WILLIAM ALLEN MAIN (858) 692-7752

Will_Main@outlook.com

Senior Design ENSC 28 - Hydraulic Track Drive

Project Description: FLSmidth Spokane designs and manufactures large material handling equipment for customers around the globe. One of the product lines sold by FLS is the mobile stacking conveyor systems (MSC). These MSCs are propelled across the mine site using a track system. This project will design a hydraulic cylinder drive mechanism to replace the motor/gearbox/sprocket drive in the current design.

Deliverables:

1. Project plan, detailed deliverables, and schedule as derived from the Scope of Work provided by FLS. 2. Literature research into similar mechanisms. 3. Detailed mechanical design of a D4 track system using hydraulic cylinders to replace the motor/gearbox/sprocket drive. 4. Finite Element Analysis of all load bearing components. 5. Detailed mechanical design of a scaled model track system. 6. Test plan of the track system.

This was our yearlong senior design project. Four of my Mechanical Engineering classmates and I

collaborated to present FLS with a newly designed track system. We designed, from scratch, both a scale

model and full-size model.

Scale Model Full-Size Model

I was the team leader, coordinating our communication between our team and advisor, engineering

department, machine shop, and FLS. I personally modeled the frames on SolidWorks. I also designed and

modeled the braking system for the sprocket for the scale model and the braking for the track on the Full-

Size model. Additionally, I wrote up a test plan for the scale model. This plan tested key components and

simulated various environments that the Full-Scale model would experience. I also assisted with FEA on a

few components. Additionally, I designed concept 1 which can be seen on the PowerPoint.

I will insert a PowerPoint about this project at the end of this document. This PowerPoint was

accompanied by an oral presentation, but I believe the slides will still provide additional insight on the

project.

Junior Design Pawn Tray Loader Project

Goal: Design device to sort 2 different colored pawn pieces into a tray in any specified order

using sheet metal, 3D printed parts and pneumatic cylinders.

Requirements:

- Limited to 4 pneumatic cylinders,

- Use provided trays and pawn pieces

- Use only sheet metal, 3D printed parts, and fasteners

- Computer program needs to be able to sort pawns in any specified order

- Footprint constraint

I personally designed the main loader portion of the project. This was a 3D printed part designed on

SolidWorks. There was an incentive to have a lower number of total parts, so I designed it as one solid

piece taking into thought the alignment on the 3D printer.

I have provided a link of a video of our machine in operation. This video shows our Pawn Tray Loader

loading the trays in a checkered pattern. The main difficulties with this project were the light weight

pawns constantly tipping over and the depth of the wooden trays. The video shows that we were able to

overcome these obstacles as our machine flawlessly loads the trays.

https://www.youtube.com/watch?v=83OVvw_7i5M

Junior Design Chip Flipper

Goal: Design device out of cardboard which takes a stack of two different colored poker chips, flips each chip once, and finishes with a single stack of alternating colored chips. Materials available: cardboard, hot glue gun, paperclips. Speed and accuracy are key

This was just a small initial project to introduce us into the engineering project system as well as have us improve our teamwork. Even though it was a minor project, I really did enjoy it. For this project, we worked in a group of four. We each designed a prototype chip flipper. My particular design was chosen for construction. My design considered both speed and accuracy.

This designed considered speed by picking one

chip up and dropping the other chip at the same

time. I do not have a video available so I will

describe the operation.

In the “slider” piece, which you push and pull to

operate, there are two square slots. In photo 2, you can see two holders. This is where two different

colored chips are placed. On the right holder in photo 2, you can slightly see that there is a slot on the

slider. The other slot is in the middle where the chips are dropped and flipped. The slider is then pulled to

the position seen in photo 3. It is now dropping off the chip from the right holder and picking up the chip

from the left holder. The three layer cardboard design where the slider is located led our device to be

accurate. The space is the near exact thickness of one poker chip to only allow one chip in the slot at a

time. After the chips were flipped as they fell through the middle section, the device is picked up and the

chips are sitting in a stack, alternated and flipped.

During the testing with the various devices made by other teams, ours was voted to be the most accurate

and quickest. Our accuracy was one hundred percent. Not one group was able to make our device fail

while following our instructions. This project was a great beginning to many more engineering projects.

1 2

Slider

3

HYDRAULIC TRACK

DRIVE

ENSC – 28 WILLIAM MAIN / KASEY RICHARDS / NICK MCDEVITT

NIKOLAY BULAKH / JERRY CURRY

ABSTRACT/BACKGROUND

CLIENT:

- MSC SYSTEM -

DESIGN PROTOTYPE

ELIMINATE NEED FOR GEARBOX

REDUCE COST AND DOWNTIME

DELIVERABLES

1. Three additional track drive concepts w/ matrix

evaluation

2. 3D models of scale and full-size design

3. 2D fabrication drawings of scale and full-size model

4. Finite Element Analysis of key components

5. Specification document for clutch requirements

6. Full-size model calculations report

7. Test plan for scale model

TARGET DESIGN SPECIFICATIONS

• INTEGRATE INTO A D4 SIZE TRACK SYSTEM

• UTILIZE HYDRAULIC CYLINDERS FOR PROPULSION

• AVAILABLE HYDRAULIC POWER OF 3000 PSI, WITH AN OPTION OF

5000 PSI

• REDUCE REPAIR TIME AND COST BY USING READILY-AVAILABLE, OFF-

THE-SHELF COMPONENTS

• CAPABLE OF MOVING MOBILE STACKING CONVEYERS 1 METER/MIN IN

EITHER A CONTINUOUS OR STOP-AND-GO MOTION

• UP TO 12 TRACK SYSTEMS WILL WORK TOGETHER SPACED 50 FEET

APART

• SUPPORT LOADS CAPABLE OF CREATING UP TO 206 KPA (30 PSI)

GROUND BEARING PRESSURE

CONCEPTS

Concept 1

Concept 2

Concept 3

Concept 5

Concept 4

Scale:

1 = Worst

5 = Best Concept 1 Concept 2 Concept 3 Concept 4 Concept 5

Mud/Weather Resistance 4 4 4 5 4

High Durability 5 4 3 5 3

Low Complexity 3 3 5 3 3

Ease of Manufacturability 5 5 5 5 4

Ease of Repair/Maintenance 2 4 4 4 3

Minimum Custom Parts 3 4 4 2 3

Totals 22 24 25 24 20

Ranking 3 2 1 2 4

Evaluation Matrix of Proposed

Concepts

SCALE MODEL DESIGN

SCALE MODEL DESIGN

• Rubber track (Caterpillar 300.9D)

• Steel inner and outer frame (A36 or A572)

• Numerous off-the-shelf components

– Sprockets, rollers, hydraulic cylinders,

SCALE MODEL BUDGET

• Preliminary budget estimate: $5400

• Final budget estimate: $4686.36

SCALE MODEL TEST PLAN

Test Type Requirements Environment

VIBRATION MIL-STD 810-514.6 Laboratory Shaker- varying frequency

and intensity

INCLINE/DECLINE Slope of 20% Grade Outdoor - Muddy, rocky and dirt

surfaces.

RUGGED/MUDDY Travel 1 meter/min

for 15 min

Outdoor – Muddy (Track should sink up

to 3 inches in mud)

SKID STEERING Performance

unaffected by winch

While track is operating - Winch is

attached to one end of track pulling at 1

meter/min

FAILURE/SAFETY Refer to FMEA

FULL SCALE DESIGN

FAILURE MODE EFFECTS ANALYSIS

FINITE ELEMENT

ANALYSIS

DRIVE CYLINDER BRACKET

PUSH PLATE

INNER FRAME

Q & A