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ST IVO SIXTH FORM Engineering Education Scheme Niamh Rawlins Ibrahim Hafiaz Nathan Downes Connor Laud


CONTENTS INTRODUCTION

2

Project Brief

2

Webtec Information

3

PREPARATIONS

4

Research

4

Risk Management Plan

6

IDEAS

7

First Ideas

7

Final Idea

8

Risk management plan Safety feature

9 10

VISITS

11

Webtec Visit

11

Cambridge Visit

12

FINAL NOTES

13

Conclusion/Evaluation

13

Teamwork and time management

13

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INTRODUCTION PROJECT BRIEF The 180 series of high-pressure aluminium hydraulic rotary shear directional control valves are a solution for control of hydraulic actuators on mobile and industrial application where internal leakage must be minimised. The valves utilise an optically flat rotary spool with pressure loaded seats, to ensure either zero or near zero leakage. They have excellent tolerance to contaminates. Flow sizes 1 & 2 with interflow were found to have a leakage of 1.67x10-4 lpm which equates to less than 1 drop of water every 10 minutes. This gives an idea of how accurate our designs need to be, so they don’t cause leakage or other problems that might lead to injury. Currently the way to attach the 180 series control valves to the adapter is with four screws inserted through the adapter. Webtec have high demand for the valves so the time it takes to test each one needs to be minimised. We have to come up with a fast and efficient way of securely fastening the valve and adapter together without leakage. There are 3 handle positions on the 180 series valve. We had to factor in while designing our products, to ensure the movement of the handle isn’t compromised by the placement of the clamp or the position of the clamp attachment.

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WEBTEC INFORMATION Webtec is a company who works internationally and are based in St Ives, they are focused on creating hydraulic services for commercial use. Webtec is a specialist company who manufactures hydraulic measurement and control products. Their products are aimed to improve the productivity of industrial size machinery. Webtec engages in the design, development, manufacture and distribution of fluid power products for mobile machinery dealers, the industrial machinery market and service technicians worldwide. They offer hydraulic control valves, flow condition monitoring products, hydraulic components, hydraulic test equipment, diagnostic test equipment, test stand instrument products, flow measurement products spare and repairs and calibration. For 50 years they have been helping customers worldwide in industrial, mobile and agricultural sectors to diagnose hydraulic faults, verify hydraulic conditions and achieve repeatable hydraulic control.

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PREPARATIONS RESEARCH There were several stages while doing the project where we had to research areas to gain a better insight. The first thing we had to research was the right clamp to use, it had to hold the pressure that the oil was pushing up on the valve. Before we could do that, we had to work out how much pressure would be acting upwards, we had to do some calculations to do this. This is shown in Figure 1.

Figure 1 This calculation was done by converting psi into MPa because it was an easier unit to use. Then the area of the cross-sectional area of the pipe was found. We then used F=PA to find the force of the oil in the pipes. We then converted this into kg to decide which clamp to use.

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We also had to research what materials were best to make each part out of, what material was the most appropriate. We decided to make the adapter out aluminum as its relatively cheap and durable enough for our purposes. This would be better than, for example, steel as steel is much more expensive and would be too much for our needs. Our attachment was loosely influenced by the attachment that came with the clamp; for this reason, it will be made from stainless steel. Steel is obviously very strong, and this component will be the part holding most of the force from the clamp in the system. For this reason, it’s sensible to make it more durable. For the final component, the clamp support, we’re planning to make it out of aluminum as again it’s cheap and durable enough for supporting the clamp. Figure 2 shows the comparison of the characteristics of each material.

Material

Price per mass £/kg

Youngs modulus GPa

Density g/cm^3

Aluminum

1.5

69

2.7

Stainless steel

2.5

193

8 Figure 2

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RISK MANAGEMENT PLAN We made a risk management plan to make sure everyone was aware of the potential risks and take the precautions needed to prevent them, Figure 3. Description of Risk

Probability

Severity

Impact

Response

Disagreement within the team.

High

Low

Disagreements will delay progress.

Discuss until the disagreement is solved.

Team member illness and missing meetings.

Medium

Medium

Progress will be delayed over a short period.

Continue with tasks assigned and dedicate another team member(s) to fill in.

Members not completing their assigned task on time.

Medium

High

The rest of the project may be put on hold if the task is critical.

Consult the Gantt Chart and review impact of the delay. Reassign task if necessary.

Injury on visit to Webtec facility.

Low

High

Team member could be critically injured.

Keep to marked out areas and follow staff’s instructions to reduce chance of injury.

3D printer issues at workshop.

Medium

Low

Impact would be minimal as Webtec have a 3D printer at their facility.

