P16601: Glass Cutting Machine:Guide Rollers
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Detailed Design

Table of Contents

Key Questions for Preliminary Detailed Design

Our goal for MSD I was to answer the following questions:

  1. Will we model off of the DS264 or develop a unique design?
  2. How many rollers will we use and what is the approximate size? Two Rollers - 420 mm long with an outer diameter of 280 mm. The final OD of the rollers will be 320 mm with the elastomer coating
  3. Where is the most power being used? During the cutting process but the inertial power is not negligible. For our individual fixture, the power will only go to turning the rollers
  4. How powerful do the motors need to be? Approximately 7.5 hp in the final system. For the individual fixtures, approximately 2 hp
  5. What material will the rollers be made of? 4140 Steel

Mechanical System

Installation of Guide Roller

Installation of Guide Roller

Updated CAD Model

Full Assembly

Full Assembly

Full Assembly

Full Assembly

Full Assembly

Guide Roller

Guide Roller

Guide Roller

Insert / Adapter Plate

Insert Assembly

Insert Assembly

Adapter Plate

Adapter Plate

Insert Plate

Insert Plate

SKF Roller Bearing

SKF Roller Bearing

Framing

Fixture Frame

Fixture Frame

Front/Motorside Frame

Front/Motorside Frame

Finite Element Analysis

Deformation of Generic Steel (20 mm Wall Thickness)

Deformation of Generic Steel (20 mm Wall Thickness)

Finite Element Analysis Results

Finite Element Analysis Results

Mechanical Build and Assembly

Mechanical Assembly Step 1

Mechanical Assembly Step 1

Mechanical Assembly Step 2

Mechanical Assembly Step 2

Mechanical Assembly Step 3

Mechanical Assembly Step 3

Mechanical Assembly Step 4

Mechanical Assembly Step 4

Mechanical Assembly Step 5

Mechanical Assembly Step 5

Mechanical Assembly Step 6

Mechanical Assembly Step 6

The live document can be found here

Electrical System

The electrical engineers from each of the three teams decided to present together rather than separately, so most of the information will be on the detailed presentation below. Essentially, the electrical engineers came up with possible alternatives to the previously proposed Rockwell solution in phase 4 as well as an updated Rockwell solution with updated prices.

From our research, it became evident that it would not be possible to have a 7.5 hp roller motor on a single phase system. However, it is very possible to have a 115 VAC system with smaller motors and drivers to perhaps run the system without being able to perform 265 cuts. Realistically, maybe 10 cuts could be performed given a 1.5 hp motor. However, asides from that, the integration of the systems and profiles would perhaps be validated with option 4 in the presentation below.

Option 4 would also allow the EE's to design and manufacture the electrical enclosure themselves without having to outsource it to a panel shop. However, given these benefits, the Rockwell solution (option 5/6) would still be the only realistic solution we currently have that would perform 265 cuts given the currently designed smaller machine. Nevertheless, it is the most expensive and would require us to outsource the enclosure design to a company such as Agile or Zeller.

The EE presentation can be found here

Bill of Material (BOM)

public/Reviews/MSD1 P5 Detailed Design Documents/BOM.jpg

The live document can be found here

Engineering Requirements

public/Reviews/MSD1 P5 Detailed Design Documents/Engineering Requirements.jpg

The live document can be found here

Test Plans

public/Reviews/MSD1 P5 Detailed Design Documents/Test Plan.jpg

The live document can be found here

Risk Assessment

public/Reviews/MSD1 P5 Detailed Design Documents/Risk Assessment.jpg

The live document can be found here

Plans for MSD 2

MSD II Gantt Chart

public/Reviews/MSD1 P5 Detailed Design Documents/MSD II Gantt Chart.jpg

The live Microsoft Project file can be provided upon request

Deliverable Completion Plan

public/Reviews/MSD1 P5 Detailed Design Documents/Deliverable Completion Plan.JPG

The live document can be found here

Individual Contributions

public/Reviews/MSD1 P5 Detailed Design Documents/Individual Contributions.jpg

The live document can be found here


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