Post on 02-Jan-2016
description
Agitator Redesign for Corrosive
EnvironmentKate KaraudaLuigi Abbate
Will FritzingerPeter Torab
Sponsored by Coating Technology Inc.
Goal is to redesign the agitator system for greater corrosion resistance and longer life
Project Overview
Tank Layout
Current Cam System
Luigi
Vertical Axis Rotary Motion (VARM)
Carousel with part mounts
Corrosive resistant materials
Utilization of current tanks and framework
Motor and gearbox moved away from vapors
Continuous motion vs. sinusoidal
System Design
Rotational Motion vs. Ultrasonic◦ Ultrasonic shows a lot of potential
Capillary Forces Quick Wear Calculations Power Selection Belt Wear Rates Component Design Off Shelf Part Considerations
Design Areas Not Yet Complete
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;
Project Schedule
1 2 3 4 5
1
2
3
4
5
OCCURRENCE
S E V E R I T Y
Risk Prevention Plan Mitigation Plan Severity Occurrence Status
Missed deadline
Review planning and scheduling tools at every meeting; verify all assigned work is being completed in a timely
manner
Complete work ASAP, group discussion to get project back on track, meet with guides
3 1
Missed milestone
Review planning and scheduling tools at every meeting; verify all assigned work is being completed in a timely
manner
Complete work ASAP, group discussion to get project back on track, discuss with guides
4 1
Over the budget
Prior to completing the technical design review create a detailed BOM to verify all necessary parts are within the
project budget
Meet with the sponsor and the customer; see whether budget can be increase: if impossible
minimize the design as much as possible to drive down the cost
3 2
Exposure to corrosion cannot be reduced due to the current hardware
setup constraints
While completing the initial design take detailed measurements of the current setup; after completing the
design verify once again the new system fits in place of the old one
Explore the use of materials and off-the-shelf hardware with increased corrosion resistance
(might drive the cost up: use caution)2 3
Materials used cannot withstand the corrosive environment
Verify the BOM for all parts which might have a significantly decreased
lifetime due to corrosion fatigue
Discuss with the customer a possibility of using more expensive materials. Alternatively, settle on
current materials and create maintenance plan which would help increase the lifetime of parts.
2 2
System performance issues
Create a functioning protytpe; run the prototype in similar or harsher
enviornment under maximum load to verify its functionality
Review design, observe system in operation, collect data and interpret to identify the part(s) causing
the issue5 1
Prototype beyond scope of project
During the design phase focus only on functions directly related to the
hardware in question; ommit functions not closely related to the current
system
Redefine system objectives and functions 1 3
Customer needs not met
Create several review meetings: present the design idea to the
customer and if approved create a prototype; follow the list of customer
needs and review along with the design
Meet with customer to discuss and reach consensus on every need which has not been met; if the
customer is still not satisfied propose one of the alternative design which might meet their needs
better
5 1
Compatibility issues with current tank framework
Measure the framework; ensure the measurements are included in the
design phase of the new system
Adjust layout of system; if budget allows, redesign framework
1 4
Underpowered for desired application
Verify that the new design can handle maximum loads required by the
customer; test the prototype under at least maximum load
Meet with customer and discuss possible design changes; add an extra motor or another power unit
to increase the power output of the system3 2
Higher than expected operating costs
Run the prototype under similar conditions as those in the factory;
record power input required, power output, load handling and
maintenance cost
Limit and eliminate factors driving cost as much as possible; alternatively adjust the design
3 2
High maintenance
Use off-the-shelf parts which require as little maintenance as possible; use self-
lubricating parts where possible to decrease the required maintenance
Minimize system maintenance requirements for customer; create a revised maintenance manual for the customer to simplify maintenance requirements
2 2
Inconsistent performanceVerify that the prototype is functional
and performing as expected in the testing phase
Identify factors causing inconsistencies in performance and make improvements accordingly; take data and observe the system for several cycles
4 1
Project Risks & Mitigation Plans