Date of Award

5-5-2025

Degree Type

Capstone Project

First Advisor

Bahram Nassersharif

Abstract

This project focuses on the design and development of a small-format diverter valve for Toray Plastics, intended to redirect polypropylene pellets between two basins in an industrial production system. The primary goal is to create an efficient, fully automated valve that fits a 4-inch internal diameter, supports smooth pellet flow, and complies with food safety standards. To meet these requirements, the valve is constructed entirely from stainless steel, ensuring compliance with sanitary regulations and long-term durability in a production environment. It is also designed to be lightweight enough for installation in the limited space available and compatible with Toray’s existing automation infrastructure, utilizing either pneumatic or electronic actuation.

The design process began with clear specifications related to size, material selection, and automation compatibility. Initial challenges included defining spatial constraints, determining the necessary actuation method, and finalizing the exact diversion angle for optimal flow. A site visit and discussions with Toray engineers helped clarify that the valve would be integrated directly into their current automated system. As a result, mechanical and structural considerations became the focus. A key design decision was made to configure the valve to redirect flow at a 60-degree angle, while incorporating a stainless steel lining for food-safe operation and material longevity.

The final valve design features a centrally hinged flap within a circular chamber, allowing the flap to pivot smoothly between two outlet paths set at a 60-degree offset. This configuration provides effective flow control with minimal resistance and is targeted to stay within a production budget of $3,000 to $5,000. Automation was implemented using a stepper motor system controlled by an Arduino microcontroller, allowing precise control of the flap position within the housing for seamless integration with Toray’s automated processes.

A proof-of-concept prototype was initially developed using 3D-printed PLA components, which included a manually actuated flap for early-stage testing. Feedback from Toray prompted improvements including enhanced flap precision and the addition of seals to prevent pellet leakage. These revisions are being incorporated into ongoing development.

Due to limitations in available equipment at the University of Rhode Island machine shop, the project team coordinated with external machine shops to outsource critical fabrication tasks. This included cutting and welding the required stainless steel components to meet the project’s scale and material specifications.

Overall, this project delivers a functional, cost-effective, and automated diverter valve solution tailored to Toray Plastics’ operational needs. With its stainless steel construction, automated flap actuation, and compliance with food safety standards, the valve is well-positioned for full-scale implantation following final prototype refinements and integrations into Toray’s production line.

Comments

Team Name: Team 13

Company Sponsor: Toray Plastics

Sponsor Representative: John Derbedrosian, Alex Duarte, Jack McNamee

Document Reference: URI-MCE-402-013-2025

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