Final Year Project Report

Bachelor of Science
In
Process Plant Technology
Project Report
To Design an Automated Ice Cream Cake
Mould Dispenser
Daniel Howard
Supervisor: Niall Morris May 2014

Daniel Howard R00072566
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Abstract
The cake industry has the highest product income for the Ice Cream factory based in Fermoy.
Baskin Robin has a contract with Silver Pail Dairy in producing up to 2,500 cakes per day.
Currently the factory is making roughly €75,000 worth of cakes each day. The method of
removing the mould off cakes is carried out by six people manually peeling them at a table;
this is before a worker places them on the production line. During this stage many cakes are
wasted due to the melting of the ice cream, such cakes are left standing for a substantial
amount of time before the workers get to the bottom of each trolley. Also, on the rare
occasion the ice cream physically lifts off the base of the cakes when workers are trying to
remove the plastics.Up to 150 cakes can be wasted each day and this is adirect loss of €4,500
that can be greatly reduced. Recently there has been a substantial amount of cakes refused
overseas, the reason for rejection is the bacterial count on the cakes were found to be too
high and was traced back to manual peelers hands coming in contact with the ice cream
surface.
My brief was to produce an automated rig to remove the plastic moulds off the cakes
automatically, which would result in a full cake production line at all times therefore, more
cakes could be produced each day. The new cake peeling system would immediately cut out
the amount of waste melted cakes each day, and no contact between an outside source and
the ice cream would be at risk. Only one trained operator would be operating the rig so
immediately, 5 peoples wages wouldn’t be an assetanymore. This as well as more cakes being
produced would have the potential of the automated rig paying for itself in a very short space
of time. All materials used to design the rig, and means of operation all comply with company
standards in the cake room and health and safety standards in the food industry. Silver Pail
had their reservations on a means of a design a rig. The information they later shared with
me proved to be a great benefit in the design of my project.

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Acknowledgements
I would like to express my deep gratitude to my project supervisor Niall Morris for his
guidance and for his helpful critiques of this research work.
I would like to thank CIT for the use of their mechatronics room and various types of
equipment throughout the college for use in my project.
I would also like to thank the staff in Silver Pail Dairy who was always so helpful and obliging
when I arrived into the factory, especially Mr. John Murphy and Mr. Sean Eagan who showed
me around the factory and organised maintenance staff to be available when I arrived at the
factory.
Finally, I would sincerely like to thank my partner, family and friends, for their endless
support, encouragement and advice throughout my project.

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Table of Contents
1. Introduction ........................................................................................................................6
2. Background to Company ....................................................................................................7
The Cake Room.......................................................................................................................8
Meeting Production Manager/Data Collected.....................................................................11
3. Initial Aims ........................................................................................................................12
4. Project Schedule ...............................................................................................................14
Project Timescale and Milestones .......................................................................................14
Semester 1 ........................................................................................................................14
Semester 2: .......................................................................................................................14
Resources:.........................................................................................................................15
5. Research............................................................................................................................15
6. Design Choices..................................................................................................................17
7. Systematic Design.............................................................................................................28
Analysis.....................................................................................................................................30
Tests Carried Out On Design................................................................................................33
Choice of Pneumatic Components...........................................................................................35
Pneumatic Cylinders.............................................................................................................36
Semi – Rotary Drive..............................................................................................................37
Vacuum Technology.............................................................................................................38
Suction Gripper/Bernoulli Gripper ...................................................................................38
8. 3D Inventor Parts..............................................................................................................41
9. Assembly...........................................................................................................................46
10. Quotes to build Automated Rig ....................................................................................50
11. Safety.............................................................................................................................53

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Risk Assessment ...................................................................................................................54
More Risk Reductions...........................................................................................................58
Conclusion............................................................................................................................58
12. Operating Procedure.....................................................................................................59
Exhibition .................................................................................................................................64
13. Discussion and Conclusion............................................................................................66
Appendix A (Materials Specification).......................................................................................67
Appendix B (Industrial Products) .............................................................................................74
Appendix C (FESTO Products Data Sheets)..............................................................................77
Appendix D (Joining Methods and Specifications) ..................................................................83
Appendix E (Quotations)..........................................................................................................88
Appendix F (Safety) ..................................................................................................................93
Appendix G (GX Developer Programme) ...............................................................................104
Appendix H (Engineering Drawings) ......................................................................................107
14. References...................................................................................................................115

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1. Introduction
This report will consist of the work carried out with silver pail dairy in designing a rig to find a
solution to a problem the factory encountered during production of their ice cream cakes in
the factory.
The specialised brief given by silver pail will be strictly followed; design requirements and pre
cake preparation will also be discussed before the automated rig will remove the plastic
mould off the frozen cakes.
The expected project schedule will be incorporated into the report, discussions on how
efficient work was carried out throughout the year and in completing set goals each week.
A full design analysis will also be discussed later in this report, as well as the exhibition and
what silver pail thought of the final product design.
Figure 1.1.1 Final Design after Process

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2. Background to Company
Silver Pail Dairy is an ice cream factory based in Fermoy Co. Cork. Manufacturers of quality
ice cream and frozen desserts for foodservice and retail customers
It was founded in 1978 by Michael Murphy and has gone on to be the largest ice cream
manufacturer in Ireland with 30 years experience in the manufacturing of high quality ice
cream and frozen desserts. The company is the enviable position of being able to use fresh
milk and cream, sourced from farms in the surrounding locality. They process 30 million litres
of Irish milk annually.
The Silver Pail factory is 80,000sq ft is size and has the capacity to produce 40 million litres of
ice cream per annum. The purpose built factory meets Global Food Standards and fully
conforms to all appropriate food service legislation.
Silver pail have a workforce of 60 people, many who have been part of the company for over
20 years, whose experience allows production of consistently high quality ice cream, sorbets
and desserts.
Silver Pail Dairy has British Retail Consortium (BRC) Higher Level Accreditation since 1998.
Maintained an accredited HACCP Quality Assurance Programme which itself incorporates full
microbiological testing and auditing. In the interest of food safety, silver pail maintains full
product traceability. All the suppliers are regularly audited on their quality systems.

