Susana Borrero ValentínSusana Borrero ValentínRodolfo Rivera MaldonadoRodolfo Rivera Maldonado

University Of Puerto RicoUniversity Of Puerto RicoMechanical Engineering DepartmentMechanical Engineering Department

Course:Course:

Computer Aided Design Computer Aided Design Dr. Vijay K. GoyalDr. Vijay K. Goyal

RTSARTSA

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AgendaAgenda

• BackgroundBackground• Literature SurveyLiterature Survey• Problem DescriptionProblem Description• Project FlowProject Flow• Final DesignFinal Design• AnalysisAnalysis• CostCost• RecommendationsRecommendations• ConclusionsConclusions

BackgroundBackground

Automobile IndustryAutomobile Industry• In-line High Scale Production: In-line High Scale Production:

- - Over 5 MM Cars/YrOver 5 MM Cars/Yr

• Efficiency: Continuity, Reliability & SpeedEfficiency: Continuity, Reliability & Speed

• Component Assembly Involve:Component Assembly Involve:

- - Repetitive TaskRepetitive Task

• Organization of Tools : Constant useOrganization of Tools : Constant use

• Rotary Devices: Rotary Devices:

- - Electric drills, Wrenches, etcElectric drills, Wrenches, etc..

Project Focus:Project Focus:

Literature SurveyLiterature Survey

Existing Aids – Tool HoldersExisting Aids – Tool Holders

PROS:PROS:– HoldHold– Organized Organized

– Keep Tools IdentifiedKeep Tools Identified

CONS:CONS:– Not handy on the toolNot handy on the tool– Lack: Fast tool switchingLack: Fast tool switching– Time consuming: ++ stepsTime consuming: ++ steps Standard Tool belt Standard Tool belt

Drill Bit Set Drill Bit Set

Tool Cabinet Tool Cabinet

Problem DescriptionProblem Description

• There was a need to There was a need to increase efficiencyincrease efficiency in repetitive tasks that take in repetitive tasks that take place at the high speed production lines of the Automotive Industryplace at the high speed production lines of the Automotive Industry

• Being Being Rotary toolsRotary tools the most frequently used: the most frequently used:

• This was achieved through theThis was achieved through the Design Design & & AnalysisAnalysis of a universal rotary of a universal rotary device adapter, which will carry up to 6 toolbits at a time:device adapter, which will carry up to 6 toolbits at a time:

• Ready - Fast switching between toolbitsReady - Fast switching between toolbits

• Reduce- # of steps & timeReduce- # of steps & time

• Reduce human effort requiredReduce human effort required

Overall Line efficiency

Individual

task performance

RotaryToolsefficiency

Project FlowProject Flow

Automobile IndustryAutomobile Industry

NEED NEED

#1#1

#2#2

#3#3

GENERATE IDEASGENERATE IDEAS FINAL DESIGNFINAL DESIGN

#1#1

Pugh MethodPugh Method+/- Comparison+/- Comparison

ANALYSISANALYSIS

ANSYSANSYS

Optimization: Optimization: Minimize WeightMinimize Weight LAGRANGELAGRANGE

Structural Structural AnalysisAnalysis

A.

B.

C.

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FinalFinal RemarksRemarks

&&RecommendationsRecommendations

CONCLUSIONSCONCLUSIONS

CostCostAnalysisAnalysis

• Two different design ideas were Two different design ideas were considered for the design of the RTSAconsidered for the design of the RTSA

• Pugh’s Matrix Method was used to Pugh’s Matrix Method was used to make the selectionmake the selection

#1#1

#2#2

Idea SelectionIdea Selection

Idea 1Idea 1

• Off-Center Rotating Star Adapter Off-Center Rotating Star Adapter

Idea 2Idea 2

• Centered Rotating Star Adapter Centered Rotating Star Adapter

Selected Idea – Idea # 1Selected Idea – Idea # 1

Universal AdapterHigh Visibility

Fast Switching

Holds Up To 6 Toolbits

Adjustable Position

Accepts Wide

Variety of Toolbits

Lower Cost

OptimizationOptimization

• MethodMethod: LaGrange's Optimization Method: LaGrange's Optimization Method

• FocusFocus: Minimize the Weight of the Star-shaped component: Minimize the Weight of the Star-shaped component

