Agitator Redesign for Corrosive

EnvironmentKate KaraudaLuigi Abbate

Will FritzingerPeter Torab

Sponsored by Coating Technology Inc.

Goal is to redesign the agitator system for greater corrosion resistance and longer life

Project Overview

Tank Layout

Current Cam System

Luigi

Vertical Axis Rotary Motion (VARM)

Carousel with part mounts

Corrosive resistant materials

Utilization of current tanks and framework

Motor and gearbox moved away from vapors

Continuous motion vs. sinusoidal

System Design

Rotational Motion vs. Ultrasonic◦ Ultrasonic shows a lot of potential

Capillary Forces Quick Wear Calculations Power Selection Belt Wear Rates Component Design Off Shelf Part Considerations

Design Areas Not Yet Complete

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;

Project Schedule

1 2 3 4 5

1

2

3

4

5

OCCURRENCE

S E V E R I T Y

Risk Prevention Plan Mitigation Plan Severity Occurrence Status

Missed deadline

Review planning and scheduling tools at every meeting; verify all assigned work is being completed in a timely

manner

Complete work ASAP, group discussion to get project back on track, meet with guides

3 1

Missed milestone

Review planning and scheduling tools at every meeting; verify all assigned work is being completed in a timely

manner

Complete work ASAP, group discussion to get project back on track, discuss with guides

4 1

Over the budget

Prior to completing the technical design review create a detailed BOM to verify all necessary parts are within the

project budget

Meet with the sponsor and the customer; see whether budget can be increase: if impossible

minimize the design as much as possible to drive down the cost

3 2

Exposure to corrosion cannot be reduced due to the current hardware

setup constraints

While completing the initial design take detailed measurements of the current setup; after completing the

design verify once again the new system fits in place of the old one

Explore the use of materials and off-the-shelf hardware with increased corrosion resistance

(might drive the cost up: use caution)2 3

Materials used cannot withstand the corrosive environment

Verify the BOM for all parts which might have a significantly decreased

lifetime due to corrosion fatigue

Discuss with the customer a possibility of using more expensive materials. Alternatively, settle on

current materials and create maintenance plan which would help increase the lifetime of parts.

2 2

System performance issues

Create a functioning protytpe; run the prototype in similar or harsher

enviornment under maximum load to verify its functionality

Review design, observe system in operation, collect data and interpret to identify the part(s) causing

the issue5 1

Prototype beyond scope of project

During the design phase focus only on functions directly related to the

hardware in question; ommit functions not closely related to the current

system

Redefine system objectives and functions 1 3

Customer needs not met

Create several review meetings: present the design idea to the

customer and if approved create a prototype; follow the list of customer

needs and review along with the design

Meet with customer to discuss and reach consensus on every need which has not been met; if the

customer is still not satisfied propose one of the alternative design which might meet their needs

better

5 1

Compatibility issues with current tank framework

Measure the framework; ensure the measurements are included in the

design phase of the new system

Adjust layout of system; if budget allows, redesign framework

1 4

Underpowered for desired application

Verify that the new design can handle maximum loads required by the

customer; test the prototype under at least maximum load

Meet with customer and discuss possible design changes; add an extra motor or another power unit

to increase the power output of the system3 2

Higher than expected operating costs

Run the prototype under similar conditions as those in the factory;

record power input required, power output, load handling and

maintenance cost

Limit and eliminate factors driving cost as much as possible; alternatively adjust the design

3 2

High maintenance

Use off-the-shelf parts which require as little maintenance as possible; use self-

lubricating parts where possible to decrease the required maintenance

Minimize system maintenance requirements for customer; create a revised maintenance manual for the customer to simplify maintenance requirements

2 2

Inconsistent performanceVerify that the prototype is functional

and performing as expected in the testing phase

Identify factors causing inconsistencies in performance and make improvements accordingly; take data and observe the system for several cycles

4 1

Project Risks & Mitigation Plans