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The Cake Room
1. The cakeroom facilityis avery hygienicand sterileroom; a standard cleansing process
is carried by every personnel entering the cake room no matter how long an individual
is present for. Figure 2.1 below shows the cake room from an individual’s perspective
upon entering the cake room.
Figure 2.1 Cake Room
Machinery is placed in the corners of the room, to prevent accidental tampering from
the largemass of traffic travelling up and down the centre of the room throughout the
day. This machine controls the amount of cream that needs to be injected on top of
the cakes once the dressing procedure has commenced in Figure 2.2.
Figure 2.2 Commencing of Dressing Procedure

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2. All components including the production line are made of stainless steel, and are
washed after each quarter while the workers/operators take their break. Here shown
in Figure 2.3 is a cake dressing head that ejects cream onto the surface of the Baskin
Robins cake. Also shown in figure 2.4 is the washing machine, where dressing
components, hoppers, tools etc. are washed and sterilised every break.
Figure 2.3 Cake Dressing Head Figure 2.4 Washing Machine
3. The cake room has an extremely organised system, from how often cakes are brought
in, to how many boxes are required each day to pack each individual cake. The process
of dressing each cake is a constant procedure carried out on the cake dressing line
shown below in Figure 2.5.
Figure 2.5 Dressing of the Cakes

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4. Here is a visual aspect on how the cakes are produced each day:
 Cakes are brought in on a trolley from the freezer after producing the cake
bases at the other side of the factory. They are then transported from the
trolley to the table where the manual peeling process begins.
 The cake’s Plastic mould is removed which is known as ‘peeling cakes’ in the
factory.
Figure 2.6 Removing Plastic Moulds From Cakes
 Cake’s are then placed on the production line where they are automatically
dressed and finished.
Figure 2.7 Cakes are placed back on the Production Line
 The finished product are packed and returned to the freezer until they need to
be shipped the cakes are out of the freezer for a maximum of 30mins. A longer
timeframe than this and the cake would melt.
Figure 2.8 Finished Product

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Meeting Production Manager/Data Collected
The first step in gathering information for the project was to go on-site to the factory. A
meeting with the production manager of the factory Mr. John Murphy was organised and
information on the task at hand was discussed. Mr. John Murphy proceeded to present the
cake room in the factory and gave time to completely analyse how the cakes were produced.
A brainstorming meeting was held in the office after all the information was gathered. This
meeting was held to try and figure out where and when the problem was occurring on the
production line.
It was then found that the main issue occurred when the cakes were being ‘peeled’ (the
plastic mould was manually being removed from the cakes), It was discovered that because
the workers could not manually keep up with the automated machine, gaps were occurring
and reoccurring in the production line. This resulted in several losses throughout a day’s 8
hour shift. Further analysis into the cake room revealed another flaw in the process. As the
workers were getting tired and beginning to slow down, cakes were getting dropped. This
caused workers gloves to touch the top of the cakes which undeniably added bacteria onto
the cake. It was time to discuss what requirements were required in the design.
Eventually an agreement was reached and the best option was to design a single rig that was
able to remove the plastics safely, effectively and without difficulty. The condition discussed
was to peel a cake in seven seconds or less, so there were no gaps in the production line. It
was not required to produce a conveyer belt or any other type of process as it would be a
waste of resources and would over complicate the entire design of the rig. Cakes will be
manually fed into the rig and once the plastic is removed they will be manually taken out of
the rig and placed on the production line.

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3. Initial Aims
The main objective of the project was to produce an automated rig that would remove the
plastic mould off ice cream cakes in seven seconds or less.
 The reason the plastic mould is required to be taken off in seven seconds or less is to
ensure the rig was able to match or better the current system of six people manually
peeling cakes. Providing a machine capable of this would mean, there would be no
gaps in the production line and silver pail could achieve maximum efficiency
throughout the day.
Little or no contact with the ice cream was a necessity when designing a means of separation.
This was solely for hygienic reasons:
 Silver Pail recently had a batch of cakes rejected from retailers overseas due to
excessive bacteria on the cakes. Silver Pail sourced the problem to the manual peeling
process which leads to human contact with the ice cream.
The rig is to be easily accessible:
 Ideally the cakes should be easily inserted into the rig. Once the operation starts the
mould is to be removed relatively quickly and the cake then taken out to be placed on
the production line. This ensures that the rig is more efficient than the current
standard of a manual worker. The rig should carry out this task in a quick, easy and
safe way, with no risk of injury.

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The material used in construction of the rig must be easily cleaned and sterilised due to
hygienic standards the factory entails:
 The rig itself was preferably to be made out of stainless steel as well as the material
for pneumatic components. The reason stainless steel was chosen is due to its ease of
cleaning and its ability to withstand both low and high temperatures throughout the
day.
Ultimately the design would save the factory money by cutting down operators cost, reduce
waste and increase cake production by the end of each day.

