Phase IV Report - University of Delaware
Contents
1. 5 38561310597 1 5449 5000 SearsHardware Ducting G PMDSE 445559 72 558 500 SearsHardware 4 PasicBCMDS 98262051618 1 579 5000 SearsHardware x Selam 7079818086 1 54 500 SearsHardware MDS 44549050645 1 549 000 SearsHardware Valve 3 4MDS 1 59 500 SearsHardware TubingyRedTMDSE NotGiven 4 636 500 SearsHardware 2 5000 Sears Hardware pm 3 sss oo ow aa pve senso i is GT Bird Feeder Brush 9 Texture Roller 9 Texture Roller Wheel Detailing Brush 9 Roller frame 4320 1 227 50 bowes Subtotal 5388 66 511 96 Total S400 62 Project Management A Microsoft Project file has been maintained tracking tasks responsibility and progress Gantt chart was used to provide an overview of the project timeline at a glance full sized version of the chart 15 located in the appendix of this document Correspondingly labor tracking analysis was also performed Labor Tracking 08 29 07 12 06 07 3 7 _ 08 29 07 49 05 07 lg 09 1407 09 19 07 09 26 07 r O 10 03 07 k 10 10 07 10 17 07 11 07 07 11 14 07 _ 11 21 07 11 28 07 12 05 07 Figure 262. 5 O 2 Figure 24 Control Interface Appendix Liquid Control Equipment Description and Quotation Equipment Descriptions The DL 2 is a stand alone rotary pump metering system consisting of two gear pumps a PLC controller with a touch pad operator interface a monochrome screen with intuitive graphical displays The mixed material flow rate and volume mix ratio are fully programmable An Anti gel timer is included to ensure the mixer will be purged periodically Access to critical process parameters is password protected to prevent tampering by unauthorized personnel The DL 2 features material recirculation valves and is intended to be used with Liquid Control mix heads that incorporate pneumatic actuation such as the Twinmixer series The mix head must be specified as a separate proposal line item A footswitch is supplied as standard equipment The PLC supports a number of optional features such as the EnGarde ratio monitor printer as well as feed system low material level sensors and auto refill capability These valuable features can be incorporated at the factory or can be readily upgraded later The rotary metering pumps are gravity fed directly from 55 gallon drums or reservoirs using optional feed systems supplied by LCC The precision high and low volume rotary pumps are each driven by AC low maintenance gear motors The system ratio accuracy is easily and accurately achieved by using the software dri
3. O F Q PE F R O Running Total 24 350 Fabrication Labor 0 O O O O KH O GQ NO G OQ BO QO O O O O O O O O O O O O O O O Test amp Evaluation Labor 0 N N U N G O O O O O O O O O O O O O O N O O Total Hours 13 13 10 18 12 10 10 19 16 14 12 13 13 17 13 16 9 16 6 10 17 13 16 12 12 13 12 20 10 10 5 8 7 16 9 9 19 19 Total Cost 650 650 500 900 600 500 500 950 800 700 600 650 650 850 650 800 450 800 300 500 850 650 800 600 600 650 600 1 000 500 500 250 400 350 800 450 450 950 950 3 4 gt Figure 26 Appendix Labor Tracking Loading Chart Labor Tracking 08 29 07 12 06 07 Date m Design amp Analysis Labor m Project Management Labor Fabrication Labor m Test amp Evaluation Labor 12 05 07 Appendix Roller Selection Lab Objective Determine the physical attributes of different store bought cylindrical brushes associated with the specific epoxy and fiber infiltration Theory The brush filler bristles material needs to be optimized for stiffness and also minimized for abrasiveness Because the fluid flow is too complicated to model or fully understand the aim of the experiment is to mimic the current human application by way of an automated cylindrical brush infiltration Several store bough
4. Design amp Analysis Labor E Project Management Labor Fabrication Labor m Test amp Evaluation Labor Labor was subdivided into Design amp Analysis Project Management Fabrication and Test amp Evaluation An arbitrary rate of 50 hr has been chosen in order to provide an accurate approximation of simulated contract labor Up to this date 24 350 in labor is estimated This is a cost that will not be incurred upon the sponsor Instead it 1 an exercise to impart an additional element of realism to the project An itemized chart is shown in the appendix of this document graph depicting the workload as a function of time 15 shown in Figure 26 Future Considerations One of the most prevalent considerations for the future use of the production model 15 mechanical stiffness and shifting It Is recommended that all assembly bolts be coated with bolt sealant tightened and examined every time the frame is adjusted Loose bolts if ignored for long enough could allow the roller holder to shift position adversely affect resin infiltration The production model has been designed to minimize resin and hardener freezing joints but potential still exists for unforeseen problems A sealed joint in the machine could stop the production model from working as it was designed This 1s specifically noteworthy on the hinge of the secondary application arm as this would force the secondary roller to apply too much pressure to the bundle This build u
5. It was determined that part of the problem in pouring the resin was due to resin viscosity which was found to be closely tied to the resin temperature during application A target value of forty degrees Celsius was then established for the resin temperature at application When the team began testing with resin at this temperature it was found that the application was made much easier More importantly the viscous effects that had been preventing proper infiltration were now helping in infiltration Heating the resin to approximately forty degrees Celsius lowered the viscosity and provided not only a more reliable method of pouring the resin but a smoother infiltration by the roller onto the fiber sheet as well Updated Target Values 1 significant voids 2 One technician to oversee Prototype Details The proof of concept prototype was constructed to demonstrate key design and technology recommendations for a final desten Specific parameters were optimized in a laboratory environment and the proof of concept was used to create a test bundle on the production forming machine The testing configuration for the machine trial can be seen fully set up in Figure 5 The primary roller seen in Figure 6 coats the top of the fiber sheet as it advances and the secondary roller shown in Figure 7 coats the bottom of the sheet as the sheet 15 rolled onto the bushing The performance of this subsystem was the primary focus of the proof of concept ae
6. XX 010 AU t 050 DRAWN BY Laura Shultz DATE 12 6 07 FRACTIONAL APPROVED BY DATE 1 32 MATERIAL GUANTITY 1 ANGULAR SCALE tope DWG NO 7 0 5 DEG BILLING ACCOUNT 3 8 screw c clamp DWG No secondary holder DWG NO 4 c clamp 2 DWG NO TOLERANCES PROJECTOR CLASS UNLESS OTHERWISE i NOTED Roller Infiltration DRA WING TITLE Xxx 005 Assembly 2 010 090 DRAWN BY Laura Shultz DATE FRACTIONAL APPROVED BY DATE 12 6 07 1 32 MATERIAL QUANTITY 2 ANGULAR SCALE 13 DWG NO 9 0 5 DEG BILLING ACCOUNT Liquid Control Resin System bly 1 Assembly 2 Assernbly 1 NAssembly 2 Liquid Control Resin Pump 1 Liquid Control Resin System TOLERANCES PROJECTOR CLASS 4 UNLESS OTHERWISE NOTED Roller Infiltration Assembly 2 2 DECIMAL DRAWING TITLE XXX 005 Implementation XX 010 050 DRAWN BY Laura Shultz DATE FRACTIONAL APPROVED BY DATE 12 6 07 1 32 MATERIAL QUANTITY ANGULAR scale 1 20 DWG NO 9 0 5 DEG BILLING ACCOUNT