• Due to the component is Due to the component is symmetrysymmetry: Analysis of 1 segment: Analysis of 1 segment

SegmentStar-shape component

OptimizationOptimization

• Design VariablesDesign Variables

All six design variables are the dimensions that All six design variables are the dimensions that define the star’s volumedefine the star’s volume

OptimizationOptimization

Objective Function:Objective Function:

W = mg/gc = ρgV = ρg(AW = mg/gc = ρgV = ρg(ATTt)t)

f(x) = (Af(x) = (ATTt)t)

Inequality ConstraintsInequality Constraints

06)( 22131 XXPXSFXg y

0)(0)( 2min2min2 XtXgttXg

0)(0)( max23max3 tXXgttXg

•Thickness RangeThickness Range

•Bending MomentBending Moment

03)(03)( 144 XdXgbdXg

•Width of ExtremitiesWidth of Extremities

0)(0)()( 31555 XXXgLbXgbLXg

•Lenght of ExtremitiesLenght of Extremities

Equality ConstraintsEquality Constraints

•Length “LLength “L22””

•Length “LLength “L11””

•Dimension “a”Dimension “a”

•Dimension “h”Dimension “h”

h1(X) = X3 – R + X1cos(30) = 0

h2(X) = X4 – X3 + X1/2 = 0

h3(X) = 2X5 – X1 + d = 0

h4(X) = X6 – X1cos(30) = 0

Optimization ResultsOptimization Results

• The dimension obtained from the optimization The dimension obtained from the optimization analysis comply with K-T conditionsanalysis comply with K-T conditions

• Analysis give us the following results:Analysis give us the following results:

f(x) = (Af(x) = (ATT* * t) = Volume = t) = Volume = 4.583 in4.583 in3 3

W = ρgV = ρg(AW = ρgV = ρg(ATTt) = Weight= t) = Weight= 0.2088 lbs0.2088 lbs (Feasible Weight)(Feasible Weight)

Adapter

ANSYSANSYS

• After optimizing the design, it was verified using an FEM After optimizing the design, it was verified using an FEM analysis : ANSYSanalysis : ANSYS

Geometry and MeshGeometry and Mesh Force & RestrictionsForce & Restrictions

30 lbs

Stress PlotsStress Plots

The maximum stress due to a point load of 30 lbs = 131.785 psi

Note: Does not exceed our yield strength

Stress Plots - AnimationStress Plots - Animation

Deflection PlotsDeflection Plots

• The maximum deflection is 0.15 in, when 30 lbs are applied at the end

30 lbs

Restricted end

Deflection Plots - AnimationDeflection Plots - Animation

Cost AnalysisCost Analysis

Total Cost: $64

Great cost for such incredible features!

Final DesignFinal Design

• After all relevant analyses performed:After all relevant analyses performed:

Final Design: RTSA Final Design: RTSA

RecommendationsRecommendations

In the case the RTSA were to be produced in mass numbersIn the case the RTSA were to be produced in mass numbers ::

• FEA analysis should be performed on the unit for other conditions:FEA analysis should be performed on the unit for other conditions: - - Manufacturing conditionsManufacturing conditions: :

* Thermal & Shear stresses due to casting and others* Thermal & Shear stresses due to casting and others

• Optimization of other components should be performed to ensure Optimization of other components should be performed to ensure only the best quality product is produced:only the best quality product is produced:

- - RTSA Cylinder armRTSA Cylinder arm

- - RTSA adjustable ringRTSA adjustable ring

ConclusionsConclusions

The different studies performed show the RTSA to :

Guarantee a reduction of steps and time to your overall processes

Excel under harsh machine shop conditions

Minimize human effort required to perform repetitive tasks

Break the standards in tool-handling products available today

Increase Gross Production Volume, and Company's overall savings

Provide the perfect opportunity to convert a problem of inefficiency into an extraordinary profitable solution to your Industry

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QuestionsQuestions

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