1. Improved Honeycomb Expander Levi Gordy Karl Grabczewski Andy Olenderski Stephanie Swain Team Alcore

2. Overview What is Alcore? Process of Interest Current Problems Alcore Wants Metrics Our Concept Subsystem Development Cost Analysis Value to Sponsor Path Forward

3. What is Alcore? Located in Edgewood, MD Produces and Processes Aluminum Honeycomb Core Product applications in Aerospace, Marine, and Construction Industries Used in Commercial Airlines and Military Hardware

4. Process of Interest Aluminum Core Expansion (7 steps) Transfer CartHolding Table Nailing Station Finished Stack ExpanderHolding Table Cutting Station

5. Process of Interest (Graphically)

6. Expansion Phase Aluminum Core Module Aluminum Core

7. Current Problems Unnecessary Handling –Transfer between stations Labor intensive –Nailing, loading, unloading, resetting Inconsistent Process – Human error causes delays – Higher variability in timing

8. Alcore Wants Driving Wants –Reduced Handling –Reduce cycle times Varying Cores Require Adaptability Other wants result from driving wants Training Time Manageable Weight Improved Safety Transfer Cart Cutting Station Finished Stack Expander

9. Metrics We can improve many aspects of the process Further improvement not possible in all areas MetricCurrent ValueTarget Value Nailing Time150 sec10 sec Loading Time60 sec30 sec Expansion Time60 sec30 sec Quality Check Time160 sec130 sec Unloading Time80 sec60 sec Operators Needed2 to 42 Cores per Expansion1 to 22 to 4 Cycle Time8.5 min4.3 min

10. Current Expansion Table 1 2 3 4

11. Our Concept… Incorporate an automatic gripping system

12. Critical Subsystems Five critical design components Overhead Press Gripping Module Slide Rail Resetting Mechanism Linear Actuators Support Frame Examined Alternatives for each subsystem

13. Sliding Module Considerations Needs to support insertion forces Resist binding from expansion forces Minimal deflection along guide rail Mating modules can’t obstruct one another

14. Sliding Module F Nylon Lined Plain-Bearing System Static Load Capacity of 2240 lbs F = 400 Newtons ≈ 90 lbs Approx 20 Modules along width of table ≈2000 lbs Cumulative Load Cumulative Load < Rated Load Capacity

15. Sliding Module Components 1. Guide Rail 2. Guide Block 3. Gripping Nail 4. Retaining Plate 5. Eyelet Screw 1 2 3 4 5

16. Return Mechanism 1 2 1 – 3/32” Aluminum Cable Ferrules 2 – 25ft x 3/32” coated cable Winch pulls cable taught

17. Actuator Considerations Small profile to easily attach to frame Suitable for high cycles: Raising and lowering slide rail and modules Produces required forces to puncture 12 lb core ( 8000 N / actuator assuming 10 ft width) Lightweight

18. Actuators Rod screw actuator with In-line motor –Low profile (8.6’’ x 3.8’’) High Cycles Time to Fatigue –(90% reliable to 10^6 inches) Meets required forces –Max force ~4300 lb (~16000 N) Low added weight (14.2 lb) Can operates at 25 in/sec Multiple Mounting Options –Foot mount and Externally threaded screw

19. Support Frame Utilize Existing Mobile Gantry Proven in this application Eliminates cost of producing new frame

20. Cost Analysis (Full Scale System) PartPrice Guide Rail900.00 Guide Block4141.92 Nitride Ejector Pin118.08 Retaining Plate1920.00 Retaining Screw16.18 Eyelet Screw620.16 Cable19.90 Cable ferrules94.08 Winch69.99 Linear Actuator31595.16 Total Cost39,495.47 Benefits Estimated Profit per annum Reduced Operators$49000 More Cores per cycle$500,000 Faster Cycle time$500,000 Total New Earnings (est.)$1,049,000

21. Our Prototype Overhead Press Concept proved to be the best Prototype to Simulate one section Proves insertion times, removal times, resetting times.

22. Completed Prototype

23. Testing and Validation Prototype crosshead mounted into Instron Single module on guide rail to test insertion quality and time

24. Testing Video Video_Core Insertion.MOV

25. Testing and Validation Used same speed as linear actuator to insert nail into 1 to 5 cores –At most Alcore currently expands only 2 cores at a time Nail was inserted cleanly and quickly –Nailing, loading, and unloading currently take 290 sec at Alcore –Our prototype reduces time to 100 sec

26. Testing and Validation Our resetting mechanism resets the modules in 1 second

27. Testing Video Video_Resetting.MOV

28. Results vs. Target Values Improvement Criteria Target ValueResults Nailing Time10 sec Loading Time30 sec Expansion Time40 secuntested Quality Check Time130 secuntested Resetting Time40 sec1 sec Cores per Expansion45 Operators Needed22 Time saved per cycle ≈ 3.5 min

29. Time Charts Comparing Old vs New Process 0 100 200 300 400 500 600 700 Old AverageWorst Case (Old)Estimated New AveragesWorst Case (New) Process Time (seconds) Unloading Time Quality Check Time Expansion Time Loading Time Nailing Time

30. Value to Sponsor Reduces handling time/labor intensiveness –Happier work force Reduces # of operators needed –Operators used more effectively elsewhere Increased number of cores per cycle – Higher Productivity

31. Path Forward Determine max number of cores subject to expansion force constraint Prepare transition/full scale implementation package Validate expansion time on full scale system

32. Questions?

33. Supplementary Information

34. DimensionDistance (mm) A70 B36 B131 D57 G23 Side View

35. DimensionDistance (mm) C96 E45 FM8 x 24.8 G23 H21.5 J60 K40* M10 NM6 P6

36. Resisting Bind-up of Module Guide Blocks are rigid Designed for much higher loads than will be experienced Prototype testing could further validate Ball Bearing Modules much more costly

41. Cable/Module Reset Winch –Portable –12 V DC –2000 lb capacity –$69.99 –Cable goes through eyebolts on modules –Master Lock Model# 2953AT

42. Slide Rail Slide Rail available in 1 m sections Support Beam used to mate sections/add rigidity 1m