7. 15 recommended that one replace the secondary system half way through bundle creation with another secondary system that has a longer clamp arm Finishing a bundle again calls for the use of an operator After the bundle has reached the expected diameter the fibers need to be cut by the operator The Resin Application System may be turned off after the end of the fiber sheet has passed by the application point As remay 15 wrapped around the bundle excess resin will build up in front of the rollers This resin must be controlled by the operator so that it is present but does not overflow to the inner side of the roller When the operator is prepared to wrap both sides in plastic he may remove the secondary application systems or simply rotate them off of the bundle The operator 15 then expected to wrap both sides of the bundle in plastic wrap heat both sides to shrink the wrap to the bundle and label the bundle Trouble Shooting Possible Issues Symptoms and Solutions A rotating roller 1 characterized by a roller holder that wobbles and thus adversely affects the penetration This problem is typical of a roller holder that has been improperly secured to the arm of the system This issue can be remedied by having the operator ensure that all bolts are securely fastened after attaching a new roller If the problem is not noticed it 1s possible for the roller holder to become loose enough to come free of the arm and become caught in a pinch zone
8. BY Laura Smultz APPROVED BY MATERIAL SCALE 2 1 BILLING ACCOUNT DATE DATE 12 6 07 QUANTITY 2 DWG 3 lt X 1 c TOLERANCES UNLESS OTHER WISE NOTED DECIMAL AXX 005 XX 010 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG APPROVED BY PROJECTOR CLASS Roller Infiltration DRA WING TITLE Secondary Holder DRAWN BY Laura Shultz DATE 12 6 07 MATERIAL AL2024 QUANTITY 2 SCALE Bal DWG 4 BILLING ACCOUNT RO 75 7 TOLERANCES PROJECTOR CLASS UNLESS OTHER WISE i NOTED Roller Infiltration DRAWING TITLE DECIMAL XXX 005 010 C Clamp 2 X 050 DRAWN BY Laura Shultz DATE 12 6 07 FRACTIONAL APPROVED BY DATE 1 32 MATERIAL AL2024 QUANTITY 2 ANGULAR scALE 1 1 DWGNO 6 0 5 DEG BILLING ACCOUNT 2 47 12819 TOLERANCES UNLESS OTHERWISE HOTEL DECIMAL AAA OOS AA O10 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECTOR CLASS Roller Infiltration DRAWING TITLE C Clamp 1 DRAWN BY Laura Shultz DATE APPROVED BY DATE 12 5 07 MATERIAL 2024 QUANTITY 9 DWG 5 SCALE BILLING ACCOUNT EE Roller DWG No 2 FO22 4 al E Wooster RZ32 4 4 EpoxyGlide stand DW 3 8 screw TOLERANCES PROJECTOR CLASS UNLESS OTHER VISE NOTED summer research 005 Assembly
9. Controls for advice as the issue 1s most likely related to the Resin Application System If the secondary application arms take up the room on the pull bar that is needed for plastic wrapping or removing the bundle the arms may either be folded back or the assembly can easily be removed Extending the arm away from the looming machine may create safety hazards as the operator would have to be cognizant of the arms while moving the bundle to the drying station Drawing Package TOLERANC ES SS OTHER WISE NOTED D EC IMAL XXX 005 AKSJE OT fe FRACTIONAL 1 32 ANGULAR 05 DEG SCALE 1 20 PROJECT Roller infiltration DRAWING TITLE Stand DRAWN BY Laura Shultz DATE APPROVED BY DATE 12 6 07 MATERIAL AL80 20 3 8 AL Plate QUANTITY DWG NO 1 BILLING ACCOUNT 2X EM l LAM ar p McMaster Corr 3 FAKT TOLERANCES PROJECT UNLESS OTHERWISE NOTED Roller lafilttration SECURE DRAWING TITLE 005 Primary Holder 4 010 090 prawner Laura Shultz 12 6 07 FRACTIONAL APPROVED BY DATE 1 32 MATERIAL AL2024 QUANTITY 2 ANGULAR SCALE 1 2 DWG NO 2 0 5 DEG BILLING ACCOUNT TOLERANCES UNLESS OTHER WISE HOTEL DECIMAL OOS AKA 10 O80 FRACTIONAL 1 32 ANGULAR 05 DEG PROJECTOR CLASS Roller Infiltration DRAWING TITLE secondary Arm DRAWN
10. Given logistics and budget constraints a makeshift resin application system was devised to apply resin in a controllable manner Caulking guns where outfitted with custom cartridges to deliver resin in 50g increments as shown in Figure 8 The primary roller maintains fixed position throughout bundle formation The secondary roller s height is adjusts as the bundle expands through the use of a simple rotational joint All components are modified store bought systems selected for low cost disposability and adaptability The prototype was outfitted on the production forming machine and a bundle was produced One end of the bundle was hand painted by an operator for comparison The bundle was then cured machined and analyzed to determine the Figure 8 performance of the prototype A close up of resin infiltrating the bundle is shown in Figure 9 The first indications of superior results were observed during bundle formation The prototype laid down a very consistent application band and infiltration appeared to be sufficient Engineering factory personnel were present to supervise the process and were in agreement with the observations made by the team Performance Evaluation Having formed a bundle on the production forming machine specific performance characteristics could then be evaluated Data was gathered and analyzed in a systematic format to validate the performance of the concept technology and legitim
11. between bundle and the looming machine This would most assuredly result in the loss of a bundle and possibly damage the machine as well In the primary application it is possible that the arm begins to noticeably lean away from the position it was originally placed in This is noticeable because the roller holder will drift closer to the bundle as it 1s being rolled If the arm can visually be seen experiencing a bending moment there is too much downward pressure being applied by the roller Excess pressure can be created by mounting the arm too low on the pillars or if the spring mechanism in a roller holder 15 stuck In a depressed position This issue should be caught by the operator after a quick visual inspection To solve this Issue one merely needs to re secure the arm to the pillar or replace the roller holder DO NOT merely jog the spring free from its depressed position it will most likely get stuck again later If a dispenser nozzle of the application system is clogged or stops dispensing the proper amount of resin the control system of the Resin Application System will alert the operator and can be set to automatically stop the looming machine The nozzles snap on and off along with the mixing screws This error 1s most likely caused by operator failing to replace the nozzle mixing screw with a new bundle If this error persists confirm that enough resin and hardeners are in the source buckets If no solution can be found contact Liquid
12. due to the constant applied pressure from the ic 2 rollers Typical voids are shown in 524 Figures 13 and 14 The third test that was performed was a gas leak check The bundle was pressurized to approximately 9 psi and glass beads were placed on the surface of the end caps as shown Figure 15 Any leaks in the bundle would cause 4 the glass beads to displace showing a distinct motion on the end cap As shown in Figure 16 no leaks were detected on the end formed by the prototype Given the very positive results of the bundle the sponsor decided to post treat the bundle 21 12 19 and perform post production testing From this testing further void mapping wicking characterization and nitrogen recovery rate information will be obtained This bundle has been post treated and the data from all tests will be available to the sponsor in approximately one week A final leak check also yielded satisfactory results In order obtain a basic idea of the wicking experienced by the bundle the resin band was examined for both end caps The end formed with the prototype showed a much more consistent band than the Figure 18 operator painted end Both end caps are shown to the left prototype end in Figure 17 operator end in Figure 18 This provides a general idea of the extent of Internal wicking Internal wicking will be determined following post production testing and bundle dissection Proof
