cumulative Load < Rated Load Capacity
Sliding Module Components
1. Guide Rail2. Guide Block 3. Gripping Nail4. Retaining Plate5. Eyelet Screw
1
2
34
5
Return Mechanism
1
2
•1 – 3/32” Aluminum Cable Ferrules•2 – 25ft x 3/32” coated cable•Winch pulls cable taught
Actuator Considerations
• Small profile to easily attach to frame • Suitable for high cycles: Raising and
lowering slide rail and modules • Produces required forces to puncture 12 lb
core ( 8000 N / actuator assuming 10 ft width)
• Lightweight
Actuators
• Rod screw actuator with In-line motor– Low profile (8.6’’ x 3.8’’)
• High Cycles Time to Fatigue– (90% reliable to 10^6
inches)
• Meets required forces– Max force ~4300 lb (~16000
N)
• Low added weight (14.2 lb)• Can operates at 25 in/sec • Multiple Mounting Options
– Foot mount and Externally threaded screw
Support Frame•Utilize Existing Mobile Gantry
•Proven in this application
•Eliminates cost of producing new frame
Cost Analysis (Full Scale System)Part Price
Guide Rail 900.00
Guide Block 4141.92
Nitride Ejector Pin 118.08
Retaining Plate 1920.00
Retaining Screw 16.18
Eyelet Screw 620.16
Cable 19.90
Cable ferrules 94.08
Winch 69.99
Linear Actuator 31595.16
Total Cost 39,495.47
Benefits
Estimated Profit per
annum
Reduced Operators $49000
More Cores per cycle $500,000
Faster Cycle time $500,000
Total New Earnings (est.)
$1,049,000
Our PrototypeOverhead Press Concept proved to be the best
Prototype to Simulate one section
Proves insertion times, removal times, resetting times.
Completed Prototype
Testing and Validation• Prototype crosshead mounted into
Instron• Single module on guide rail to test
insertion quality and time
Testing Video• Video_Core Insertion.MOV
Testing and Validation• Used same speed
as linear actuator to insert nail into 1 to 5 cores– At most Alcore
currently expands only 2 cores at a time
• Nail was inserted cleanly and quickly– Nailing, loading, and
unloading currently take 290 sec at Alcore
– Our prototype reduces time to 100 sec
Testing and Validation
• Our resetting mechanism resets the modules in 1 second
Testing Video• Video_Resetting.MOV
Results vs. Target Values
Improvement Criteria
Target Value Results
Nailing Time 10 sec 10 sec
Loading Time 30 sec 30 sec
Expansion Time 40 sec untested
Quality Check Time 130 sec untested
Resetting Time 40 sec 1 sec
Cores per Expansion 4 5
Operators Needed 2 2
Time saved per cycle ≈
3.5 min
Time Charts Comparing Old vs New Process
0
100
200
300
400
500
600
700
Old Average Worst Case (Old) Estimated New Averages Worst Case (New)
Process
Tim
e (s
eco
nd
s)
Unloading Time
Quality CheckTime
Expansion Time
Loading Time
Nailing Time
Value to Sponsor
• Reduces handling time/labor intensiveness– Happier work force
• Reduces # of operators needed– Operators used more effectively elsewhere
• Increased number of cores per cycle– Higher Productivity
Path Forward• Determine max number of cores
subject to expansion force constraint
• Prepare transition/full scale implementation package
• • Validate expansion time on full scale
system
Questions?
Supplementary Information
Dimension Distance (mm)
A 70
B 36
B1 31
D 57
G 23
Side View
Dimension
Distance (mm)
C 96
E 45
F M8 x 24.8
G 23
H 21.5
J 60
K 40*
M 10
N M6
P 6
Resisting Bind-up of Module• Guide Blocks are rigid• Designed for much higher
loads than will be experienced
• Prototype testing could further validate
• Ball Bearing Modules much more costly
Cable/Module Reset•Winch
–Portable–12 V DC–2000 lb capacity–$69.99–Cable goes through eyebolts on modules–Master Lock Model# 2953AT
Slide Rail
• Slide Rail available in 1 m sections• Support Beam used to mate
sections/add rigidity
1m 1m 1m