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4. Project Schedule
Project Timescale and Milestones
Semester 1
Start date- Monday 30th September 2013 – Choosing of the project.
First Presentation – This presentation consisted of an outline of the desired project, a
background to the problem at hand, coming up with a mechanical solution for the factory’s
brief would be a bonus at this early stage, the scope of the project and it would commence
was also discussed in this presentation.
Second Presentation – An outline of the project - description, background and objective. A
project plan which willinclude the following: outline of approach, resource requirements, and
work scheduled to produce factory standard design. The presentation will also show
examiners the reasoning behind the decisions made to complete the project, which will be
backed up by company data. A review of the schedule as it stands compared to where it
should be, any changes made to the project since the first presentation and changes to
resources and plans for second semester had been discussed.
Written Progress Report hand up – Friday 13th December: An outline of the project,
description, background and objective. A project plan; how to approach the project, safety
that needs to be incorporated into the designto meet the safetyregulations, key components
of the rig and resources available.Choosing adesign and why, would have alsobeen discussed
referring back to the data collected and the key components required to remove the plastic
quickly and efficiently. Certain aspects that will need to improve were also discussed when
coming up with a final design when designing the rig in the second semester.
Semester 2:
Return to college: 3rd of February – the drawing aspect of the chosen design commenced.
Further research with Silver Pail was undertaken into finding a process that would make the
plastic mould easier to remove.

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Finish date of drawing: 15th March – the drawing phase of the project finished and the
initiation of the write up phase of the project began.
Final presentation Engineering Exhibition April 10th – this presentation demonstrated
what had been achieved throughout the year and an overview of the design and operation of
the rig. Any information or enquiries that lecturers or members of the public had were
presented and explained from the stand itself.
Finish ofwrite up: May 9th – The finishing touches of the write up willbe applied this week.
It will then be proof read by myself.
Resources:
Monetary
The financial requirements for this cake dispenser is available later in this final report after a
full product design will be drawn up and attached the list of requirements to produce the rig.
Time Requirements
Two hours a week was recommended to the project in semester one. In semester two the
workload increased to 4 hours a week since Fridays are designated solely to project work.
Client Information:
The project was researched in Fermoy Co. Cork and design was undertaken in Cork Institute
of Technology. The design will be passed onto Silver Pale Dairy to produce the rig if they so
wish.
5. Research
At the beginning of this project the research included, the process of producing the cakes
from the beginning to how the factory made the cake bases to the finished product.

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The process is as follows:
 There is an automated machine at the rear of the factory where freshly made ice
cream is injected to a plastic mould, a yellow base is attached to the plastic mould,
packed onto trolleys and frozen at -40°
 Once the cake bases are frozen they are transported on the trolleys to the cake room
 The frozen bases are then taken from the trolleys to a table where there are 6
operators. These operators peel the plastic mould manually from the cakes.
 Once acake is peeled, it is then moved onto the cake dresser stations to be decorated.
 The cake is then passed through the 24 stations where only sixstations have a dressing
process, and placed into a box and into the freezer ready to be shipped off site.
Hygiene was a vital consideration in the project because of working within the food industry.
There are standards which must be followed on the acceptable amount of bacteria that may
be found on the working surfaces.
Recently there were over a hundred thousand contracts rejected from Baskin Robins. It was
found that there was an unacceptable level of bacteria found within the cakes. Analysing the
cake production procedure, the problem was sourced at the cake peeling process, where
operator’s hands had come in contact with the ice cream before being dressed.
The extreme temperatures that would be exposed to the automated rig were also an
important part of the research field. Finding components that would function sufficiently in
freezing temperatures and continue working after being washed with boiling water between
processes had to be taken into consideration.

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The purpose of scalding the working surfaces is to get rid of any excess ice, ice cream or
bacteria that will affect the quality of the cakes in anyway.
6. Design Choices
Some of the choices that lead to the final design were directly related to the set up silver pail
currently had throughout the factory.
The majority of the equipment was powered by air pressure. The machines that were
pneumatically powered set a good base point to begin the choices for my design. There was
an abundance of air line access points especially in the cake room. The maximum pressure

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that was found in the cake room was 6 bar and this was constantly running through the main
lines.
It was then decided that the rig would be pneumatically powered. The rig would be placed in
the cake room beside the line where the cakes were currently being peeled which would
create fewer disturbances.
Figure 6.1 Festo Pneumatic Products (Shl-group.com, 2014)
The material that was going to be used in this rig had to be easily cleaned, suitable in the food
industry and be able to withstand the forces that were going to be applied to the rig while in
operation.
The CES Package in CIT gave a huge amount of information and research was carried out on
what materials would be best suited to the design project.

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The figure below shows the materials graphed for various different parameters. A graph was
used so a third party could visually inspect which material is best and why, for various
conditions.
Figure 6.2 Graph of Different Materials under Various Conditions
After setting conditions to the design project, it was possible to zone in on the limits at which
the rig should be designed at. It was then discovered that stainless steel and aluminium were
constant materials every time.

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Figure 6.3 Comparison of Stainless Steel and Aluminium in Density vs Tensile Strength
Figure 6.4 Machinability vs Weldability
As you can clearly see
Stainless Steel has a higher
Tensile Strength and Density
as opposed to the Aluminium
This graph shows that Stainless
Steel has the same machinability
as aluminium, but is more
weldable than the aluminium;
therefore stainless steel is the
superior material.

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Figure 6.5 Young’s modulus vs. Yield Strength
Stainless steel
The material
Stainless steels are alloys of iron with chromium, nickel, and - often - four of five other
elements. The alloying transmutes plain carbon steel that rusts and is prone to brittleness
below room temperature into a material that does neither. Indeed, most stainless steels resist
corrosion in most normal environments, and they remain ductile to the lowest of
temperatures.
Composition (summary)
Fe/<0.25C/16 - 30Cr/3.5 - 37Ni/<10Mn + Si,P,S (+N for 200 series)
General properties
Density 7.6e3 - 8.1e3 kg/m^3
Again stainless steels structure
and composition surpasses the
Aluminium’s qualities, this is
another example of Stainless
Steel’s competitive structure
compared to Aluminium.

