1. 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 *

2. 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

3. 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

4. *
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 *

5. 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 *

6. 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 *

7. Specifications Must haves*
07/16/96
Specifications
Must haves
Maximum load: 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 *

8. 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 *

9. Propulsion - Possible Solutions
11/28/2018

10. 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

11. The Solution

12. 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 *

13. 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 *

14. 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

15. 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 *

16. 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 *

17. 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 *

18. The Prototype

19. 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

20. 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

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

22. 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

23. Questions?