AGITATOR REDESIGN FOR CORROSIVE ENVIRONMENT Kate Karauda Luigi
Abbate Will Fritzinger Peter Torab
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Project Overview Sponsored by Coating Technology Inc. Goal is
to redesign the agitator system for greater corrosion resistance
and longer life
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Current Tank Layout
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Current Cam System
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Failed Hardware Analysis
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First impressions: Worm gear not suitable for this application
Current process puts severe load on motor/gearbox Many wear points
Failed motor did not appear to be affected by corrosion Will
conduct more detailed motor analysis
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System Requirements
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Solutions 123456 Sub Functions 1 Create flow over entire
surface High pressure sprayLow pressure mist Move fluid via
propeller Move parts linearlyMove parts radially Ultrasonic
vibration 2 Create flow through capillaries High pressure spray
Move fluid via propeller Move parts vertically Move parts
horizontally Move parts radially Ultrasonic vibration 3 Minimize
chemical bath degradation Decrease cycle time Limit contaminates
above/around tank Cover tank Stabilize bath temperature and
properties 4Maintain bath temperature Use current systems, address
if needed Heater 5 Maintain homogeneous mixture Keep solution
agitated Circulate via pump 6 Reduce corrosive environment exposure
of system Move system away from tank vapors Install vapor hood
system Corrosive vapor shielding Forced air 7 Increase corrosion
resistance of materials Select corrosion resistant materials Apply
corrosion resistance coating to materials 8Operating
instructionsPrepare handbookPrepare videoMaintenance
tablePowerpointGraphics on system 9Cover moving partsShielding
Reduce number of joints and pinch points Controls in safe spot
10Limit exposure to chemicals Move system away from tank vapors
Install vapor hood system Personal respiration devices (PPE)
Increased ventilationCover tank Morphological Chart
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Datum1234 Sub Function s 1 Create flow over entire surface Move
parts vertically High pressure spray Move fluid via propeller Move
parts radiallyUltrasonic vibration 2 Create flow through
capillaries Move parts vertically High pressure spray Move fluid
via propeller Move parts radiallyUltrasonic vibration 3 Minimize
chemical bath degradation N/A Recollect fluid, seal system No
Change Covered tank, less fluid used 4 Maintain bath temperature
Current system Use current systems, address if needed Included
Heater 5 Maintain homogeneous mixture Keep solution agitated N/A 6
Reduce corrosive environment exposure of system Cover over tankN/A
Move system away from tank vapors N/A 7 Increase corrosion
resistance of materials N/A Select corrosion resistant materials 8
Operating instructions Word of mouthPrepare handbook 9 Cover moving
parts N/A Protective bars over propeller Cover shaftN/A 10 Limit
operator exposure to chemicals Cover over tankEnclosed tankCover
over tank Enclosed tank Pugh Chart
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SprayPropellerRotationalUltrasound CriteriaDatum1234Criteria A
DATUM -S+-ACost B+ +++BOperating costs C-+++CEase of use
D-+-+DAvailability ES+++EMaintenance F++++F Corrosion resistance
G++++GFatigue H++++HLifetime I++++IAesthetics J+S++JPerformance
KS+++KSafety LS+++LErgonomics +61011 Score-3011 S3200 Pugh
Chart
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System Design 1 - Rotational Vertical Axis Rotary Motion
Carousel with part mounts Corrosive resistant materials Motor and
gearbox moved away from vapors
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System Design 1 - Rotational Can utilize current tank framework
Limited corrosion exposure Fewer moving parts than current system
Increased motor/ gearbox lifetime Difficult to accommodate
different size dies Need new die fixtures May be difficult to
access parts More custom parts ProsCons
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System Design 2 - Ultrasound Off-the-shelf ultrasonic cleaning
unit Built-in temperature control Small unit can accommodate 1-3
dies
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System Design 2 - Ultrasound Significantly decreased cycle time
Built-in heater Smaller batches of fluid used No minimum number of
parts to run/batch Versatile High initial cost for commercially
available systems Completely replace current system Repairs may be
through an outside company ProsCons
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Design Areas Not Yet Complete Rotational motion vs. Ultrasonic
Complete capillary force calculations Corrosion testing and process
validation Off-shelf part selection Detailed component design
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Corrosion Testing Polarization Cell Measured current is
proportional to the rate of metal stripping Stripping rate will be
proportional to bath decomposition rate. Variable Corrosion Testing
https://edge.rit.edu/edge/P13656/public/WorkingDo
cuments/Review%20material/Variable%20corrosion% 20Chart.pdf
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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
