Date of Award

2020

Degree Type

Capstone Project

Abstract

Sponsored by Toray Plastics, Team 23 was tasked with solving a lingering issue in their production line. The team participated in the design process of a safety device utilized to transport a tray weighing upwards of 600 lbs, containing molten liquid polymer at a temperature of approximately 500 degrees Fahrenheit. The tray is used to collect this molten plastic when the plastic production line is not in use. Shutting down the entire extrusion process when maintenance needs to be performed is too costly. Continuously running the line and recycling the collected plastic proves a better and much cheaper option. That collection is done through a purge tray. The environment of the production line is also an area to consider, as the facility sprays mist into the line to keep the humidity levels high. This forced the team to consider rust resistant materials and/or coatings.

The teamstarted with multiple design ideas, and narrowed it down to a final concept called the Purge Tray Extractor. Trolleys connected to two overhead I-beams would attach to fork armassemblies that carry the purge tray. The entire assembly carrying the tray will move back and forth along the I beams, from the starting position to the work area, and then back to the opposite side of the work area where it will be placed at rest and cool. After hand calculations and finite element computer analysis, the team was able to prove the system would be able to support all the forces acting upon it.

The extractor itself has seen numerous design changes along the way, and working closely with Toray associates, had its final design approved and sent off for fabrication by AMC Design andManufacturing. Along with fabrication, installation was coordinated with IPC Lydon and parts were ordered throughMcMaster-Carr formodifications to existing structures. Lead time on fabrication was an ongoing issue, and original installation deadlines set forth by Toray were not be met while the production line was down for the month of March. Instead, the installation process beganMay 1st and will likely be completed by the 6th or 7th, while the production line is down for periodic inspection. The ongoing issues with the COVID-19 pandemic have made it difficult for Team 23 to coordinate with Toray, AMC for fabrication and Lydon for installation. Although this was not ideal, it ended up working out and will be completed shortly so that the technicians can begin to utilize the product, eliminating the risks associated with moving the tray manually for good. Testing parameters have been sent to Toray, and even though the results will not make it into this report, they will be completed and reported back to the team.

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Sponsor: Toray Plastics

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