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Agitator Redesign for Corrosive Environment

Agitator Redesign for Corrosive Environment. Kate Karauda Luigi Abbate Will Fritzinger Peter Torab. Project Overview. Sponsored by Coating Technology Inc. Goal is to redesign the agitator system for greater corrosion resistance and longer life.

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Agitator Redesign for Corrosive Environment

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  1. Agitator Redesign for Corrosive Environment Kate Karauda Luigi Abbate Will Fritzinger Peter Torab

  2. Project Overview • Sponsored by Coating Technology Inc. • Goal is to redesign the agitator system for greater corrosion resistance and longer life

  3. Current Tank Layout

  4. Current Cam System

  5. Failed Hardware Analysis

  6. Failed Hardware Analysis

  7. Failed Hardware Analysis

  8. Failed Hardware Analysis

  9. Failed Hardware Analysis

  10. Failed Hardware Analysis • First impressions: • Worm gear not suitable for this application • Current process puts severe load on motor/gearbox • Many wear points • Failed motor did not appear to be affected by corrosion • Will conduct more detailed motor analysis

  11. System Requirements

  12. System Requirements

  13. Morphological Chart

  14. Pugh Chart

  15. Pugh Chart

  16. System Design 1 - Rotational • Vertical Axis Rotary Motion • ‘Carousel’ with part mounts • Corrosive resistant materials • Motor and gearbox moved away from vapors

  17. System Design 1 - Rotational Pros Cons • Can utilize current tank framework • Limited corrosion exposure • Fewer moving parts than current system • Increased motor/ gearbox lifetime • Difficult to accommodate different size dies • Need new die fixtures • May be difficult to access parts • More custom parts

  18. System Design 2 - Ultrasound • Off-the-shelf ultrasonic cleaning unit • Built-in temperature control • Small unit can accommodate 1-3 dies

  19. System Design 2 - Ultrasound Pros Cons • Significantly decreased cycle time • Built-in heater • Smaller batches of fluid used • No minimum number of parts to run/batch • Versatile • High initial cost for commercially available systems • Completely replace current system • Repairs may be through an outside company

  20. Design Areas Not Yet Complete • Rotational motion vs. Ultrasonic • Complete capillary force calculations • Corrosion testing and process validation • Off-shelf part selection • Detailed component design

  21. Corrosion Testing • Polarization Cell • Measured current is proportional to the rate of metal stripping • Stripping rate will be proportional to bath decomposition rate. • Variable Corrosion Testing • https://edge.rit.edu/edge/P13656/public/WorkingDocuments/Review%20material/Variable%20corrosion%20Chart.pdf

  22. Project Schedule • Current Action Items: • Pick a design to satisfy customer needs • Defining test conditions for the prototype design • Document and investigate previous failure modes • Invite the customer for Systems Decomposition Review

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