Silicon Powder Dispending System Team GE Energy

1. Structural Validation Final Design Finite Element Analysis • The design is a cantilever structure which supports the full weight of both totes. • The design fits the tight and limited space constraints • Once totes are in place requires little operator interaction Minimum Factor of Safety For 2 totes correctly loaded 4.8 Silicon Powder Dispending System Team GE Energy Mike Bauman Ben Binder-Macleod Kait Hatton Eric Persak Minimum Factor of Safety For 1 tote correctly loaded 3.8 Project definition Graphical Display of Von Mises Stresses of 2 totes correctly loaded from FEA To enhance the silicon powder dispensing method for the use in PV solar panels, by automating dispensing of silicon and designing a support structure Full system set up with totes, structure, furnace, and conveyer • The totes will be lowered into tracks with wheel stops that will prevent sliding once in place • When in place totes valve will mate with the electric actuator (shown in red) • Because of the tight height constraints the actuator will swing down to allow the tote to pass by (shown below) • The controls use the out put of load cells for both the hopper and tote to control the actuator Current Process • Totes come in from two separate directions • Totes are hand operated to empty into hoppers • Hopper filled 2-3 times an hour • Hopper feeds silicon into drop spreader • Silicon travels on conveyer belt into furnace FEA of Von Mises Stresses of 1 tote correctly loaded FEA of Von Mises Stresses of 2 totes of misaligned loading on wings 1. Path Forward • Assemble structure • Integrate into the production line • Install control system Structure with actuators 2. 3. 4. Target Performance Metrics • Tote 2. Hopper 3. Drop spreader • 4. Conveyer Belt Subsystem Wants Problems in Current Method • Support Structure • Mount to floor • Stabilize totes • Minimal obstruction for operator • Easy access for maintenance • Actuator • Run off existing power • Requires little to no modification to existing totes or assembly line • Controls • Easy to modify • Reliable • Hard for operator to manually open and close valve on tote • Totes weigh close to 1,500 pounds each and are stabilized by chain hoists • Chain hoists cause sway of tote and potential spillage of silicon powder. • Very limited space constraints! Actuator rotated up Actuator rotated down Alignment Validation All wheel, valve, and position alignments worked