P19415: Vacuum Former for Haiti
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Preliminary Detailed Design

Table of Contents

Our team's plan for this phase was to is to begin the preliminary design of our vacuum former. Using the subsystems that we determined in the previous phase, we created designs for each subsystems, as well as bills of materials and cost projections. Due to the uncertainty of our choice of heating system, we created designs for both electric and propane systems. Our team visited a vacuum forming company Farro Industries and were able to learn from their industry experience. At the end of this phase, the majority of our design is finalized and components are ready to be purchased, with only a few detail design questions remaining to answer in the next phase.

Team Vision for Preliminary Detailed Design Phase

During this phase, our team's plan was to:

We have successfully accomplished all the plans listed above and uploaded them on EDGE.

Feasibility: Prototyping, Analysis, Simulation

Faro Industries

Heat Diffuser Example

Heat Diffuser Example

Plastic Clamping Spikes Example

Plastic Clamping Spikes Example

Propane System

Propane Heating System

Propane Heating System

If the heating system is chosen this is a diagram of how it will look. The parts you see in the diagram are on the BOM. Goes from propane tank from through the hose and connector to the heating element. The Heating element then heats up the diffuser which is a metal mesh so the heat will be more evenly distributed when it gets to the plastic. That diffuser will be held in play by split ring hangers attached to thread which will be attached to the roof of the superstructure.
Wall Cut-Out of Heating System

Wall Cut-Out of Heating System

This picture is a side cut-out of how the walls of the superstructure are and how the heating element will be placed on it. The first layer will be thermal flocking to protect operators from burns the next will be the metal structure, insulation, and then a metal plate to mount the heating element to.

Superstructure

The superstructure of the vacuum former was designed in Fusion 360 primarily using downloaded components from 80/20 Inc and McMaster Carr.
3d Model of Superstructure and vacuum box with top plates removed

3d Model of Superstructure and vacuum box with top plates removed

3d Model of Superstructure (Top) with top plates removed

3d Model of Superstructure (Top) with top plates removed

Motion system of plastic plastic holder

Motion system of plastic plastic holder

Vacuum System

Schematic of Vacuum System

Schematic of Vacuum System

Schematic of Vacuum Box

Schematic of Vacuum Box

Electric Heater

Electric Heater Schematic

Electric Heater Schematic

Bill of Material (BOM)

Superstructure

Super Structure BOM

Super Structure BOM

Vacuum System

Vacuum System BOM

Vacuum System BOM

Vacuum System's Box

Vacuum System's Box

Electric Heating System

Electric Heater BOM

Electric Heater BOM

Propane Tanks

Potential Propane Tanks and Cost

Potential Propane Tanks and Cost

Propane Heating System

Potential Heater Arrangements and their costs

Potential Heater Arrangements and their costs

This is the bill of materials for the propane heating element design I showed. This bill of materials shows different heating element configurations and what that will do to the price. The design is based of 1 propane tank for 1 propane heater because we do not know if will be able to do have 2 or 4 heaters on 1 propane tank. So the 4 heaters is the worst case scenario.

Test Plans

Propane Heating Element Testing: machine shop welding area

  1. Distance/Temperature Testing – taking infrared thermometer readings at different distances to find the optimal distance to hold the plastic from the heater
  2. Time to Heat – determining how long it will take to heat the plastic to the correct forming temperature
  3. Diffusion – using screens to attempt to diffuse the heat to achieve even heating and ensuring that there is only a need to use one heater

Vacuum Pump Testing: Construct or MSD Design Center

  1. Power – determine if there is enough power to fully pump down the tanks
  2. Time to Pump Down – determine how long it takes to remove air from the tanks
  3. Time to Form – determine how long it takes to draw all the air from the mold

Risk Assessment

Risk Management additions

Risk Management additions

This shows the risks that were identified during this phase, many of which came from our visit at Faro Industries. The full Risk Managment document can be found under the Risk Management page.

Design Review Materials

Link to Presentation:

Plans for next phase

Propane Heating System

Propane Heating System


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