13. had elapsed The fibers were analyzed for wicking Contrary to the team s hypothesis the wicking was very minimal in all 3 trays measuring less than I inch in all cases After talking to the technicians and Air Liquide employees it was understood that the wicking does not necessarily come from the resin application itself but the pressure the fibers are faced with This occurs when the fiber weave is rolled up and squeezed in the nip Discussion After performing the lab analyzing the fibers it was determined that wicking 15 a problem that 18 very hard to avoid The majority of the wicking comes from the bundle rolling and not the application itself fixing the problem and making it an uncontrollable Therefore the team will move on focusing it s efforts on other areas of concern Appendix Hardness Testing Lab End Cap Hardness Lab Objective To determine the hardness of the end caps of the cured bundle formed using the prototype Theory A hardness test is often performed to determine the density and saturation of the epoxy resin Areas with good resin saturation are harder vs areas with voids and only fiber hardness test was done on each end of the bundle to compare the roller side with the technician painted side of the bundle and to assess the quality of the bundle Procedure 1 Divide the bundle into quadrants with 5 testing points in each quadrant working in a line from the inside outward 2 Measure the hard
14. inlet The A and B components enter through individual shut off spool valves and pass through the Twinmixer in separate streams Upon exiting the Twinmixer nose the A and B materials converge in the Posimixer and are thoroughly blended prior to reaching the mixer outlet The shut off valve rods are operated together for synchronization of the two streams and when closed the valve rod spools create a snuff back in the mixer outlet which controls drip and stringing between shots The Twinmixer comes complete with 10 teflon lined stainless steel overbraid hoses The Twinmixer is equipped with standard threaded mounting locations to be remotely attached as desired DL machine telescoping mounting brackets hand held pistol grips and counter balance mounting may be specified as separate proposal line items 5 17DEC 10 gallon 37 85L stainless steel pressure vacuum tank with 2 bottom outlet 2 stainless steel ball valve shutoff two 2 stainless steel barb nipples 2 dia chemical hose two hose clamps and teflon coated lid with three 1 4 F npt ports for plug petcock and relief valve 3 49A Continued on the next page Air Liquide con t 15 gallon 56 78L pressure vacuum tank with 2 bottom outlet 2 mild steel ball valve shutoff two 2 metal barb nipples 2 dia chemical hose two hose clamps two 3 4 npt half couplings 90 in side wall and one 1 2 npt half coupling in bottom adjacent to bottom outlet Tank exterior
15. remay position the application systems and most importantly apply resin to the remay that 15 attached directly to the bushing It is vital that the remay adhere properly to the tube Once the fibers reach the area where the resin is applied the operator is expected to activate the resin dispensary system Following this the operator Is needed to make sure that the ends of fibers from starting the wrapping process protrude from the side of the bundle Stopping the process would still be controlled through a kill switch which could be relocated to a more convenient station designed for a single operator This switch is electronically tied to both the Resin Application System and the feed for the looming machine This switch 1 to be used in case of emergencies or if a fiber breaks and needs to be rewound by the operator Adjusting the secondary roller holder position may be necessary for the larger diameter bundles On the six inch bundle created during testing adjusting the secondary roller holder was not necessary This is a preventative measure that keeps the roller from advancing past the top of the bundle A roller that 1s allowed to advance too far could interfere with a secondary resin application system if there 16 one or could tip and fall backwards away from the machine Falling away from the machine in this manner could possible injure a worker and would most certainly create an inconsistency in the bundle To overcome this issue it
16. C that either alerts the operator to a low material level condition or signals an auto refill transfer pump to stop and start Level sensors are mounted in sealed teflon fittings and provide positive level recognition in real time Sensors never touch the resins thus can not become contaminated 4 51DL Provide the required electric pneumatic actuator and controls to stop and start one 1 transfer pump used to automatically refill one 1 DL reservoir Requires prox material level sensors and transfer pumps which are priced separately 4 56 DL NEMA 12 enclosure fitted with digital temperature controller load circuit breakers service disconnect circuit breaker control power selector switch On Off and pilot light for three heat loads Service requirement 208 240 1 60 Maximum wattage 5000 watts 3 67 21 4000 watt electric resistance heat blanket and foamed silicone insulation blanket for a 15 gallon capacity feed tank Heater maximum temperature 275 F Feed tank and heat controls are not included 3 67 06 Continued on the next page Air Liquide con t Quotation Summary Product Code Qty Description DL 2 2 DL 2 Rotary pump metering system 3 06DEC 1 DL Extruded aluminum support for 10 or 15 gallon tanks 2 33DEC 33MS 2 Progressive Cavity Pump Upgrade 33cc sec Mild Steel 2 42 DEC 2 DL Extended Frame Length for PC Pumps 2 34 DEC 2 Ultraprecision 55300 Gear Pump amp Fitting Upgrade 5 17DEC 2 Twinmixer Dispense V
17. Team 16 Sponsor Air Liquide Synopsis Phase IV Report Dept of ME Senior Design 2007 AIR LIQUIDE The following report is a written statement of progress for Phase IV of the 2007 Senior Design Project It is intended to provide an overview of the design process that has been implemented up to this point All graphics are shown full size in the appendix of this document Experimental Design Having finalized the proof of concept design in Phase III specific laboratory experiments were performed in order to fine tune the prototype for final testing Make sura lab is A modular up z dina to 5 design which and safety standards accepted multiple types of rollers was constructed for the preliminary tests of rollers and resin application In order to determine the specific type of roller that would This includes recording weight data notes on the process and answering the infiltration questionaire Run test procedure on roller NO Was enough resin used YES final machine trial mock trials were held using all candidate Did tha olla Porn rollers mimicking the perform YES secondary wetted xceptionally reliability test operation of the proof of concept as shown in Figures 1 and 2 The logic of the testing process that was followed 15 shown to the left in Figure 3 Roller parameters are shown in Table 1 A full laboratory procedure