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Price *4.59 - 5.06 EUR/kg
Date first used 1915
Mechanical properties
Young's modulus 189 - 210 GPa
Shear modulus 74 - 84 GPa
Bulk modulus 134 - 151 GPa
Poisson's ratio 0.265 - 0.275
Yield strength (elastic limit) 170 - 1e3 MPa
Tensile strength 480 - 2.24e3 MPa
Compressive strength 170 - 1e3 MPa
Elongation 5 - 70 % strain
Hardness - Vickers 130 - 570 HV
Fatigue strength at 10^7 cycles *175 - 753 MPa
Fracture toughness 62 - 150 MPa.m^0.5
Mechanical loss coefficient (tan delta) *2.9e-4 - 0.00148
Thermal properties
Melting point 1.37e3 - 1.45e3 °C
Maximum service temperature 750 - 820 °C
Minimum service temperature -272 - -271 °C
Thermal conductor or insulator? Poor conductor
Thermal conductivity 12 - 24 W/m.°C
Specific heat capacity 450 - 530 J/kg.°C
Thermal expansion coefficient 13 - 20 µstrain/°C
Electrical properties
Electrical conductor or insulator? Good conductor
Electrical resistivity 64 - 107 µohm.cm
Optical properties

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Transparency Opaque
Processability
Castability 3 - 4
Formability 2 - 3
Machinability 2 - 3
Weldability 5
Solder/brazability 5
Eco properties
Embodied energy, primary production *80.3 - 88.8 MJ/kg
CO2 footprint, primary production *4.73 - 5.23 kg/kg
Recycle True
(CES Package, 2014)
Design guidelines
Stainless steel must be used efficiently to justify its higher costs, exploiting its high strength
and corrosion resistance. Economic design uses thin, rolled gauge, simple sections, concealed
welds to eliminate refinishing, and grades that are suitable to manufacturing (such as free
machining grades when machining is necessary). Surface finish can be controlled by rolling,
polishing or blasting. Stainless steels are selected, first, for their corrosion resistance, second,
for their strength and third, for their ease of fabrication. Most stainless steels are difficult to
bend, draw and cut, requiring slow cutting speeds and special tool geometry. They are
available in sheet, strip, plate, bar, wire, tubing and pipe, and can be readily soldered and
braised. Welding stainless steel is possible but the filler metal must be selected to ensure an
equivalent composition to maintain corrosion resistance. The 300 series are the most
weldable; the 400 series are less weldable. (CES Package, 2014)

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Figure 6.6 Phase diagram
Phase diagram description
Most stainless steels are alloys of iron (Fe) with chromium (Cr) and nickel (Ni). This is the
ternary phase diagram, at a temperature of 800 C, for those three elements. The position of
AISI 302 stainless steel (Fe-18%Cr-8%Ni) is shown.
Typical uses
Railway cars, trucks, trailers, food-processing equipment, sinks, stoves, cooking utensils,
cutlery, flatware, scissors and knives, architectural metalwork, laundry equipment, chemical-
processing equipment, jet-engine parts, surgical tools, furnace and boiler components, oil-
burner parts, petroleum-processing equipment, dairy equipment, heat-treating equipment,
automotive trim. Structural uses in corrosive environments, e.g. nuclear plants, ships,
offshore oil installations, underwater cables and pipes.

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High-strength Aluminium
The material
The high-strength aluminum alloys rely on age-hardening: a sequence of heat treatment steps
that causes the precipitation of a nano-scale dispersion of intermetallics that impede
dislocation motion and impart strength. This can be as high as 700 MPa giving them a
strength-to-weight ratio exceeding even that of the strongest steels. This record describes for
the series of wrought Al alloys that rely on age-hardening requiring a solution heat treatment
followed by quenching and ageing. This is recorded by adding TX to the series number, where
X is a number between 0 and 8 that records the state of heat treatment. They are listedbelow
using the IADS designations (see Technical notes for details).2000 series: Al with 2 to 6% Cu -
- the oldest and most widely used aerospace series.6000 series: Al with up to 1.2% Mg and
1.3% Si -- medium strength extrusions and forgings.7000 series: Al with up to 8% Zn and 3%
Mg -- the Hercules of aluminum alloys, used for high strength aircraft structures, forgings and

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sheet. Certain special alloys also contain silver. So this record, like that for the non-age
hardening alloys, is broad, encompassing all of these.
2000 series: Al + 2 to 6% Cu + Fe, Mn, Zn and sometimes Zr
6000 series: Al + up to 1.2%Mg + 0.25% Zn + Si, Fe and Mn
7000 series: Al + 4 to 9 % Zn + 1 to 3% Mg + Si, Fe, Cu and occasionally Zr and Ag
Caption
The 2000 and 7000 series age-hardening aluminum alloys are the backbone of the aerospace
industry. The 6000 series has lower strength but is more easily extruded: it is used for marine
and ground transport systems.
General properties
Price *1.88 - 2.06 EUR/kg
Yield strength (elastic limit) 95 - 610 MPa
Tensile strength 180 - 620 MPa
Compressive strength 95 - 610 MPa
Fatigue strength at 10^7 cycles 57 - 210 MPa
Mechanical loss coefficient (tan delta) 1e-4 - 0.001

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Thermal properties
Melting point 495 - 640 °C
Minimum service temperature -273 °C
Thermal conductor or insulator? Good conductor
Specific heat capacity 890 - 1.02e3 J/kg.°C
Electrical resistivity 3.8 - 6 µohm.cm
Optical properties
Transparency Opaque
Processability
Castability 4 - 5
Formability 3 - 4
Machinability 4 - 5
Weldability 3 - 4
Solder/brazability 2 - 3
Eco properties
Embodied energy, primary production *198 - 219 MJ/kg
CO2 footprint, primary production *12.2 - 13.4 kg/kg
Recycle True
(CES Package, 2014)

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7. Systematic Design
With the combination of all the research, eventually different design ideas came up various
different ways of removing the plasticmould from the cake bases. Several sketches were then
produced for various removal methods and it eventually evolved into the final design. This
final design was then to be drawn on CAD.
The first idea of many was a simple turntable style stand which would keep rotating while a
heat gun simultaneously softens the area between the cake and the plasticmould. The sketch
to represent the idea is shown in Figure 7.1.

