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Mech 4860 Engineering Design Team 3 – Triple E

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Mech 4860 Engineering Design Team 3 – Triple E MECH 4860 ENGINEERING DESIGN TEAM 3 – TRIPLE E RV COMPOSITE MATERIAL UNCOILER Final Design Report Authors: Matt FROESE – Kuankuan LU – Brenden SCOTT– Mannan THAKUR – Submitted to: Dr. Paul E. Labossiere, P.Eng., University of Manitoba Kevin Peters, Triple E RV Cornie Fehr, Triple E RV Submitted on: December 6, 2017 University of Manitoba Department of Mechanical Engineering December 6, 2017 Dr. Paul Labossiere, P Eng. Associate Head, Undergraduate Program Department of Mechanical Engineering University of Manitoba, E2-327F 66 Chancellors Cir, Winnipeg, MB. R3T 2N2 (204) 474-8304 Dear Dr. Paul Labossiere, Please find the enclosed Final Design Report for the Triple E RV Composite Material Uncoiler project. The report begins by outlining Triple E RV’s issues with the composite material which are to be addressed, as well as constraints imposed on the design. A thorough needs analysis was then performed to determine design targets and marginal values. The report then presents the iterative process of brainstorming concepts to address individual issues, and evaluating the performance of these concepts. Lastly, the report explains the final design developed by the team in detail, and summarizes the overall project, goals achieved, and recommendations for the client moving forward. Several Appendices are then attached containing all technical engineering drawings developed by the team, the in-depth concept generation and selection process, analytical calculations regarding design specifications and safety, a thorough stress analysis of all components of the design including finite element analysis, weld sizing, and bolt bearing stresses, and lastly, an in-depth cost analysis of the final design. Thank you for your time, and please contact us with any concerns or feedback you may have. Sincerely, __ _____________ Matt Froese ______ _____________ Kuankuan Lu __ ___________ Brenden Scott _____ ____________ Mannan Thakur MECH 4860 – Engineering Design, Team 3 Department of Mechanical Engineering University of Manitoba Executive Summary Triple E RV, manufacturer of recreational vehicles, currently faces an issue regarding the manufacturing of floors and walls of their vehicles. The current system being used to handle 5000 lbs rolls of composite material, called Cosmolite contains no provision to maintain the tightly wrapped roll once the packaging straps are removed. Additionally, the current system is difficult to maneuver due to its large size and weight. To reduce operator strain and increase efficiency, Triple E RV has requested that a new system be designed to handle the rolls of Cosmolite material. By examining the requests of the client, the team has identified the most important needs of the project which include supporting the weight of the roll of composite material, constraining the composite material in a tightly wrapped roll during use, providing a better method of uncoiling and recoiling the composite material, positively retaining the roll of composite material, and improving the maneuverability of the roll of material. A total of 56 feasible concepts to achieve the client’s requirements were generated in the team’s concept generation and selection phase. These concepts were evaluated using screening and scoring matrices based on their ability to meet the needs of the client. The results of the screening and scoring process, along with input from the client, helped the team identify the concept which would result in the optimal final design. Numerous analyses were performed during the optimization included in the final design phase of the project. Analysis of the composite material’s stiffness was determined to evaluate the force required to maintain the composite material in a tightly wrapped roll. Safety and kinematic analysis was performed on the composite roll of material to determine the force required to move the design with a full roll of material, as well as the torque required to rotate the roll at an appropriate rate for uncoiling and recoiling. Stress analysis, including preliminary finite element analysis, welding sizing analysis, and bearing stress analysis were performed on all load bearing components to determine the required component sizes necessary to maintain a safe design. The foundation of the design is the Bottom Frame, constructed of structural steel tubing. The frame is supported by four Walking Axles, each with two steel swivel casters. The Walking Axles pivot such that all eight caster wheels maintain contact with the floor, reducing bearing and rolling friction, and thus reducing the amount of force required to maneuver the design. Four steel rollers are mounted to the Bottom Frame with pillow block bearing housings. These four rollers form a cradle in which the roll of composite material rests. Using the four- roller system eliminates the need for a shaft to support the roll of composite material, thus greatly reducing the time required during the composite roll changeover process. The composite material is constrained in a tightly wrapped roll by the Top Roller subassembly. Four steel rollers, supported by flanged bearing housings rest firmly on top of the roll of composite material. The 285 lbs weight of the Top Roller subassembly provides sufficient force to maintain the curvature of the composite material, eliminating unwanted expansion of the material. The Top Roller subassembly is supported by a horizontal Top Swinging Arm, which is in turn supported by a vertical Side Supporting Arm extending from the Bottom Frame. A hydraulic cylinder with an integrated manual pump provides the ability to raise the Top Roller subassembly during the composite material roll exchange process. Two Retaining Shafts are inserted into both ends of the roll of composite material. These subassemblies secure to the composite roll to the Bottom Frame, thus positively retain the roll of composite material from escaping the design should the composite material roll be bumped or the design overturned. Uncoiling and recoiling of the composite material is by achieved using one of two methods. Large Bus Wheels attached to the Bottom Rollers on which the composite material rests provide leverage to manually rotate the composite material in either direction. A liquid rubber coating applied to all steel rollers provides a high friction surface for the effective transfer of torque to the roll of composite material. Alternatively, an electric motor and reduction gearbox can be used to rotate the Bottom Rollers via a chain drive system. The electric drive system can reduce operator strain and increases the speed at which the composite material can be uncoiled and recoiled. Lastly, through an in-depth cost analysis, the team determined that the total cost of producing the final design is $5,072.23 USD. Table of Contents List of Figures .................................................................................................................................. vi List of Tables ................................................................................................................................... vi 1. Introduction and Project Background .......................................................................................... 7 1.1. Triple E RV ............................................................................................................................. 7 1.2. The Team ............................................................................................................................... 7 1.3. Problem Statement ............................................................................................................... 8 1.4. Design Objectives .................................................................................................................. 8 1.5. Design Constraints and Limitations..................................................................................... 11 1.6. Design Scope ....................................................................................................................... 13 2. Needs Analysis ........................................................................................................................... 13 3. Concept Generation and Selection ............................................................................................ 17 4. Final Design Details .................................................................................................................... 18 4.1. Final Design Details ............................................................................................................. 18 4.2. Roll Exchange Procedure..................................................................................................... 24 4.3. Final Design Details of Subassemblies ................................................................................ 25 4.3.1. Top Rollers Subassembly ............................................................................................. 25 4.3.2. Swinging Arm, Side Arm, and Hydraulic Lift Subassembly .......................................... 29 4.3.3. Bottom Frame Subassembly ........................................................................................ 31 4.3.4. Bottom Rollers Subassembly ....................................................................................... 32 4.3.5. Walking Axles Subassembly ......................................................................................... 33 4.3.6. Retaining Shaft Subassembly ......................................................................................
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