UTRGV / College of Engineering and Computer Science / Engineering Technology

Technical Project 1

Universal Turning & Adhesive Insertion Table

Jerry Gonzalez & Gerardo Mascorro

Project Introduction

Introducing our collaborative university project with CAP Industries: a custom-built machine designed to optimize their composite manufacturing processes. This project aims to address practical challenges faced by CAP, such as adhesive application and table rotation, with a focus on enhancing efficiency, productivity, and data collection.

Table of Contents

Project Overview.. 2

Background. 2

Procedure Flow Chart 3

Production Floor Photos. 4

Project Scope and Objectives. 4

Scope. 4

Breakdown of different components. 4

Gant Chart 6

Technical Details. 7

Concept Drawings. 8

Concept “Open Turntable”. 8

Concept “Gantry”. 10

CAD model 1 “Gantry”. 18

The Team.. 18

Collaborators and Advisors. 18

Citations. 18

Project Overview

The automation initiative at CAP Industries represents a transformative step in revolutionizing its manufacturing processes. With a focus on efficiency, quality, and sustainability, this project aims to automate key aspects of CAP's production line. By integrating cutting-edge technology and innovative solutions, the project seeks to streamline operations, enhance product quality, and position CAP as a leader in the industry.

Background

CAP Industries or Composite Access Products is a company that was founded in 2015 by Mr. Chad Nunnery. Initially the company was strictly focused on the handling of raw materials to manufacture composites, after a period of time CAP transitioned to manufacturing such. CAP’s main target is the molding and manufacturing of composite base utility cover or manhole covers. CAP became the first USA based company that achieved a mix of fiber glass and thermosets utilizing compression molding to create a product. Currently CAP distributes to 500 cities and 46 states around the United States of America.

Procedure Flow Chart

Production Floor Photos

Here are photos of the production floor, the core operational area of CAP Industries. Here, our machine will be used to innovate and introduce automation to their manufacturing processes.

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Project Scope and Objectives

The project scope encompasses the development of a custom-built machine tailored to optimize various aspects of composite manufacturing at CAP Industries. Key objectives include automating adhesive application processes, optimizing table rotation for uniform distribution, and integrating monitoring systems to ensure consistent quality. Additionally, the scope involves collaboration with CAP stakeholders to understand specific production challenges and tailor the machine's design accordingly. Through this project, we aim to enhance efficiency, productivity, and quality control in CAP's manufacturing operations, ultimately contributing to the company's long-term success.

Scope

· Data recollection for understanding the angle of insertion vs. motor RPM formula for cost efficiency.

· Instrumentation for tracking variables in the process.

· Inclusion of an HMI for operator-friendly tracking, understanding, and error reporting.

· Shaft encoders for tracking motor RPM and regulating speed.

· Cycle time counters to display the completion speed of each frame.

· Proximity sensor for precise angle detection during adhesive insertion.

· Timer for tracking the time taken to travel around the perimeter of each frame.

· Manual emergency stop for halting all machine operations if needed.

· Pneumatic actuators for opening and closing fixtures holding frames in place.

· Servo motors for moving adhesive via a gantry-style robot crane to the insertion point.

· Rotative pneumatic cylinder for adjusting the angle of the adhesive.

· Structural fixtures and mechanical tools for securing frames to the table.

· New structural design accommodating the expanded working area.

· Potential remodeling of the current production line for a larger perimeter.

· Structural fixtures and mechanical tools that will hold the frames to the table.

· A new structural design for the machine that will fit the area in question.

Breakdown of different components

Current Action being done manually	Action to be automated.	Propose Action.	Component to automate action
Currently the operator uses 3 different fixtures for the 3 different frames	Finding a universal way that all 3 different frames fit without changing fixtures.	The use of 3 straight line pneumatic cylinders actuators that will push fixture that holds the frames.	We will look for pricing on SMC actuators Master-Carr, or Automation Direct for the best deal.
Currently, the operator places fixtures on top of the table and manually spins the table with rollers directly installed on it.	Finding a way that operator pushes button and table spins safely and controlled.	The implementation of a motor with a shaft attached to the table's main fixture will be proposed. With the initial models proposed we will calculate the weight of the fixture being spun to find the best possible motor to use.	We will consult with our advisor on this matter seeking their advice, we will also investigate Automation Direct for the best option for this.
Currently the operator holds the pneumatic gun manually and the angle of insertion of the adhesive changes from one frame to the other.	The angle of insertion of the adhesive is one of the most important factors of this process. Finding the correct angle will in turn lead to a more efficient way to insert the adhesive into the groove of the frames.	Rotative actuators will be of great help in this matter. A way to alter the angle within the initial trials will show us the answer to this problem.	We will look for pricing on SMC actuators Master-Carr, or Automation Direct for the best deal.
Currently the operator manually holds pneumatic gun to insert adhesive	Manually holding the gun is another important factor in the process. The need to find a way to zero in on an insertion point that is the same for all frame’s during production is key.	Servo slide actuators that are installed in gantry style will help with this matter. With a previous redesign of the machine's structure, the gantry will be adapted to it.	We will look for pricing on SMC actuators Master-Carr, Automation Direct, or IAI for the best deal.
Since the process is done manually there is no data that can be recollected for this.	Instrumentation that will track adhesive, amount use, frames done.	Shaft encoders, Cycle counters, emergency stop buttons, and we will consult with CAP for any other request.	We will look for pricing on Automation Direct and with local suppliers.
The process will have a complete redesign to be automated.	Since the process will be automated the need for an HMI and the different sensors needed to track the actuators.	Proximity sensors for all actuators, HMI that is tracking all process.	We will look for pricing on SMC actuators Master-Carr, Automation Direct, or IAI for the best deal.

Gant Chart

The Gant Chart visualizes the timeframe and goals that are set to be done.

A screenshot of a computer

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Technical Details

This section includes detailed concept drawings and the initial CAD model. These documents provide a look at the design process we had going into the project. Our designs’ evolution, the changes that appear, and the aspects that remain unchanged are documented, offering an overview of our design process and our approach for this project.

Concept “Open Turntable”

Concept Design was made by Jerry Gonzalez. The design shows an open concept with a motorized turntable with adjustable clamps to secure the frame of different sizes to the table. There is an adjustable holster for the existing pneumatic adhesive gun, allowing for its continued use with slight modifications to monitor use of the adhesive. There is a control panel that monitors the information, speed, and other variables at the base of the machine.

sketch 1 - Jerry Gonzalez sketch 2 - angled view of design by Jerry Gonzalez

Sketch 1 by Jerry Gonzalez Sketch 2 by Jerry Gonzalez

Concept “Gantry”

Concept design created by Gerardo Mascorro. The design includes a top mounted pneumatic adhesive gun to insert above the gasket. The area where the frame is loaded into has a motorized turn table to evenly turn the frame.

sketch 1 by Gerardo Mascorro Sketch 2 by Gerardo Mascorro