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Figure 7.1 Initial DesignIdeas
Another idea was to have two mechanical chucks or jaws attach to the edges of the plastic
mould, whether it is two at either sideor 4 evenly placed at quarters around the mould. These
would hold the mould in place while a circular disk is pushed down from a pneumatic or
hydraulic cylinder on the cake and the chucks retract and the cake comes out in one action
this idea is shown above in Figure 7.2.
Figure 7.2 Other Early Design Idea
Apart from the other two possible ideas, there was a discussion on cutting the plastic so it
could be removed easier. The idea was that the mould would separate easier than manually
peeling the cakes, resulting in a simple machine with a only a small amount of force required
to remove the plastic mould. The sketch of the simple solution is shown below in Figure 7.3.
Figure 7.3 Design to Easily Remove Plastic
Eventually with extensive brainstorming and the information gathered from the factory’s
existing uses of automated machines, the following prototype was declared a valid solution

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to the problem at hand. The image below Figure 7.4 shows the final design which would
require a couple of adjustments to it before handing it over to the company.
Figure 7.4 Final Solution
Analysis
Since being in contact with silver pail it was discovered that there were various ways to
separate the plastic mould from the cake itself. The factory were also doing their own
experiments throughout my design process to try find an effective method of removing the
plastic with ease. They provided me with vital information with regards to my final design.
Heating was one option. After heat was applied to the mould of the cake it seemed to slip off
easier. The disadvantage of this method was the ice cream was partially melted when the
mould came off. The cakes cannot be dressed in this state and re freezing is not an option for
quality reasons. The cake would therefore have to be disposed off.

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Figure 7.5 Industrial Heat Gun (Steinel Professional, 2013)
Cutting was also a method tested in the labs over previous months. An incision is made into
the freezing mould and when tried to separate the plasticcame off in smallpieces.It was very
unpredictable how each cake would react, there was no constant to this method.
Figure 7.6 Knife used for Cutting Plastic off Cake (Shutterstock.com, 2014)
Freezing was the best method to work with, it was found. The head of research in the lab of
Silver Pail tried dipping the frozen cake mould into liquid nitrogen. The results they found
were very interesting. The extreme cold of the liquid nitrogen seemed to break the bond
between the plastic mould and the frozen ice cream cake. When they tried to separate the
mould it seemed to “jump off the cake” and in fact the mould came off as a whole rather
those small pieces as before.

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Figure 7.7 Liquid Nitrogen (Behealthy24.com, 2014)
After completing the final design it was time to analyse the different components that would
be part of the finished product.
With liquid nitrogen being applied to the cakes before the mould removal process, certain
tests needed to be carried out.
After extensive research in various material properties physically, with the help of the CES
package and keeping cost efficiency in mind the decision was made to produce the rig from
stainless steel.

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Figure 7.8 Stainless Steel (Buildipedia Staff, 2010)
The shape of the rig was a simple design to proceed with, although it can be assumed that the
forces would not be very significant. It was decided to make a simple four legged table shape,
with another frame to house two pneumatic cylinders to separate the plastic mould.
Figure 7.9 Initial Shape of Rig (Chinatraderonline.com, 2014)
Tests Carried Out On Design
It was necessaryto find out the amount of force which would be needed to remove the mould
off the base. This was carried out by anchoring the cake base to a table. A string was attached

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evenly around three points of the mould and a force was applied. A Newton meter was used
to measure the force needed to remove the plastic mould off the base. This test was carried
out several times to make sure the required force is constant for each cake. The resultant
force turned out to be 18-19 Newton’s of force. It can be seen in Figure 7.8 below that there
is a lip on the bottom of the mould so the yellow base is clipped onto the mould itself. This is
why it took so much force to overcome these clips.
Figure 7.10 Finding the Amount of Force Required
On researching the Festo Pneumatic products going to be incorporated into the rig, I found
various products which do the same action. Certain decisions had to me made when choosing
each product:
The suction grippers chosen apply a grip of 6 Newton’s to the surface they are attached to.
The decision was made for there to be 4 suction grippers mounted to a cylinder to attach to
the mould since the combined force would then be 24 Newton’s. A factor of safety of 33%
was applied, just in casethe liquid nitrogen did not break the bond from all areas of the mould
and the ice cream cake.
Vacuum technology is already used in Silver Pail. Maintenance knows how to deal with
different areas of the pneumatic design,and vacuum generators needed to produce adequate
suction.

