The “Yarn Bully” Transport Cart * 07/16/96 The “Yarn Bully” Transport Cart Modified Yarn Transport System with Shaw Industries Richard Trotta Kwaku Boateng James Beahn *

Shaw Industries The world’s largest carpet manufacturer! Over $4 billion in sales last year Local plants located nearby in Georgia and Alabama 11/28/2018

Description of Problem In Shaw factories carts and buggies are used to transport large spools of yarn through their factory Due to their environment, these carts quickly become difficult to operate due to contaminated wheel assemblies 11/28/2018

* 07/16/96 Scope Goal of project is to design or modify the yarn transportation system, i.e. buggies and carts, at Shaw Industries carpet manufacturing plants in Bainbridge, Ga. and Andelousia, Al. 11/28/2018 *

Problem – Self Propulsion * 07/16/96 Problem – Self Propulsion Propel carts throughout factory 1000 pound carts are hard to start moving Easy to operate once in motion Inertia! 11/28/2018 *

Needs Single operator or automated Be safe for indoor use * 07/16/96 Needs Single operator or automated Be safe for indoor use Be compatible with current factory layout Comply with any company standards 11/28/2018 *

Specifications Must haves * 07/16/96 Specifications Must haves Maximum load: 1000+ lbs & 16 spools (for peg cart) Plus weight of propulsion mechanism Cart protects product Cart easy to operate Little or no training necessary 11/28/2018 *

Specifications Desirables Effortless operation Assisted steering * 07/16/96 Specifications Desirables Effortless operation Assisted steering Increased capacity High operating speed Low maintenance 11/28/2018 *

Propulsion - Possible Solutions 11/28/2018

Decisions Use compressed air New Cart design As opposed to retrofitting Include emergency cut-off brake Inertial Design Overcomes inertia as opposed to constantly driven (i.e. motor) Needs connections specific to duties in factory 11/28/2018

The Solution

Solution Custom fabricated “push-cart” * 07/16/96 Solution Custom fabricated “push-cart” Pneumatically powered cart utilizing existing source of compressed air at factory Powerful More useful source of stored energy than electricity Cheaper than retrofitting all carts Can afford to spend more per cart 11/28/2018 *

Push-cart design Tubular steel frame Front-wheel drive * 07/16/96 Push-cart design Tubular steel frame Front-wheel drive 3-wheeled design Wheelbarrow design for cart coupling Pneumatic cylinder for powerhouse 11/28/2018 *

Push-cart design Gearing system Covering to protect from contamination Ratchet gear 11:1 Gear box Bicycle-like sprocket gearing Covering to protect from contamination User interface Handle Regulator/Power knob “Always-on” brake 11/28/2018

Push Cart – Powertrain Pneumatic cylinder pushes and rotates ratchet * 07/16/96 Push Cart – Powertrain Pneumatic cylinder pushes and rotates ratchet Turns a gear box and subsequent sprocket gear pair Chain turns axle 11/28/2018 *

Push-Cart – Pneumatic Cylinder * 07/16/96 Push-Cart – Pneumatic Cylinder Creates linear force using compressed air Efficient means of converting energy Necessitates an onboard air tank Easier and faster to refill as compared to an electric battery 11/28/2018 *

Push-Cart – User Interface * 07/16/96 Push-Cart – User Interface Lawn mower-like activation handle Bicycle-style brakes Activated off instead of on, creates safety Steel-braided cable, possibly hydraulic Regulator Valve access for increased or decreased power Regulator High Pressure gauge acts as tank level indicator 11/28/2018 *

The Prototype

Prototype - the “Yarn Bully” Prototype not identical to final design Prototype made slightly larger/stronger than necessary Many conclusions drawn from prototype 11/28/2018

Prototype - the “Yarn Bully” Prototype a “Yarn Bully ‘PX’ Model” Features a “Peg-cart” connection An experimental model which does not have reverse gearing 11/28/2018

Prototype - Conclusions Changes made Clutch bearings added to wheels Brake mounting Gear plate dimensions 11/28/2018

Acknowledgements We would like to thank: Dr. C. Luongo Kenya Roberts ME Senior Design professor Kenya Roberts MDTC coordinator Marten Hutchison Shaw Industries liaison Dr. P. Hollis Faculty advisor 11/28/2018

Questions?