WALNUT HULLER WIRE CUTTING & BENDING MACHINE Sponsor: Wizard - PowerPoint PPT Presentation

WALNUT HULLER WIRE CUTTING & BENDING MACHINE Sponsor: Wizard Manufacturing

Team (Mechanical) Keaton Dybdahl Matt Everton Brad Hogenson Andrew McIntyre Nicholas Roberts Matt Simkins (Faculty Advisor)

Sponsor Wizard Manufacturing Inc. Designing and building top of the line equipment for walnut and pecan hulling, drying, and processing.

Background

The Problem  Current processes  Produces too much waste  Needs constant adjustment  Broken parts must be machined

Project Scope  Wizard Mfg. NEEDS wire cut to length and bent to a specific shape by a machine with easily replaceable parts.  Our GOAL was to design and build a machine, using easily replaceable parts, to cut wire to size from a spool, bend it into a specified configuration, and produce less waste than existing processes.

The Wire

Requirements Must Do’s  Reliability - Small downtime, very little re-adjustment  Produce 40lbs/hr of wire  Quantitative  Reduce the amount of waste due to machine error  Cut and bend wire to standard size  Simple and mechanical  Manual Adjustment – Type of wire  Safe to operate  Have way to bypass safety to troubleshoot  Simple to operate  Qualitative  Must operate with available power supply  Shearing edge and forming edge be off the shelf parts  Overhead lighting  Durable

Requirements Should Do’s  Quantitative X Produce 80 lbs/hr of wire X Be within the same footprint (floor size) X Manual adjustment - lengths of wire  Acute bends on wire  Qualitative  Be aesthetically pleasing X Cost < $3500

Requirements Would Be Nice  Combine spool with machine  Qualitative X Portability X Machine packages wire

Initial Design  Spool  Guiding  Puller  Flywheel  Collection  Electrical

Spool

Puller

Flywheel

Electrical

Design Changes Since Fall  Frame Change  Puller Chain Tension Design  Flywheel Cutting/Bending Dyes Reinforced  Collection System  Control Panel Mounting

Final Design/Manufactured Product

Financing Expenses Misc, Fasteners, $104.70 $183.01 Mechanical Electrical Fasteners Electrical, $1,574.57 Misc Mechanical, $2,156.87  Wizard Mfg. donated all raw material  Will pay for all but $3500 of the expenses

Testing  5 Test Runs  At Least1 Hour Duration  Different Range of Speeds  Sorted and Weighed Good and Bad (Waste) Wire

Test Results: Reliability  Target: < 10% downtime  Results: ~ 8% downtime 100 90 80 70 Time (min) 60 50 Down Time 40 Run Time 30 20 10 0 1 2 3 4 5 Trial Number

Test Results: Wire Dimensions  Target: (A) 4 ± 0.125” (B) 0.5 ± 0.125” (C) 70 ± 20 °

Test Results: Wire Dimensions  Results: (A) 3.964” (B) 0.499” A 30 (C) 57.8° 20 10 0 3.8 3.9 4 4.1 4.2 Length (in) B C 20 15 15 10 10 5 5 0 0 0.47 0.48 0.49 0.5 0.51 20 40 60 80 Length (in) Angle(deg)

Test Results: Production Rate  Target: 40 lbs/hour  Result: 33 – 53 lbs / hour depending on speed Weight Produced per Hour (lbs/hr) 60.0 50.0 40.0 30.0 20.0 10.0 0.0 60 67 72 88 106 Flywheel Speed (RPM)

Test Results: Waste  Target: ≤ 0.5 lb of waste/ 40 lb of good wires  Result: 0.4 lb – 2.8 lb depending on speed 3 Waste/40lbs good wire (lbs) 2.5 2 1.5 1 0.5 0 60 67 72 88 106 Flywheel Speed (RPM)

Project Success!  Met all of our Must Do’s  Met some of our Should Do’s  Met a Would Be Nice  It works and the sponsor likes it!

Future Recommendations  Sifting through wire by hand is not fun.  Having adjustability is nice, but it takes more time to setup.  Figure out a more controlled method for cutting and bending the wire. They fling everywhere.

Acknowledgements  Advisor:  Kaman Industries:  Matt Simkins  Steve Campbell  Sponsor: Wizard Mfg.  Dept. MMEM Faculty  Alan Reiff  FMS  Dan Hankins  Forklift Operator  Jerry – Plasma guy  Omar – Electrician  Sean, Jerry, Richard – Welders

Questions?