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Figure 7.11 Suction Grippers (Festo.com, 2014)
Choice of Pneumatic Components

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In regards to the type of pneumatic components that is to be incorporated into the design,
they required the same specifications as the pneumatic rig. They had to obey all the relevant
safety standards in the work place and food industry, be hygienic to use, easily cleaned and
be able to withstand the temperatures in the cake room.
Pneumatic Cylinders
After researching the pneumatic cylinders from Festo, the choice of pneumatic drive chosen
was a Stainless Steel Cylinder with Piston Rod. This cylinder had a number of advantages over
the rest of the competitors:
 Cylinder made of corrosion-resistant stainless steel, and therefore especially easy to
clean
 The minimum piston diameter was well capable to reach the forces required, with the
factory’s air pressure in the cake room
 The cylinder has adequate stroke length to reach the cake surfaces
 Pneumatic cushioning at both ends, therefore no shock to the cakes
 Double acting cylinder as intended from day one
 Position sensing for proximity sensing
 Heat resistant seals for temperatures up to 120 degrees
Figure 7.12 Stainless Steel Pneumatic Cylinder (Festo.com, 2014)

37
Semi – Rotary Drive
The semi rotary drive for this project was to swivel 180°. Optimally it should have some sort
of way to attach the 40x40mm box section arm so the plastic mould could be dropped into a
bin away from the separation process. Silver Pail had used this type of product before for
various other processes in the factory. Festo had the ideal component for this process a Semi
– Rotary Drive DSR. The fact that this product was chosen was because:
 You had the option how have the rotary arm flanged at the end so the swivel arm
could easily be attached to the drive
 It was 32mm in size so it was the ideal size for the arm to attach to the product
 The swivel angle was in fact 180°, precisely what was needed for operating the
rotating arm
 Each end like pneumatic cylinder is cushioned, there would be no harsh forces
potentially losing the plastic mould
 Torque produced by the cylinder while operating at 6 bar is 20 Newton’s.
 Can be mounted at any angle on the rig and still operate
Figure 7.13 Semi Rotary Drive (Festo.com, 2014)

38
Vacuum Technology
Suction Gripper/Bernoulli Gripper
When deciding on what type of suction grippers to be used in this design, previous
experiments dictated what products we would use. Have completed experiments to figure
out how much force was required to remove the plastic base, (which resulted in around 19
Newton’s) it was then obvious we would need four suction pads to lift of the mould. Since
each gripper could produce 6 Newton’s of suction force to the surface they were applied on.
The grippers chosen for the upper swivel arm from Festo has many positive parts to the
component:
 Suction cup size diameter 40 mm
 Various connections available
o Male thread
o Female thread
o Push-in connector
o Barbed connector
 Round suction cup, extra deep if required
 Height compensator
 Suction can be made from various materials in this case silicon
 Each gripper creates 6 Newton’s of suction the receiving surface
Figure 7.14 Gripper (Festo.com, 2014)

39
In relation to keeping the cake anchored to the rig, there is a need for another suction pad to
rise up from underneath the cake. There wasn’t much force required to keep the base down
on the stainless steel sheet as the weight of the cake alone would nearly be sufficient. Instead
of building another customised ‘H’ frame to acquire 4 more suction pads, it was more in my
frame of mind to have one suction gripper. This would have a relatively large surface area to
anchor itself to the bottom of the cake base.
Searching the suction grippers on the Festo website, the best product was found to be a
Bernoulli gripper. The Bernoulli gripper on paper is more than efficient for the base of the
cake because:
 Suction cup size has a large area 140 mm diameter
 Holding force 10 N, the cake will not budge during the removal process
 Supply pressure 6 bar, which is what the mains are at in the cake room
Figure 7.15 Bernoulli Gripper (Festo.com, 2014)
Each suction cup and the Bernoulli gripper will have a blower incorporated into the product.
Since there will be suction forces applied to the surfaces of the mould and the base of the
cake, the pads will still be attached even if the air has turned off. The blower in this case will
release the plastic mould from the four suction pads, and the Bernoulli gripper will release
the base of the cake.

40
All the essential products such as tubing to plum up the pneumatic parts, proximity sensors
and vacuum generators etc. will all be taken into consideration but I did not find the need to
get quotes for these. Silver Pail has all these components already and knows the price to
purchase them new. This design project is to show the company the new components
combined together into a rig that they have not seen before.
Figure 7.16 Pneumatic Parts (Festo.com, 2014)

41
8. 3D Inventor Parts
Here are the pneumatic parts that were drawn up on Autodesks Inventor Package. The
decision was made to produce the components as realistic to the real product, thus a certain
amount of detail went into the drawing up of each the parts.The image below in Figure 8.1
shows the finished 3D design of the pneumatic cylinders that will be used in the automated
rig.
Figure 8.1 Pneumatic Cylinders
Figure 8.2 shows the rear of the cylinder which replicates the actual product the company
would be purchasing from Festo. Figure 8.3 shows a close up of the pneumatic piston in its
home position, with a threaded end for easy screw in attachments.
Figure 8.2 Rearof the Cylinder Figure 8.3 Pneumatic Piston

42
Here in Figure 8.4 you can see the Autodesk drawing of the Semi Rotary Drive. The drive has
a flanged front so the rotating arm can be bolted to the rotating disk. This flange was a special
order request from the Festo website.
Figure 8.4 Semi Rotary Drive
The rear of the Rotary Drive designed on the Inventor package is shown in the print screen
below in Figure 8.5 where the angle of adjustment can be made.
Figure 8.5 Rear of the Rotary Drive

43
Various angles of rotation can be determined on adjustable arms on the top of the drive,
shown in Figure 8.6 but for this application the angle of rotation will be the full 180 degrees.
Figure 8.6 Adjustable Arms on the Top of the Drive
The plan, and End View of the Rotary Cylinder can be seen in the design stage in Figure 8.7
and Figure 8.8.
Figure 8.7 Plan View of Rotary Cylinder Figure 8.8 Side View of Rotary Cylinder

44
The suction grippers that are intended to be used in this automated rig are 40mm in size
and produce a lateral force of 6 Newton’s each at a mains pressure of 6 bar. The grippers
were height adjustable due to the thread and two bolts above the suction pad as shown in
Figure 8.9.
Figure 8.9 Height Adjustable Grippers
The specified material the suction pad was going to be made out of was silicon.
Figure 8.10 Bernoulli Gripper

