Final P r o t otype

1. Senior Design 2013–TeamAlcore JeseniaVelez, Michael Garbarino, Brain Bird, Mark Jenkins Advisor:James Glancey SpecialThanksto Tom Mulrooney, Eric Franzoi PrototypeTesting And Validation Background Metrics and Target Values The Alcore honeycomb business began in the 1960’s Leader in providing high-quality, lightweight structural honeycomb materials to the aerospace, nuclear and marine markets. A comparison between the previous process capabilities and the benefits added by this design. Using test methods and comparison the team was able to meet the metrics and target values assigned in the beginning of the project. ProjectDefinition Task: Moving stacked aluminum to multilayered curing oven Current process: Single layer scissor lift system with delayed consecutive loading Problem: Delay between loading each layer leads to compromised quality Process mapping: Reduction in step number -Loading: reduced to 35 from 84 -Unloading: reduced to 30 from 59 Torque Testing : -Verification of theoretical model -Validation of motor selection -Adjust the motor specifications for the full scale design Structural Testing: - Alternate support methods shown to decrease resulting strain up 50% FEA Analysis: -Verified structural components during solid modeling FinalPrototype Scope/Project Significance • Design a machine which can simultaneously load up to four 2000 lb blocks of aluminum into the curing oven • Manufacture and test a simplified prototype. • Deliver a design package including a bill of materials and cost estimate. • Draw up prints for fabrication and installation PathForward The ¼ scale prototype of the design was simplified to demonstrate the horizontal translation of two blocks simultaneously. The design included a simplified actuator assembly (not shown). Restructure of roller bed to improve stability. Further testing of drive systems and grabbing mechanism to ensure functionality. Once fully tested, fabrication and integration of designed system into Alcore’s manufacturing process. This project will add the capability to use the fourth layer of their press. Conservative estimates show that this adds 6.6 Milliondollars to Alcore’s current capacity.