18. a clean manner without bubbles and fiber abuse primary factors that characterized these rollers were amount of resin the nap can hold and the ability of the roller to pressurize the fluid it 1s pulled under The most favorable roller parameters were found in the Wooster R232 4in Epoxy Glide Not only were the desired properties found but new properties specific for holding and releasing resin were incorporated in the construction of this roller The four inch roller was chosen to fulfill the desired resin application band During the final proof of concept testing new components for the implementation were found necessary Although these reiterated previously stated requirements of proper roller contact further details about implementation were discovered during the final test It was realized a range of pressure optimizes both resin infiltration and minimal fiber disturbance For future implementation the previous design component of a spring load initial application will be reintroduced in the final design Also the primary roller needs to be fixed more rigidly because small deflection alters the initially prescribed bandwidth Updated Performance Requirements Several performance requirements B constant were updated to ensure the success of the roller fiber contact design The new requirements were TRETEN established during the preliminary testing viscosity of the rollers Various concerns and corresponding modifications were
19. alve for DL with 15 hoses 3 49A 1 10 gallon stainless steel pressure vacuum tank 3 64 1 15 gallon mild steel pressure vacuum tank 3 64 EA 1 1 Electric agitator ass y for 15 gallon press vac tank 61 0037 S120 11 2 1 4 x 120 PTFE SS Hose Assembly SS Fittings 3 67 14A 10 1 2 heated hose length heated by the foot 3 67 14A 10 1 2 heated hose length heated by the foot 4 51DL 1 2 feed system level prox sensors for DL 4 56 DL 2 Automatic refill actuator for one 1 DL reservoir 3 67 21 1 Three load heater controller and enclosure 208 240 1 60 3 67 06 1 15 gallon tank heater and insulation Item of 1 Wet Test at North Canton OH Item of 1 On site start up services PRICE F O B NORTH CANTON OHIO Freight is additional 109 666 00 Appendix Implementation Renditions 2287 22 55 s ly 90 Figure 25 Figure 19 Figure 20 20 Appendix Optimistic Expected amp Pessimistic Resource Loading Task Name Build Prototvpe Test amp Redesign Identify Final Concerns Conclusions from primary testing Implementation Planning secondary Testing bundle testing Conclusions from secondary testing Revise Implementation Planning Update Written Report Plan work and divide amongst group Technical Information Gantt Chart Review draft with Hartman Revise Information Poster Project Create Poster Poster draft due Revise Po
20. atize the choices recommended for final design The first test that was performed was a hardness test Forty hardness point measurements were taken as shown in Figure 10 Ideally the hardness 15 65 75 Rockwell The prototype and the operator painted end were then compared and the data was plotted in Figure 11 The results of hardness testing favor the performance of the prototype Hardness Scatter Plot 75 e Prototype Operator 70 e e Average Median x Minimum Maximum 60 Variance Standard Deviation Prototype Operator 55 Figure 11 50 The second test that was performed was microscopy characterization In order to compare the performance both ends were examined The surfaces of the end caps were analyzed at 100x using an optical magnifier The inner diameter of the fibers is 90um and the outer diameter is 160um Ideally no voids should exist and the surface should show uniform distribution as can be seen in Figure 11 Small voids are acceptable as they do not necessarily constitute a full leak However as s the size of the void increases the chance of a gas leak is greatly raised The end formed by the prototype possessed fewer voids with less severity than the end painted by the operator despite his experience and skill Moreover less interface voids occur between layers on the prototype end
21. ber contact m desirable resin viscosity regulated flow rate minimize voids mautomated process Updated Target Values No significant voids 1 technician to oversee No break of roller contact 200 230 g min flow rate 4 Resin at 40 degrees C wy E S gt Q S 5 lt L A PL Appendix Performance Evaluation Images Figure 10 b p 1 Figure 13 Figure 14 Figure 15 Figure 16 a Figure 18 80 75 70 65 60 55 50 Figure 11 HardnessScatter Plot Prototype Operator Average Median Minimum Maximum Variance Standard Deviation amp Prototype Operator Resin Line Connection Interface Appendix Liquid Control Images Figure 21 DL 2 Controller Unit FLOW PRESSURE BRANCH ROTOR PROTECTIVE COVER FOR SHEAR PIM lt F c 1 2 2 JOINT Progressive Cavity Pump Figure 22 GEARB OM IN3NISDPOWV W30NDASSIV vann i 340 1 1 5 LIINI TE LT Figure 23 JOXI SSQUOQOYY 93419139 uINNSDOd 919950510 Twinmixer Liquid Control Corp D 4 2 r r 1 1 wit tiet my b O
22. e and naturally changes position as the bundle s radius grows The secondary application system 15 secured to the pull bar of the machine The first task In setting up the production model 15 to correctly determine the primary application area roller itself must make contact after the nozzle from the Resin Application System RAS and should barely hang off the edge of the sheet of fibers Be careful not to place the roller so close that it might interfere with the bundle as it is being wound The suggested placement of this roller is approximately four inches from the plastic splash guard attached to the looming machine With the application area selected one may now choose the placement for the base of the applicator system to the ground by moving perpendicularly away from the application area and directly downward This placement is crucial as the production model is not fully adjustable in this direction Make sure that this footprint does not interfere with any existing machinery The base may now be attached to the ground via bolting With the base in place the pillar may be attached via bolting Attaching the primary arm to this will help in correctly positioning the other side s base With the space for the second base selected bolt it into the ground and attach the second pillar Before securing the arm in place with the bolts make sure that the arm hangs over the previously selected application area Attach the two roller holders to
23. ed eye will be given a survey to extract his her qualitative opinion on attributes agreed on that create a proper infiltration From this it is determined which brushes are potentially able to reconstruct current infiltration with finer testing adjustments 6 Repeat process for each brush Eu Analysis From our tests we should be able to discern the type of cylindrical brush we want to spend more time on investigating its capability to proper infiltrate the epoxy through out the loom of fibers Qualitative Survey Answer with scores from I to 5 5 being the best Did the resin reach a satisfactory depth into the fibers depth is considered as looking into the sheet from above Were the fibers misaligned or handled poorly during the infiltration process Was the wicking very inconsistent or undesirable in anyway Are the fibers fully coated around its surface Is the process much messier compared to the current production process Is there a solid layer of resin encompassing the fibers 1 e no large air pockets 11 16 First Test Day 1 Smooth Surprisingly infiltrated decently Roller was not completely smooth Pressure was not much 2 Yellow mesh Coating looked better mess was due mainly to viscosity 3 Birdfeeder New epoxy used during testing 4 Yellow mesh Used to determine wet testing Performed a little bit worse in terms of wicking but besides this was about the same 11 19 Second Test Day Bunny 1 Resi