45
The Bernoulli gripper was quite easily designed on inventor, the griper consists of a large
diameter disk with suction grippers on it. It has a pneumatic fitting soa vacuum can be applied
to it, and a threaded head to it can be easily attached to the pneumatic cylinders that will be
used. This is shown in the inventor drawing Figure 8.11.
Figure 8.11 Pneumatic Cylinder
The suction grippers are evenly spaced around the Bernoulli gripper to achieve maximum
suction while attaching to the base of the cake bases; they can be seen here in blue from the
inventor part in Figure 8.12.
Figure 8.12 Evenly Spaced Bernoulli Grippers

46
9. Assembly
The intended methods to assemble the rig have been researched ideally welding up the main
frame of the rig, followed by bolting on the pneumatic parts so they are easily assessable and
can be changed with replaceable parts if needs be.
Figure 9.1 Welding of Frame Figure 9.2 Bolting on of Pneumatic Parts
As shown in the above images the pneumatic parts are bolted onto the rig. This way there is
no movement between components and the rig, ensuring secure components throughout
long production hours. Below shown are the traces of two of the parts, once they are
separated from assembly.
Figure 9.3 Exploded View of Rig

47
Here is an exploded view of how the finished rig would look, and the separation of each of
the components of the prototype.
Figure 9.4 Exploded View of Finished Rig
After drawing up the 3D design of the rig on inventor I put various stresses on it. The stainless
steel box section was more than capable to withstand the forces that would be applied on
the rig during operation.

48
A von mises stress test was applied to the assembly of the rig. It was then proven that the rig
and components are able to withstand the maximum forces that will be applied throughout
the day.
Figure 9.5 A Von Mises Stress Test
There were also many other types of tests that could have been carried out, 1st and 3rd
principal stress tests as well as displacement and safety factor tests. The one that applied to
the project the most was the von mises stress test.

49
Below you can see an exaggerated displacement of what would occur if the forces applied
would overcome the structural integrity of the main frame and components.
From the blue colour seen on the simulation, there is little or no stress on the piece of the
equipment when the 20 Newton force is applied to the rig.
Figure 9.6Von Mises Stress Test

50
10. Quotes to build Automated Rig
An email to Festo with a list of equipment was required to set up the pneumatic side of the
design project. Here is a copy of the quote they emailed back

51
Figure10.1 Quote From Festo

52
Flyco Engineering Ltd priced various materials, the 5 metres of 40x40mm box section made
from stainless steel and also 520x520mm sheet metal, 3mm thick made of stainless steel. A
qualified fabricator in the samecompany priced how much it would cost to build the rig labour
only; this included welding the rig together and plum up all the pneumatic parts to have it in
full working order.
Figure 10.2 FlycoEngineering Quotes

53
11. Safety
As for the safety in my design, the original idea was to put a cage around the rig which would
not be a difficult task.
From previously working in the factory, and from the official tour I was given when I arrived
to design a project for them, I found all other automated machinery in the factory has only
qualified operators using them.
For my rig only trained personnel will be allowed to operate the machine. It will be situated
beside all other pneumatic equipment in the cake room so no manual workers will need to
come in contact with the rig.
Safety signs and precautions will be taken into account when the rig is being built. There will
be no sharp edges and only slow moving parts will be used to reduce the risk of harm. The rig
will also have all necessary optical sensors and will only operate if a cake is present ready to
be de-moulded.
As previously stated there were several safety tests carried out on inventor. These tests
showed that the rig was structurally sound, capable of withstanding the forces being applied,
clean due to the fact it’s powered by air pressure and hygienic enough to be used in the food
industry.
Liquid Nitrogen can cause serious burns if it comes in contact with bare skin. Silver Pail have
assured me that they would be providing all the safety equipment, ventilation, and adequate
means of transport from when the cake’s are dipped into liquid nitrogen to being placed on
the dressing line.

54
Risk Assessment
The risk assessment will consist of various applications to malfunction throughout the
operation of the automated cake mould dispenser.
The correct procedure to use the automated cake mould dispenser safely before dressing the
cake products, and using it correctly can be seen below. There should be clear instructions on
the use of the automated cake dispenser nearby and on file. Only trained operators should
operate the rig. All necessary training should be carried out before using the rig. If there are
ever any uncertainties, do not operate the rig and ask the opinion of a second operator or
someone who has been trained to operate the rig correctly.
1. Select the Tooling
Depending on the size of the cake, and the force needed to be applied to separate the mould
from the cake various diameter heads will need to be applied to the pneumatic cylinders. On
this occasion Silver Pail only requested a prototype rig to remove the moulds from their
standard 9 inch round cakes.Therefore the riskassessmentwillonly apply to these conditions.
2. Determining Force Required
From previous experiments and referring back to the Festo data sheets for references, the
force required four suction grippes producing a maximum of 6 Newton’s of lateral force, to
remove the plastic mould off the cake.
As for keeping the base of the cake steady with no movement while the mould is being
removed, a Bernoulli gripper with diameter of 140mm is used and is attached to the bottom
cylinder. This will remain constant for any other diameter cake, as it produces 10 Newton’s of
force alone and the weight of the cake as well as the force of gravity will keep the base from
moving.
3. Install the Tooling

55
Once you have determined the tooling position on the bed, you should install the tooling and
align the upper and lower tooling for making the bend.
Using a hydraulic clamp for the tooling makes this procedure easier and faster; using snap
tooling is even more efficient. Both of these features are available as retrofit systems for all
press brakes.
4. Program the Operation on GX Developer
The programme on the rig should always be rechecked. Despite the fact that it may be a
simple programme it must be rechecked by another operator to assure that the rig will
perform its required task and that there will be no unexpected movements form the rig.
5. Have a test Cake
Carry out a test on a cake that will not be missed from the order the company has already
received. This cakewill be referred to a blank It must be noted however that every blank costs
money, after all.
6. Run Products
After proper setup, the rig will be ready to run good products. However, don't assume that
every product will be perfect.

