Date of Award

2022

Degree Type

Capstone Project

First Advisor

Dr. Bahram Nassersharif

Abstract

The purpose of this report is to design and model a braking system for the chill roller at Toray Plastics, Inc. in North Kingstown. This specific chill roller is the largest in the facility weighing approximately 20,000 lbs with a diameter of 3 meters. This report covers the design and testing processes Team 22 has conducted throughout the fall and spring semesters. By performing numerous calculations, it has been determined that the chill roller generates upwards of 8,000 Nm of torque as it spins 18 rpm. The design presented in this report utilizes a pneumatic Coremo C1200 brake caliper to clamp a brake rotor directly mounted to the axle of the chill roller. The Coremo C1200 caliper implemented in the design can provide approximately 22,500 Nm of braking force, more than double the chill rollers rotational force. Attaching a brake rotor to the axle has proven to be challenging, however, the team has created a custom split shaft collar to solve the issue. This collar is required to clamp on the axle and not slip when the brake is applied. Performing calculations, it was found that the collar could withstand 14,575 Nm of torque. This collar will provide more than the required clamping force to overcome the braking forces without slipping. The design has been thoroughly tested with simulations in both Solidworks and Abaqus to ensure the design was verified to fulfill Toray’s requirements.

Comments

Team Name: Team 22

Sponsor: Toray Plastics, Inc.

Document Reference: URI-MCE-402-022-2022

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