24. g 0 Fri11 20 07 11 30 07 In amp ite bundle testing 1day Fri11 30 07 Fri 11 30 07 6 Conclusions from secondary testing 1day 12 3 07 Mon 12 3 07 7 x Revise Implementation Planning 1day Mon 12 3 07 123 07 1 5 Update Written Report 27 days Thu 114 07 Fri 12 7 07 Plan work and divide amongst group 2days Thu 11 1 07 Fri 11 2 07 5 5 Technical Information 20 days 11 5 07 11 30 07 11 Gantt Chart 7 days 11 25 07 Tue 12 4 07 11 i Review draft with Hartman 0 Tue 12 4 07 Tue 12 4 07 12 13 Revise Information 3days Wed 12 5 07 Fri 12 7 07 14 8 8 4 Poster Project 10 days 11 26 07 Fri 12 7 07 Create Poster 2days Mon 11 26 07 Tue 11 27 07 s Poster draft due 0 days Thu 1125 07 Thu 11 23 07 17 Revise Poster 1day Thu 12007 Thu 12 6 07 18 Poster finalj due days Fri 12 7 07 Fri 12 7 07 19 i Transition planning for AL 27 days Thu11 1 07 Fri 12 7 07 Implemented testing Tdays Thu 11 07 Fri 11 8 07 Integration 7 days Wed 11 21 07 Thu 11 29 07 5 i User Manual 15 Fri 1146 07 Thu 12 6 07 Documentation 12 days Wed 11 21 07 Thu 12 6 07 Cad Images 1 days 11 4807 Thu 11 29 07 Path forward Tdays Thu11M 07 Fri 11 8 07 Handoff Prototype to AL 1 Fri127 07 Fri 127 07 22 23 27 12 24 i Final presentation Tue 12 11 07 Tue 12 11 07 28 15 1211 Cost Analysis Table 4 6060 Aluminum rod 12m
25. identified and implemented on the final proof of concept The updated wants from N MADE vols Figure 4 were then rescored and translated to new target values that are N automated process displayed in Table 2 next page The two primary metrics concerning technician interaction and void content remained unchanged as the proof of concept evolved The behavior of the rollers was translated into a metric Initial tests were performed on rollers that contained bristles and were similar to the paint brushes that are currently used After testing the misalignment of fibers air bubbles and incomplete infiltration were identified as prominent issues Variations of smooth rollers were found to produce the best results A new performance metric added is a quantified flow rate Testing began by pouring resin from paper cups and approximating the flow rate then measuring the amount of resin used It was found regulated flow rate Figure 4 that some areas of the loom sheet had too much resin applied while others did not have enough This lead to some areas having great infiltration and others having very poor infiltration thus a very inconsistent method The bandwidth varied greatly along the length of the loom 2 break of roller contact which was reflected in the inconsistency of the wicking 200 E g min flow rate As a result initial resin application in terms of bandwidth and flow rate was found to be of great importance
26. ire Run test procedure on roller NO Was enough used YES Did the roller Perform E perform ves secondary wetted xceptionally reliability test NO Record summarize and make a conclusions about the data in an organized format Make not of undesirable properties of a brush Bristle D Nap Length Name MM Inches Inches Bird feeder brush 0 9201 Metal wheel al 2 2413 White plastic 0 8579 Bendy black plastic 0 6268 Long black 1 3004 Paintbrush current 1 6142 Short black 022 00087 1245 0 4902 Primary Roller Testing Table Questions Scoring 1 Date nihil Wail Dae 2 3 4 7 16 1 smooth 787 64 173 day mewepxy 3 5 4 4 5 25138 77 2 yelow 614 279 35 dy 31 45 4 4 51 25 2 71 3 bird 9369 6748 2621 dy nweoy 1 145 4 21 5 15 5 66 4 yellow 6744 4219 2525 3145 3 4 5125 2 69 19 1 bunny 363 1565 2065 hotepoy 40 4 s5 4l 4s sl afafp 87 2 4013 2482 1531 wet 40 4 5 4 45 514141 87 hae CESSISSE Z s SA FS CAE ee ee T en eres 2 5 powerspiral 95 1988 1762 4 1215 3 3 513121 6 6 guy 286 130 156 we 40 45 5 5 48 5 48 5 iii RASE gt EE Appendix Updated Performance Requirements Images Updated Wants E constant roller fi
27. is shown in the appendix of this document Following trials of the rollers the results of each trial were qualitatively analyzed by examining the process the end product and then quantified in a survey The amount of resin applied to the testing sheets was measured and compared for consistency The survey rated resin depth Compare data to ather tests Record summarize and make a conclusions about the data in an organized format Make not of undesirable propertias of a brush used during kommen k q m V W lj NY 7 gt Table 1 Bristle Nap Length Name MM Inches MM Inches Bird feeder brush 2337 09201 Metal wheel 2 2413 White plastic 21 79 0 8579 Bendy black plastic 0 0114 15 92 Long black 0 0087 33 03 Paintbrush current 0 0051 Short black 0 22 0 0087 12 45 0 6268 1 3004 1 6142 0 4902 resin coating air pockets fiber alignment wicking and waste through the opinions of factory engineering personnel The results of this analysis clearly favored a particular roller model designed for epoxy application as can be seen in the scores listed in Table 2 Primary Roller Testin Table 2 16 Nov 19 Nov oe ser Fet 7 como 25 s 25151515 7 _ A thin nap length optimized infiltration in
28. is painted Slate Gray 3 64 1 Electric agitator assembly for 43 64 15 gallon pressure vacuum tank complete with a 1 2 HP AC electric motor 30 1 gear reducer and sshaft blade assembly A 3 position selector switch allows low speed 29 RPM high speed 58 RPM or OFF Requires 115V 1 60 Hz 10A max For maximum viscosity of 100 000 cps and maximun material temperature of 275 F 3 64 EA This 1 4 hose assembly has a PTFE innercore with stainless steel wire overbraid for minimal expansion and moisture permeation It has a 120 overall length including end fittings which are stainless steel 1 4 JIC female swivel 61 0037 8120 11 Qty is per foot 35 watt per foot electric resistance heat tape foamed silicone insulation and protective covering for a 1 2 Teflon lined stainless steel braided hose Heater maximum temperature 275 F Heat controls are not included Requires item 3 67 14 Basic heated hose assembly to complete the assembly Qty is per foot 35 watt per foot electric resistance heat tape foamed silicone insulation and protective covering for a 1 2 Teflon lined stainless steel braided hose Heater maximum temperature 275 F Heat controls are not included Requires item 3 67 14 Basic heated hose assembly to complete the assembly 3 67 14A Provide two 2 prox type electric feed system level sensors in a DL drum feed kit assembly or reservoir wall Depending on configuration options sensors provide a signal to the DL s PL
29. loying temporary boom stands next to the machine a fixed frame will be permanently located bolted or welded in place in a stable position This will ensure steady application and eliminate variance in the application area and initial bandwidth Moreover the frame will provide a greater degree of rigidity providing precise positioning of components without concern of shifting during operation The cost of the final implementation is much greater than the cost of the proof of concept The working budget of the project is 1500 while the final implemented system is 112 000 The prototype was chosen in accordance with the approved concept budget as a technology demonstrator Having proven the concept fundamentals a production solution may be constructed using applicators purchased from Liquid Controls The system from Liquid Controls will provide more reliability temperature control and flow rate control than the application system design to showcase the concept technology of the proof of concept Design Integration The final proposed design 1s a synthesis of the roller technology that was validated 1n the proof of concept and the trusted technology of Liquid Controls resin dispensary systems The final design addresses the Issues discovered in the proof of Lem _ E concept and go provides a reliable solution 2 E for production full operations manual including design drawings 15 located in the a
