Date of Award

5-4-2026

Degree Type

Capstone Project

First Advisor

Professor Bahram Nassersharif

Abstract

The Extended Bridge Bar Rotor Removal System was developed to provide a safe, structurally validated, and repeatable method for removing a 1,940lbs grinder rotor within a confined industrial cell at Toray Plastics. The existing removal process relied on vertical lifting and indirect maneuvering methods that increased risk exposure and operational variability. Manufacturer recommendations specified side extraction; however, the current configuration did not provide controlled lateral motion. The objective of this project was to design a lifting system capable of providing controlled three-axis motion while integrating with existing facility I-beams and remaining under a defined cost constraint. The final design consists of a 20 ft structural bridge beam supported by three overhead trolleys mounted to facility I-beams. Two bridge mounted trolleys and dual manual chain hoists provide vertical lift and controlled perpendicular translation. Mechanical travel limiting stoppers were incorporated to prevent trolley derailment and reduce collision risk. Engineering validation was performed using both analytical calculations and finite element analysis. Three load cases were evaluated including centered and offs et loading conditions. Maximum deformation was reduced from 28.72 mm in the fin al configuration to less than 0.07 mm in the fin al design. Von Mises stresses remained well below the yield strength of structural steel, resulting in safety factors between 32 and 51 across all evaluated cases. A total of 30 documented tests were conducted across both semesters, verifying structural integrity, hardware ratings, operational functionality, and safety features. The system remained within the project’s financial constraints and eliminated reliance on external contractor crane services, reducing downtime and improving operational flexibility. The fin al design meets all established engineering specifications and is ready for phased industrial implementation.

Comments

Team Name: Team 6

Company Sponsor: Toray Plastics

Sponsor Representatives: Jack McNamee, John DerBedrosian

Document Reference: URI-MCE-2026-FDR-006

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