Overlook 3D model to try find any flaws in advance as our testing phase will be delayed.

3D models incomplete by the time of the workshop visit.

Medium

Low

Impact would be low because Webtec has a 3D printer.

Work as a team to complete the models by the time of the visit.

Figure 3

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IDEAS FIRST IDEAS When we were first given our project brief, we came up with several ideas, but we had to decide which one was the most appropriate. A brief idea we had was to have a covering attached to the moveable parts of the test bench. It would go over the valve and the adapter to minimize movement. This design wouldn’t have worked because it would have stopped the jaws of the test bench closing properly. Another idea was to have four pins coming up from the adapter that would go into the previously existing, threaded holes on the valve, Figure 4. The pins would stop movement horizontally but not vertically. To stop movement vertically we would have to use a clamp to hold the adapter and valve. However, we figured that if we went ahead with this the threads inside the valve would get damaged, so we couldn’t give damaged products to customers. The customer might need to use these threaded holes because they might want to bolt the valve to something.

Figure 4

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FINAL IDEA Our final design would be a collar around the adapter and use a clamp to hold the valve down on the adapter. We had to model 3 different components for this design. The first would be an improved version of the adapter, Figure 5. We altered the adapter by increasing the height by 2cm and adding a collar to cover the side of the valve on top, show in Figure 5. We increased the height of the adapter so that the collar wouldn’t inhibit movement of the test bench. We added the collar, so the valve didn’t move horizontally, we used the clamp to stop it moving vertically. We used a clamp to apply a large amount of pressure, this meant that we had to make an attachment for the clamp so that it could apply even pressure to the top of the valve, Figure 6. We also made a model of the support that would be needed to hold the clamp, Figure 7. The support that was made needed to be very sturdy and would raise the clamp to an appropriate height. We decided to go for this design because it was the most suitable and would be able to hold the pressure easily. It would also be easy to replace the clamp, if it needed to be altered for a higher pressure.

Figure 5

Figure 6

Figure 7

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RISK MANAGEMENT PLAN We made this second risk management plan, Figure 8, so we were are aware of the risks that come along with our design. It also makes it clear where improvements could be made.

Description of Risk

Probability

Severity

Impact

Prevention

Operating the

Medium

High

Could injure

We created a safety

equipment when

surrounding

feature shown in

the clamp is not

workers

figure …, the

closed to its full

severely. This

pneumatic diagram.

rotation.

might also

This means the test

damage the test

rig can’t be turned

bench and the

on.

equipment around. While operating the

Low

Medium

Might cause

Wear appropriate

equipment workers

moderate injury

clothing that won’t

could get fingers or

or damage to

get caught in the

clothing caught

clothing.

equipment. Ensure

under the clamp.

to keep hands away while clamping down.

When setting up

Medium

High

It would mean

Ensure that the

equipment the

that the valve

clamp attachment is

clamp attachment

and adapter

connected to the

would need to be

wouldn’t be

height that was

attached correctly.

clamped down

determined each

properly. This

time it is installed.

would mean that if the test rig was turned on if would cause severe injury. Figure 8 Page | 9


SAFETY FEATURE For this design we decided to make a safety feature, Figure 9 that would determine if the handle on the clamp was locked in place after being pulled down. This safety feature would ensure that the workers were safe while working the machine. If the handle wasn’t completely down, then they couldn’t turn anything else on. We also made a risk management plan for this design to evaluate the potential risks. The plan is to add a pneumatic roller switch to the clamp, making it so the clamp would need to be engaged to enable the circuit. This switch would be connected via an AND gate, meaning that both the test rig doors would also have to be engaged to activate the circuit, allowing the system to operate.

Figure 9

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VISITS WEBTEC VISIT Towards the beginning of our project, we visited Webtec’s local facility to gain insight into the task at hand. From visiting the assembly line and the testing area, we learned about the scale and demand for their products. This revealed to us the level of detail our project required, indicating the scope of our project. With this knowledge, we could carry on with our project with a good idea of the processes that we could apply to our solution allowing us more creative freedom in our design. We were shown the test bench, Figure 10, that would be used for the valve. The current method of clamping was demonstrated to us which helped us understand how to make the clamping easier for the workers. We kept this in mind when choosing the clamp, also when we were deciding the placement of the clamp.

