1. Team Dow Electronic Materials Nicholas Bishop, Jessica Harrington, Rachael Lutchmedial, Alexander Stachnik, Anthony Vacaro. Overview Background Information Project Scope To create a system that will consistently and easily extract liquid raw material from a 330 gallon industrial tote. This system must integrate into the existing production line and be safely and ergonomically operated by individuals of any physical strength and stature. Final Design Concept Generation Testing Plan and Validation Acknowledgements Metrics Dow Electronic Materials currently extracts material from a 275 gallon intermediate bulk container tote by manually inserting an attachment at the top. Upgrading to a 330 gallon tote saves $250,000/year, but the height of the tote increases We would like to thank our sponsor, James Romesberg and Dow Electronic Materials, and our advisor, Dr. James Glancey, Steve Beard, and the rest of the Senior Design Staff. Prototype Design Process MetricsTarget Value Material Loss< 1 gallon (set by Dow) Lifting Weight< 35 lbs. Distance of Reach for Operator< 2ft. 5 in. Height of Operator4-7 ft. Permanent Bay Space Occupied≤ 5 sq. ft. Temporary Bay Space Occupied≤ 12 sq. ft. Cost< $12,500 Time to Setup< 3 minutes Amount of Residual Material in Tote (depth) < 1 in Fixture Weight< 200 lbs. The final prototype was tested both to ensure that all metrics were satisfied. The final prototype will be immediately implemented into Dow’s process. A complete drawing packet, installation instructions, and path forward will also be given to Dow. Five different concepts were generated and compared to each other on how well each met the top five wants of the customer. The Linkage was chosen as the final concept by the team, the sponsor, and Dow’s operators. With a selected concept, a mock-up was made out of inexpensive materials to demonstrate a proof of concept. While testing, potential problems arose and respective solutions were developed. ConcernsCommentsSolution SafetyPinching Hazard, Sharp Edges Spring Cover, Linkage Redesign, Nylon Covers Height Top of the linkage was hitting the ceiling, could cause damage or it will not fit in the bay Created stops so the linkage can not exceed 10‘; implemented a latch so the linkage can remain in the upright position Torque and Bending 60'' Output link could not support its own weight, 20'' wand support arm caused unwanted torque 80/20 T-Slot Construction: Strong in Bending and Torsion Altered Linkage, only 1 output arm Wand Placement Wand must enter the hole without touching the tote when plugging Funnel apparatus to guide wand into tote opening AdjustabilityPlacement of spring, links, wheels 80/20 T-Slot Less machining, Linear Slider w/ hand brake Weight Spring must counteract weight of linkage Gas spring Unwanted Linkage Movement Links were sliding along their pinsAdded Spacers and Notches Wand Connection Allow for easy attachment and release, stable while pumping Two Spring Clamps on a Rotating Plate Assembly Distance Device distance from tote is very specific for linkage to work as designed Lightweight Locators to guide placement of Linkage Simple Finite Element Analysis showed that for less deflection in the output link, 1” Double T-slot should be used instead of Single T-slot for this link. After several iterations, a final prototype was made out of Extruded Aluminum T-slot with a total cost of $2168. The prototype addresses and resolves all issues encountered with the mock-up. MetricsPrototype Value Material Loss0.0 gal Lifting Weight3.7 lbs Distance of Reach for Operator2 ft. 4 in. Height of Operator4’ 5” – 7’ 9” Permanent Bay Space Occupied0 sq. ft. Temporary Bay Space Occupied10 sq. ft. Cost$2168 Time to Setup36.4 sec. Amount of Residual Material in Tote (depth) 1 in. Fixture Weight118 lbs. by 7 in. and the manual process becomes difficult. Dow is seeking a design to improve ease of use and efficiency for this extraction process.