Final Presentation

1

• Final Presentation
• December 2, 2004

2
Project Objective and Deliverables

• Convert traveling ring to traveling roll assembly
• Modular roll assembly to accommodate different
  window applications
• 8-10 CAD drawings of conceptual design
• Decision matrices to determine best design
• Weight consideration, approximate weight of
  assembly 650lbs
• Cost consideration, each modular assembly
  6000-8000

3
Design Decisions

• Frames Dimensions and Materials
• Inner
• Outer
• Adjustments
• Height
• Radii
• Drivetrain
• Motor
• Gears and Timing belts
• Rollers
• Rods
• Donuts

4
Frame Dimensions and Materials

• Inner frame and adjustments
• Overall dimensions 70 L X 45 W X 8 H
• Length and Width range of window sizes
• Height constrained by current layout of quench
  boxes
• Material Selection
• Adjustments Steel (Brass plates for dove tail
  slides)
• Inner frame Aluminum
• Pins Steel
• Based on weight and cost
• Outer frame
• Overall dimensions 82 L X 45 W X 3.5 H
• Dimensions determined by inner frame and existing
  track
• Material selection Steel tubing
• Based on weight and cost

5
Inner Frame
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Inner Frame Decision Matrix

• Window Ranges
• Horizontal Radii Range 400in to Flat
• Vertical Radii Range 38in to 90in
• Max width 30in Max length 48in
• 5 Modular Units
• Crossbars differ for quench clearance
• Rods are interchangeable
• Weight Range 300lbs 500lbs
• Depending on Material (Al or Steel)

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Adjustments

• Height Adjustment Vertical slide
• Radii Adjustment Horizontal slide

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Outer Frame
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Outer Frame Graph Comparison
¼ in. thick x 3in square Aluminum tubing was
chosen because it kept the weight the lowest and
was within the acceptable range of deflection.
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Drivetrain Motor

• Motor location Outer frame
• Position influenced by convenience and cost
• Placement on permanent frame results in universal
  motor for several modular units
• Electric motor ORMEC Servomotor D-series
• Power 2.7 HP
• Continuous Torque 56 lb-in
• Moment of inertia 2.82 X 10-3 lb-in-sec2
• Maximum speed 4500 rpm
• Cost 3500

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Drivetrain Gears and Belts

• Timing belt Berg W.M. Inc. Steel-reinforced
  polyurethane
• Chosen over chains due to weight consideration
• UTS 50 lbs
• Operating temperature (-15 to 150 oF)
• Cost 11.37 per belt, 12 belts per assembly
  (150)
• Gears Aluminum XL ANSI
• Pitch diameter 3.82, speed reduction
  calculations 1.91 1
• ¼ width
• ½ bore, based on ½ rod
• Cost 41.84 per gear, 24 gears per assembly
  (1000)

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Rollers

• Rods Preformed Stainless Steel, ½ dia.
• Material based on cost consideration
• Size based on weight consideration
• Cost 110 per rod, 12 rods per assembly (1320)
• Donuts Carbon fiber hub with Duratemp donut
• Donuts every other insert, staggered on rods
• Curbell Industrial Plastics, carbon fiber hub
• Cost 7 per insert, 420 inserts per assembly
  (2940)
• Duratemp Corporation, carbon donut
• Cost 15 per donut, 210 donuts per assembly
  (3150)
• Sleeve Kevlar material
• Cost 6.39 per ft., 60 ft. per assembly (385)

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Roller Material Decision Matrix
Assumptions 1. Kevlar sleeve is insignificant
to cost 2. New sleeve (Thermosleeve) would also
be insignificant to cost, but cost does not
include computer analysis to determine perfect
sleeve for application 3. Cost of 210 is for
staggered donuts (every other hub has a donut) 4.
Stainless Steel rods, wear considerations
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Modular Roller Assembly Cost

• Drivetrain 4,600
• Rollers 8,000
• Outer Frame 2,000
• Inner Frame 6,800
• Subtotal A 21,400 per assembly
• Subtotal B 14,000 for full assembly
• Subtotal C 8,000 for each additional
  assembly
• TOTAL 46,000 (5 assemblies)

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THANK YOU