30. m diameter 1 M length Wooster R232 4 x 1 4 Epoxy Glide roller cover Wooster R232 9 x 1 4 Epoxy Glide roller cover 4 Heavy Duty Cage Frame 2 PVC Test Cap 131 0800 1 5 PVC Test Cap 131 060 13 Quart 1 2 Barrel Caul 2 by 2 PVC SCH40 Solid P Tubing 3 4 MDS Pipe PV 1 MDS Ducting 6 P MDSE Plastic BC MDS Sealant CL MDS Gar Fun 8 MDS Valve 3 4 MDS Tubing Red T MDSE Paint Pail MDS Boom Stands Cardboard 13 Quart 1 2 Bar 2 PVC Test Cap 1 2 x 2 PVC SCH40 GT Bird Feeder Brush 9 Texture Roller 9 Texture Roller Wheel Detailing Brush 9 Roller frame Subtotal Total Appendix Materials Cost Tracking HemNumber Quantity Cost Shipping Costs 5 388 66 11 96 400 62 Date 08 29 07 09 03 07 09 04 07 09 05 07 09 14 07 09 16 07 09 17 07 09 18 07 09 20 07 09 25 07 09 27 07 10 08 07 10 10 07 10 14 07 10 16 07 10 22 07 10 26 07 10 28 07 10 29 07 11 04 07 11 06 07 11 08 07 11 09 07 11 11 07 11 12 07 11 14 07 11 15 07 11 19 07 11 25 07 11 26 07 11 27 07 11 28 07 11 29 07 11 30 07 12 04 07 12 05 07 12 06 07 12 07 07 Design amp Analysis Labor 9 7 CO P P P N N BN N NN N G P N e e UT Per hr Cost 50 Appendix Labor Tracking Sheet Project Management Labor 4 O gt O O P O ES O E E NAN N N P VL
31. n technology that has previously been used by Air Liquide and other manufacturers The core of the system 1s two DL 2 gear driven pump metering systems Figure 21 with attached hardware The same model 1s already in use in the factory floor and has been proven effective and reliable The metering units draw resin from a common feed FLOW PRESSLIRE BRANCH PROTECTIVE source via vacuum Via a progressive cavity qj a LER 1 5 ROTOR ig pump Figure 22 0 5 heated tubing transports lt 2 2222 2222 resin to of application The heating elements on the tubing 357 keep the resin at an adjustable temperature allowing for constant temperature at the point of application The feature allows for lowered resin viscosity aiding infiltration greatly The application heads of the system are actuated through Twinmixer system Figure 23 which is also currently employed in factory operations The head may be outfitted with various application nozzles given the desired resin application bandwidth The Twinmixer assembly will be attached to the same frame as the primary application roller The entire system is linked to an EnGarde ratio monitor which automatically checks the content of the resin before the point of application and adjusts the system automatically for optimal E Vols performance All controls for the system are run through a touch screen m
32. n was heated which resulted in a significant drop in viscosity 2 Bunny 2 Heated slightly above 40 degrees c assuming there would be a drop in temperature during actual application Resin band was about the same same ratings 3 Gray 1 Sheet 1s very thick and the roller was still able to infiltrate well 4 Gray2 Roller performed as well wet This tells us that the roller does not need to be pre wetted before use More resin could have been used this is the only reason that the score for question four was lower than the first test of the gray roller 5 Power spiral Lots of resin was left on the surface of the fibers Inadequate pressure from the roller 6 Gray3 There was quite a bit of excess resin being pushed of the side We learned that the infiltration was maximized when the application area was within an inch and a half of the edge this also prevented the resin from wicking in too deeply By pausing between tests of this roller we learned that the roller won t respond differently if the a fiber breaks and the worker is forced to stop the looming machine 7 Control Infiltrated top just sitting there though Active infiltration is found to be critical Appendix Resin Application Lab Resin Application Lab Objective To determine the amount of resin applied to the fibers during the formation of a 6 inch bundle The team will also analyze inconsistencies in resin application amount between trials technicians Theory A main c
33. ness of the surface at all testing points Results Prototype Measurements in Rockwell Scale The optimal hardness range for the bundles is between 65 and 75 Both ends of the bundles were tested and 1t was found that a majority of the scores fell into this range The table is divided into values in groups of 5 to show the variance of the scores with respect to location on the bundle end It was found that the lower scores softer areas were often present the middle to mid bundle regions This may be because the team took a few turns to get the technique down and thus missed a few small areas at the very beginning of the bundle forming Process 80 75 e 70 65 60 55 50 Hardness Scatter Plot Prototype Operator Average Median Minimum Maximum Variance Standard Deviation 9 Prototype 9 Operator User Manual For the Resin Application System Production Model Written by University of Delaware Students Kevin Malik Pete John Laura Shultz Adam Willoughby Knox December 7 2007 Table of Contents o Terminology o Important notes Assembly eolnistallatiOD cfe pg4 o Primary application system o Secondary application system Recommended pg5 o Attaching amp removing rollers Starting a new bundle Stopping the process Adjusting the secondary roller holder position O O 20 0 Finishing a bundle Trouble Sho
34. ng T days 4 5 8 8 9 12 Build Prototype 3 days Test amp Redesign 14 days Technical Information 20 days Implemented testing 7 days Test amp Redesign 14 days Technical Information 20 days t1 12 14 15 18 T Test amp Redesign 14 days Technical Information 20 days D ocumentation 12 days Create Poster 2 days Technical Information 20 days Documentation 12 days Appendix November Scheduling Calendar December 2007 77551555 Implementation Flanning 3 days Gantt Chart days Revise Information 3 days Foster final due Integration 7 days Final presentation Handoff Prototype to AL Integration 7 days Appendix Gantt Chart e e sy de ta pal p BE BOLLE GE Duration Start Finish Predecessors 4 07 Now11 07 Nov18 07 _ _ Nov25 07 Dec 8 07 i W T F S S M T WITI F SISIMITIWIT F S SIMITIWITIF SIS MITIW T F SI IS WMITIWITIF SI SIMITIW T F Build Prototype 3days Thu 11 07 Mon 11 5 07 Test amp Redesign 14 days Tue 11 6 07 Fri 14 23 07 1 i Identify Final Concerns 20 days Tue 11 6 07 Mon 12 3 07 Conclusions from primary testing 3days Tue 11 6 07 Thu 11 8 07 Implementation Planning 3 days Fri 11 8 07 Tue 1113 07 4 Secondary Testin
35. of Concept amp Solution Differences There are several differences between the proposed proof of concept and the final recommended implementation design One of the major differences between the two 1s the use of Liquid Controls systems to provide consistent resin application This application system will provide a designated constant flow rate The constant flow rate will add a much greater degree of consistency by applying the optimal amount of resin in an automated manner Because of this factor undesirable wicking and resin voids will be decreased Moreover less resin will be wasted in the manufacturing process The temperature of the resin will be continually regulated the final implementation plan unlike the proof of concept While testing the prototype the resin was heated to approximately 40 degree Celsius before it was loaded to the resin gun and applied The heating of the resin enabled a better viscosity but the temperature slowly dropped below the 40 degrees as the resin was applied to the fibers The implementation plan provides heating of the resin lines until the exact moment of application through the tube and nozzle tip This will eliminate any cooling before application providing a regulated temperature 40 degrees Celsius This creates a favorable resin viscosity aiding effective fiber infiltration during production A permanent setup at the forming machine 1s incorporated in the final implementation proposal Instead of emp
