P17432: Plastic Bottle Rope Machine
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

Summarize: During this phase the team developed detailed drawings and analytics to the final design, we prototyped the design on a 1:10 scale through the use of 3-D printing as a validation to the overall concept.

Progress Report

Outcomes

Prototyping, Engineering Analysis, Simulation

Prototype of Bottle Reshaping

Bottle Reshape Feasibility

Bottle Reshape Feasibility

Bottle Reshape Process

Bottle Reshape Process

Bottle re-inflation tests were performed successfully using the water pressure supplied from the faucet. To maintain a seal with the bottle a rubber stop will be used in conjunction with a plastic nozzle thru element. This will allow for the bottle to release upon full inflation and facilitate rapid transition to the next bottle in the production line.

Prototype of 3D Printed Braiding Machine

Base

Base

Carriage Clip

Carriage Clip

Exit Eyelet

Exit Eyelet

Pin

Pin

Spindle

Spindle

Spindle Carriage

Spindle Carriage

Sprocket

Sprocket

Display Model

Display Model

Drawings, Schematics, Flow Charts, Simulations

CAD Renderings

Bottom Cutter

Bottom Cutter Iso

Bottom Cutter Iso

Bottom Cutter Razor Placement

Bottom Cutter Razor Placement

String Cutter

String Cutter Iso

String Cutter Iso

String Cutter Close Up

String Cutter Close Up

Crank Assembly

Crank Assembly Iso

Crank Assembly Iso

Crank Assembly Side

Crank Assembly Side

The crank assembly is built around the interchangeable spool geometry found in the weaving machine. The spool is held in place with the assistance of a mating slot design. The hand crank will be used to drive the bottle cutting process and maintain even distribution of the string on the spool.

Prototype of Spool Assembly

Guide

Guide

Spool Assembly

Spool Assembly

Spool & Guide Assembly

Spool & Guide Assembly

The spool assembly was designed to allow for free rotation of the spool within the spindle. The weave path guide fixture is screwed into the bottom of the spindle assembly to fit into the weave machine. The spool may be removed by removal of the top guide eye bolt to move from the cutting to the weave.

Bottle Reshaping

Bottle Reshape CAD Design

Bottle Reshape CAD Design

Hose Valve Adapter McMaster Carr #7082T24

Hose Valve Adapter McMaster Carr #7082T24

Weaving Machine

Weave picture 1

Weave picture 1

Weave picture 2

Weave picture 2

Weave picture 3

Weave picture 3

Weave picture 4

Weave picture 4

Weave picture 5

Weave picture 5

Weave picture 6

Weave picture 6

Weave picture 7

Weave picture 7

Bill of Material (BOM)

Cleaning Bill of Materials

Cleaning Bill of Materials

Cutting Bill of Materials

Cutting Bill of Materials

Weaving Bill of Materials

Weaving Bill of Materials

A link to the live document is here.

Manufacture / Test Plans

Manufacturing and Test Plans

Manufacturing and Test Plans

Testing Definition

Testing Definition

Manufacturing Operations Definition

Manufacturing Operations Definition

Design and Flowcharts

Joining: After testing with melting, heat sealing and soldering, joining of the plastic strands was deemed unfeasible as the heat source either melts through the plastic too quickly or is not enough to meld the plastic together. Going forward we will not be joining the strands and will try to make the rope as long as each individual strands allow when braiding them together. The design flowchart was changed accordingly.

Process Flowchart

Process Flowchart

A link to the live document is here.

Part Drawings

String Cutter

Blade Holder

Blade Spacer

Crank Handle

Crank Knob

Crank Shaft

Square Drive

Spool

Spool Drawing Package

Weave

Weave Page 1

Weave Page 2

Weave Page 3

Weave Page 4

Weave Page 5

Weave Page 6

Weave Page 7

Drawings for Waterjet

Risk Assessment

Click on photo to zoom in and read the PDF.

Risk Assessment

Risk Assessment

A link to the live document is here.

Design Review Materials

Plans for next phase

MSDII Gantt Chart

MSDII Gantt Chart

Cutting

Operation

Braiding

Table of Contents

MSD I & II MSD I MSD II

Home

Planning & Execution

Project Photos and Videos

Imagine RIT

Problem Definition

Systems Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Integrated System Build & Test with Customer Demo

Customer Handoff & Final Project Documentation