Figure 10 Page | 11


CAMBRIDGE VISIT When we first got to Cambridge, we were given a tour of the engineering department. We then allocated our roles for the two days: two of us worked on the models while the rest of us proposed a safety system, worked on the report and updated the Gantt chart. We didn’t have any problems to begin with, but we encountered a few as we went along. It was mentioned by our mentors that the test rig only used 3,000 psi but we used 10,000 psi in our calculations. We purchased two clamps to hold the pressure, but we only needed one because of the new calculation. This didn’t postpone our continuation, but it meant that money was wasted. Another inconvenience we encountered was that the clamp was placed in a way that it compromised movement of the other components. To overcome this problem, we had to adjust the size of our models and reposition them. We also created a safety feature to make sure the water can’t flow if the clamp isn’t fully down, this would mean that the people working the machine wouldn’t be injured. Also, we realized that the clamp attachment would scratch the top of the valve when its clamped down. So, we thought it would be a good idea to add a rubber cover on the bottom.

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FINAL NOTES CONCLUSION/EVALUATION TEAMWORK AND TIME MANAGEMENT During the project our group met weekly with our mentors from Webtec so that we could make sure we were on time and would meet all our deadlines. We would also meet between meetings when necessary. Throughout the project we used a Gantt chart to keep on track and determine if we were behind, Figure 12. The Gantt chart also made it very straightforward to reorganize if there are any inconveniences. There were times when some people had to miss meetings and inevitably started trailing behind, the Gantt chart made it very easy to keep track of how much we completed each target. During the project we all worked well together, there weren’t many disagreements. Our time management meant that we completed everything by the due date. When we first started, we formatted the Gantt chart so that all dates were visible and everyone in the group was aware of the time they need to dedicate for each particular assignment. This helped establish if it was essential to adjust the rate of completion. If we were to do the project again, we would set smaller deadlines, so it is easy to alter and adjust them to difficulties. This would also make it more manageable to keep track of completed tasks. Our final design completed what the project brief was asking for, during the project we kept the project brief in mind and ensured we were meeting all the criteria. The overall composition of the components is big and not as cohesive as we aimed for, one way that this could be Page | 13


improved. Another thing that we kept in mind while designing and modelling our products was cost. We wanted to keep costs as low as possible while still making each thing to a high quality. The only point where money was wasted was when we bought an unnecessary clamp. This mistake was caused by an assumption made within the group, this mistake didn’t majorly affect the project. Figure 11 shows all components in the final 3D model.

Figure 11

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Engineering Project WBS NUMBER

TASK TITLE

TASK MANAGER

1

Planning

1.0

Understanding task

All

1.0.1

Initial Idea

All

1.1.0

3D Models

Niamh

1.1.1

Understaning CAD

1.1.2

Concept for Adapter

1.1.3

Adapter TD

1.1.4

Clamp Attachment TD

1.1.5

Adapter 3D Model

1.1.6

Clamp Attachment Model

1.1.7

Clamp Raiser TD

1.1.8

Clamp Raiser Model

1.2.0

Pressure Calculations

1.2.1

Understaning pressure applied

1.2.2

Calculating pressure needed

1.3.0

Clamps

1.3.1

Understanding Styles

1.3.2

Select Clamp(s)

1.1.2

Report

2

Maintenance

2.0

Safety Features Nathan

2.1

Presentation

2.1.1

Scripts

2.1.1.1

Nathan

2.1.1.2

Ibrahim

2.1.1.3

Connor

2.1.1.4

Niamh

2.1.2

Powerpoint

Nathan

2.1.3

Demo Model

Ibrahim

2.1.3.1

Cardboard

2.1.3.2

Wooden

4

Poster/Board

Earliest Start/Can Start

Duration

Latest Finish/ Finished

WEEK 1

WEEK 2

WEEK 3

WEEK 4

WEEK 5

WEEK 6

WEEK 7

WEEK 8

WEEK 9

WEEK 10

WEEK 11

WEEK 12

WEEK 13

WEEK 14

WEEK 15

WEEK 16

WEEK 17

WEEK 18

WEEK 19

WEEK 20

WEEK 21

29/10/18

5/11/2018

12/11/2018

19/11/18

26/11/18

3/12/2018

10/12/2018

17/12/18

24/12/18

31/12/18

7/1/2019

14/1/19

21/1/19

28/1/19

4/2/2019

11/2/2019

18/2/19

25/2/19

4/3/2019

11/3/2019

18/3/2019

Order Deadline

Cambridge Workshop

Nathan

Connor

Ibrahim

4.1 4.2 4.3 4.4

Figure 12

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Profile for Lorena Pérez UNIR

Proyecto Engineering Education Scheme  

Proyecto referido en la actividad 1 'Fomento de vocaciones STEM' para la asignatura 'Complementos para la Formación Disciplinar"

Proyecto Engineering Education Scheme  

Proyecto referido en la actividad 1 'Fomento de vocaciones STEM' para la asignatura 'Complementos para la Formación Disciplinar"

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