36. oncern in the application of resin is the inconsistency that is present There are discrepancies in the amount of resin applied on each side of the bundle due to different technicians and techniques There 15 also a variation in the resin application amount throughout the process due to a lack of a predefined application method Materials Forming machine setup scale multiple resin cups Epoxy resin Procedure 1 Once the forming machine is set up obtain 2 cups of resin from the dispensing systems 2 Weigh the cups of resin on the scale and return them to the technicians on each side of the machine 3 Record the weight of each cup Once the technicians are finished with the cups of resin weigh them again on the scale and record their values 5 Repeatthese steps weighing the cups of resin before and after use until process is finished with a completed bundle Data Bundle 1 Left Side Resin amount used TotalResinused gt Right Side 2 TotalResinused Bundle 2 Left Side Weight before use Weight after use 802 6 752 9 0 794 8 748 2 793 7 656 4 137 3 Total Resin used 000 1638 4 Right Side TotalResinused 133110 Bundle 3 Left Side TERDUM DM 211 798 9 754 3 Toi Resin usd F C C 1394 9 Right Side se TotalResinused 1 gt 1300 2 Results Bundle number 1 was not analyzed due to holes in the data
37. onitor Figure 24 allowing a great degree in flexibility of application parameters Installation and setup of all components will be handled by Liquid Controls This system will provide a reliable consistent method of applying resin in a controlled manner which 15 one half of the key to improving product quality and production optimization A rendition of the complete system 15 shown to the left The total cost of the system is quoted at 112 000 This includes the total cost of the system plus additional estimated shipping and material costs itemized description 1s provided in the appendix of this document Although this is a significant sum the initial cost of the system will be offset 1f only 2 3 bundles are saved from being reduced to scrap Coupled with the proven and upgraded roller technology of the proof of concept this solution will provide the optimal answer to production difficulties given current process and factory constraints rendition of the entire system is shown in Figure 25 Cost analysis The total cost of the project is 400 62 This is well under the maximum developmental budget of 1500 A summary chart is shown in Table 3 A full sized chart is shown in the appendix Cost Analysis Table 3 fem Shipping Costs _ 598 34250001 seer som 925 searsmardware x
38. oting Possible Issues Symptoms and Solutions pg o Rotating roller o Bending arm o Clogged dispenser tip o Secondary application arm interference Drawing uu suspa a halun pg Before you get started Terminology Browsing through this section before reading the rest of the user manual will vastly help in understanding the mechanics of the production model While reading through the user manual you will notice direct references made back to these terms will be marked in bold upon their first use Pull Bar Clamp Arm Bushing Roller Housing Production Model whole system shown to the left Primary Applicator Application System assembly Secondary Applicator Application System assembly Base Pillar Primary Arm Roller Holder Roller Clamp If there is any confusion over the parts please reference the drawing package included at the end of the manual Important Notes 1 2 Please read through all of the directions before proceeding Please keep personal safety and the safety of others in mind at all times Assembly amp Installation The production model 15 comprised of two applicator systems The primary application system makes contact with the flat sheet that is produced by the looming machine and is secured to the ground The secondary application system makes contact on the rolled bundl
39. p of pressure could potentially ruin a bundle Another potential aid for infiltration 1s an agitator placed on the side of the roller frame This agitator would create movement in a new direction which may aid in penetration This option 15 recommended only if penetration of the fibers 16 lacking because this agitation will adversely affect fasteners and frame positioning during operation Potential agitators are mechanical pneumatic or ultrasonic in nature At this point the prototype will be handed off to the sponsor The results of testing have been compiled along with recommendation for full production implementation of the chosen system The testing performed on the bundle using the proof of concept has ytelded very good results The sponsor has initiated full production testing from which recovery rate data leak testing and further void characterization will be available in the coming weeks further enhancing analysis of the chosen design technology Initial post production testing results are promising Overall the proof of concept was highly successful and provides a stable theory base for the use of a similar system in future production _ Appendix Liquid Control Equipment Description and Quotation 70 wa Make sure lab is setup according to lab documentation and safety standards This includes recording weight data notes on the process and answering the infiltration questiona
40. ppendix of this document The roller design of the proof of concept proved to be very effective in providing resin infiltration with minimal operator interaction The design remains largely unchanged for production implementation Renditions of the final design Figure 20 are shown in Figures 19 and 20 The use of 80 20 aluminum frame to replace the makeshift boom stand used the proof of concept will provide greater rigidity and stability The more frame bases will be bolted to the floor adjacent to the machine The 80 20 frames provide the adjustability of the stands with the rigidity of a permanent frame Moreover the primary applicator preserves the same design additionally including a vertical translation system to mirror the ability of the secondary roller to adjust on the fly based on the instantaneous height of the loom sheet as it advances The rollers and roller mounts will remain unchanged as their performance and 22 low cost make them ideal candidates for continuous production implementation The rollers will be mounted onto a frame instead of a paint roller applicator which will also fix the resin applicator The again adds rigidity and consistency in application The cost of aluminum fasteners and small components 15 conservatively estimated between 1 500 2 000 The resin application of the final design 15 the recommended system quoted by Wayne Pellicane and Bob Thompson of Graco Inc It consists of prove
41. skewing any obtained results These holes occurred when the technicians used the resin cups before being initially weighed or when the technicians discarded the used cups before being weighed After recording and analyzing the amount of resin applied to bundles 2 and 3 it is confirmed that there 15 a great deal in variability of resin amount applied to each end of the bundle as well as from bundle to bundle Bundle 2 used a total of 2989 5 while bundle 3 used a total amount of 2695 1 By calculating the amount of resin used by each technician in each bundle it 1s also clear that different techniques yield variable resin application amounts Looking at bundles 2 and 3 the initial amount of resin provided was very consistent throughout the process However the final weights of the cups were continually different measuring anywhere from 94 7 to 287 3 difference in the finished bundles The technician on the left side consistently used more resin than the technician on the right Discussion After performing the lab and analyzing the results it is clear that a more consistent and standard application method needs to be implemented There are not only differences in amount of resin used from bundle to bundle but more importantly between the left and right side of the bundles themselves These resin amount discrepancies can be directly related to failure of the product and loss of revenue Appendix Wicking Length Lab Wicking Leneth Lab Objec
