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Preliminary Detailed Design Review Phase I: Assembly Stations 1-5

Preliminary Detailed Design Review Phase I: Assembly Stations 1-5. P13458: Dresser-Rand C ompressor Assembly Line Team Members: Lauren Kraft –Project Manager, Nick Feng – IE Cole Bowden – ME, Shawn Moseley – ME Jordon Boggs – ME, Alex Peterson – ME. Agenda.

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Preliminary Detailed Design Review Phase I: Assembly Stations 1-5

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  1. Preliminary Detailed Design Review Phase I: Assembly Stations 1-5 P13458: Dresser-Rand Compressor Assembly Line Team Members: Lauren Kraft –Project Manager, Nick Feng – IE Cole Bowden – ME, Shawn Moseley – ME Jordon Boggs – ME, Alex Peterson – ME

  2. Agenda • Key Objectives of this Review • Problem Statement • Preliminary Detailed Design of Caster System: • Caster Design • Cart Design • Universal Frame Interface • Frame and Caster Plate Stress Analysis • Design Risks Identified • Detailed Design Needs • Ergonomic Justification • Process Layout Update • Economic Analysis • Project Outlook & Timeline

  3. Key Objectives of this Review Prototype Design Overall Process layout Catch mistakes Improve design from operator feedback Specs (needs) are addressed Risks are addressed Decisions are made to further design Receive feedback on current layout Consider alternatives and application of lean principles What are we missing?

  4. Problem Statement Design a flexiblematerial handling system to incorporate 5,000 to 22,000 pounds that is easy to useand incorporates the safest design elementswithin cost and functionality constraints. This design fully supports the new process layout in Dresser-Rand’s strategic project.

  5. Caster Design • Designing to 5000lbs/plate • Casters per plate: 4 • Caster load: 1250lbs • Caster considerations • Swivel lock • Low diameter • Non-Metal Construction • Cost • Hamilton WH-4NYB • 4 inch diameter nylon wheel • 2000lb load capacity

  6. Swivel Lock Casters • Locking casters allow for strict 2 directional motion • Each caster must be turned and locked by hand • 4 unidirectional caster sets will over-constrain the system • Solves guidance issue • Creates a directional control issue • Creates an ergonomics issue

  7. Preliminary Cart Design

  8. Preliminary Cart Dimensions

  9. Universal Frame Interface • Single interface compatible with all 3 compressor families • Tapered pin on top face for ease of frame positioning • Dual pin configuration on bottom face for stability • Ease of manufacture and assembly

  10. Universal Frame Interface Unloaded Beam MOS HOS HOSS

  11. Beam Model Output

  12. Frame Stress Analysis – On Casters • Peak stress of 6850psi, n<4 • Agrees well with initial calculation of 6930 psi, n<4 • Max deflection .01 inches

  13. Frame Stress Analysis – On Jackstands

  14. Caster Plate Stress Analysis

  15. Design Risks • Casters cannot support cylinder weights • Tugger integration not yet determined • Directional control issues with casters • Ergonomics of swivel-lock rotation • Tolerance stack-up • Weld joint stress analysis • Caster bolt pattern not standard • Manufacturability deadlines Highest Risk Lowest Risk

  16. Detailed Design Needs • Dimensioned frame drawings with tolerance • Design safety standards (if applicable) • Finalized cylinder attach decisions • Finalized caster decisions • Casters or air bearings decision

  17. Ergonomics Male horizontal reach = 731 mm (95%) Female horizontal reach = 676 mm (95%) 10% of female = 641 mm Height of compressor (711.2 mm) + carts (457.2 mm) = 1168.4 mm Male vertical reach = 1732.5 mm (mean) 1844.04 mm (95%) Female V.R = 1602.7 mm (mean) 1711.96 mm (95%) 1518.9 mm (10%)

  18. Ergonomics • Horizontal Reach Envelope

  19. Conceptual Assembly Process Sub-assembly Main Assembly Phase I Phase II Source: Dresser-Rand

  20. Process Layout

  21. Economic Analysis • AFE presented to team and reviewed • Estimates apply only to MOS compressor product launch and does not take into consideration the financial effects of the mixed model format of the line • Inflow and Outflow data used to calculate several figures to justify the pursuit of this project

  22. Project Outlook

  23. Project Timeline • ①Completed: • Systems Design Review for Assembly Stations 1-5 (Phase I) • Preliminary Detailed Design of Caster System • ②Current Work: • Process Layout of Assembly Line • Concept Development of Phase II – test, paint, shipping • ③Future Work: • Finish detailed design of Phase I • Review Phase II concepts

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