42. ster Poster final due Transition planning for AL Implemented testing Integration User Manual Documentation Cad Images Path forward Handoff Prototype to AL Final presentation Duration 3 days 14 days 20 days 3j days 3 days days 1 day 1 day 1 day 27 days 2 days 20 days T days days 3 days 10 days 2 days days 1 day days 2f days days T days 15 days 12 days 10 days T days 1 day days 2 days 10 days 20 days 2 days 1 day days 1 day 1 day 1 day 27 days 1 day T days 1 day days 1 day 11 days z days days 1 day days 21 days z days 2 days 15 days 3 days 9 days 3 days 1 day 0 days 3 days 14 days 3 days 3 days days 1 day 1 day 1 day 27 days 2 days 14 days T days days 3 days 11 days days days 1 day days 21 days T days T days 15 days 12 days 10 days T days 1 day days Optimistic Dur Expected Dur Pessimistic Dur 5 days 15 days 20 days 6 days 4 days days 3 days 1 day 2 days 27 days 3 days 18 days 10 days days 2 days 11 days 5 days days 3 days days 27 days T days 7 15 days 12 days 1 days T days 1 days Appendix November Scheduling Calendar November 2007 Monday Tues day Wednesday Thursday Friday 1 z Build Frototype 3 days Plan work and divide amongst group 2 days Implemented testi
43. t brushes will be used to create an array of data for optimal brush attributes Nap size relative stiffness individual bristle diameter and bristle density arrangement will be initially measured quantitatively and qualitatively As a side note manual shaking of the rollers support stand will give insight as to whether more investigation on mechanical vibrations as an aid for infiltrating is worthwhile Materials store bought cylindrical brushes experimental variables epoxy resin resin containing catalyst will be used because of availability Although the catalyst will require additional safety measures safety reasons proper ventilation will be needed as along with proper safety garments including gloves arms sleeves and safety goggles pre fabricated fiber loom fibers will be wrapped around cardboard covered in Reemay boom stand help locate the brushes in the proper location for infiltration Procedure Place the loomed sheet of fibers under the ventilation hood Attach the brush of Interest onto the boom stand Adjust the boom stand so the brush is at the desired location relative to the fibers Carefully poor epoxy at one end of the loom sheet as another person slowly advances the sheet through the roller setup Note The pouring of epoxy and pulling of sheet don t need to be exact compared to current process for this initial test but these actions should be comparably for a proper test 5 A train
44. the primary arm to help you position the arm at a height on the pillar that allows for the spring mechanism the roller holders to be depressed Once the arm 1s bolted place the primary applicator system 16 fully installed Congratulations you are more than half way there similar to the primary applicator installation begin the installation of the secondary application system by orienting the roller at its contact point The secondary roller makes contact on the bushing that the bundle builds up on Again the roller should just barely hang off of the edge of the bundle The clamp on the secondary applicator system should be mounted in line with the roller on the pull bar Make sure that the clamp arm 15 near horizontal to the ground Next attach the roller holder to the second arm so that the roller makes contact on the far side of the bushing Recommended Use Attaching and removing rollers is a simple matter of loosening the set screws attaching the roller holder to the roller housing of the application system primary or secondary When this is done the entire roller holder may be removed The epoxy roller may then be slid on or off When removing the roller proceed with caution the roller will be filled with unused epoxy Starting a new bundle will call for the attention of operator The first step the operator is responsible for is replacing the two nozzles of the Resin Application System The operator 15 then expected to setup the
45. tive To determine the wicking length of the resin once applied to the fibers Theory Wicking has been a large problem with the bundle forming process at Air Liquide When the resin is applied to the fibers the resin tends to wick further down the length of the fibers until it ceases from curing This reduces the active filtration area In the bundle this making it less efficient The more the resin wicks down the fibers the larger area of bundle needs to be cut off while preparing the bundles Materials I bobbin of fibers stopwatch ruler 3 aluminum trays pocket knife permanent marker Epoxy resin notepad Procedure 1 Obtain 3 aluminum trays and using a pocket knife punch a small hole on each end of each tray 2 Obtain fibers and wind them approximately 10 times around a notepad forming a thin layer 3 Pull the fibers off of the notepad and arrange in the aluminum trays pressing the ends of each fiber bundle through the small holes 4 Oneach tray using the permanent marker mark off a designated length of fiber where the resin will be applied and record 5 Apply the resin with a paintbrush in on each marked off section of fibers and start the stopwatch 6 Wait for resin to cure and observe wicking outside application area 7 Record length of wicking from each section and the time elapsed Data Application Area Wicking length negligible negligible Time elapsed 1 hour Results After the resin was cured and 1 hour
46. ven 5 minute calibration process Outlet check valves and fluid pressure gauges are provided for each metering pump Over pressure limit switches are provided in each material stream pair of low material level sensors are included to provide protection from letting the pumps run in a detrimental dry condition The control console is easily accessible with top and side hinged doors The entire DL frame is mounted on an extruded aluminum frame with heavy duty hard rubber casters for portability Extruded aluminum feet instead of casters for DL frame are available if item 7 24DEC is specified on the proposal Extended extruded aluminum tank support frame and console for use with 10 or 15 gallon tanks Extended extruded aluminum tank support frame and console for use with 10 or 15 gallon tanks 3 06DEC This upgrade provides one 1 progressive cavity metering pump with maximum flow rate of 33 cc sec Wetted components include 300 series stainless steel rotor cast iron pump internals and plated mild steel fittings For use with nonlubricious or mineral filled resin systems 2 33DEC 33MS Extended DL frame length required to accomodate the longer length progressive cavity metering pumps 2 42 DEC This upgrade provides one 1 ultraprecision 300 series stainless steel gear pump and fittings 2 34 DEC The pneumatically actuated Twinmixer Ill dispense valve for DL is designed to isolate materials until they reach the disposable Posimixer
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