56
RA#
Action
WhatIf
Hazard
LO
FE
DPH
NPR
HRN
Risk
Control
HRNWithctrl
RiskWithctrl
1 Setting
the cake
inthe
centre of
the
removal
area
The cake is
not setup
properly
Flying
debris
1
5
0.5
1
2.5
VeryLow
Double checkall
fittingstomake
sure theyare
secure,and
cake isself
centred
<2.5
VeryLow
2 Operator
Presses
Start
Button
The cylinder
comesdown
and crushes
the
operators
hand
Pinch
2
5
1
1
10
Significant
Have all limbs
clearbetween
the cylinderand
the cake
<5
VeryLow
3a As the
mouldis
removed
The machine
isunguarded
and a bitof
plasticgoes
astray
Eye
damage
Impact
0.5
5
0.5
1
1.25
VeryLow
Mandatory
operatorwears
safetyglasses
<1.5
VeryLow
3b As the
mouldis
removed
The PLC
Programme
suffersa
malfunction
Pinch,
Impact,
Flying
debris
0.5
1
8
1
4
VeryLow
Make sure trial
run iscarried
out eachday
before process
<4
VeryLow4 A leak
occurs
and
Operator
checks
leakwith
hand
High-
pressure air
easily
punctures
skincausing
injury
Impact,
2
2.5
0.5
1
2.5
VeryLow
Have safety
inspectionsto
all pressurised
hoses,Wear
SafetyGloves
<2.5
VeryLow
5 Safely
goggles
are worn
but they
are
scratched
- visual
impairme
nt while
working
Hand or
clothingmay
be caught in
the machine
Pinch,
entangl
ement
1
2.5
1
1
2.5
VeryLow
Have new
disposable
safetygoggles
readilyavailable
inthe cake
room
<2.5
VeryLow

57
Risk Calculation Formula
(LO * FE * DPH *NPR) = HRN (Hazard Rating Number)
HIERARCHY OF CONTROLS (Risk Reduction Measures)
Elimination
Substitution
Enclosure
Segregation
Guards
Information
Training
Supervision
Communication
6 The floor
around
the rig
may have
plastic
debris
Someone
may slipor
fall,injuring
themselves
or getting
caught inthe
machine
Impact,
Pinch
1
2.5
1
3
7.5
Low
Keepwork
space tidyat all
times,empty
waste binwhen
required
<0.5
Negligible
HRN 0-1 1-5 1-
10
10-50 50-
100
100-
500
500-
1000
>1000
RISK Negligible Very
Low
Low Significant High Very
High
Extreme Unacceptable

58
Personal Protective Equipment (PPE)
More Risk Reductions
 Avoid coming in contact with leaks - High-pressure air easily punctures skin causing
injury. If injured, seek emergency medical help. Do not use finger or hand to check for
leaks.
 Keep hands and limbs away from moving parts
 Never place any part of your body under the piston or within the cake area.
 Never Operate, change heads, or maintain this machine without proper instruction
and without first reading and understanding the operators or owners machine
maintenance manual.
 Never change heads or service this machine with the motor “on” and control in “on”
position.
 This rig should only be operated by trained operators.
Conclusion
The risks associated with using this automated rig for manufacturing ice cream cakes can be
reduced if all safety procedures are complied with, and common sense is applied when using
such high power machinery. Frequent checks should be made to the rig after a specified
amount of time or after long hours of production. Although you cannot make this process a
risk free one, using protective gloves, eyewear etc. willstand to an operator on the off chance
if something does malfunction. Constant training and updated training should be carried out
on a regular basis to ensure operators are fully aware of how the equipment works. Safety
checks and updates should also be carried out regularly to ensure the rig is continuously safe
to use and nothing has changed.

59
12. Operating Procedure
After completing the design of the rig it was necessary to design a programme for the rig for
it to be capable of completing its desired task. The components of the rig that would be
carrying out a task were divided into an inputs and outputs allocation list with corresponding
symbols.
 Cylinder A – Bottom Cylinder with Bernoulli Gripper
 Cylinder B – Top Cylinder with Four Suction Pads
 Cylinder C – Rotary Drive with Rotating Arm Attached
Initial conditions –
o The cake will have been submerged into liquid nitrogen
o Cylinder A will be home (down) with the Bernoulli gripper attached
o Cylinder B will be in its home position (up) with the suction pads attached
o Cylinder C will be home (away from the removal area as if it completed a task already)
The sequence will be as follows:
 The cake will be placed on the rig and pushed against the centres marks
 Upon pressing the start button Cylinder B will rise up, attach itself to the base of the
cake and anchor it to the rig with the suction of the Bernoulli gripper
 Cylinder C will then swivel around 180 degrees above the cake mould
 Cylinder B will move down, when a vacuum is generated, the suction grippers will
attach to the mould of the cake
 Cylinder B will then retract to its home position bringing the plastic mould with it
 Cylinder C will rotate back to its original position away from the cake

60
 Blowers will then turn on the Bernoulli gripper and the four suction grippers releasing
the grip on the cake and releasing the mould into a bin or waste area behind the rig
 Cylinder A will then move down to its home position again ready for the process to
start again
Here highlighted you can see the arm attached to the semi rotary drive, which will swivel 180
degrees dropping off the waste plastic mould and come around again to remove another
mould off the cake.
Figure 12.1 Plastic Casing Being Removed
This process was then programmed on a pneumatic software package suitable for a
Mitsubishi System. The software was called GX Developer and programmed using a

61
combination of a Ladder Diagram and Sequential Function Chart; the programme can be seen
on the next page.
The allocation list and pneumatic sensor list can be seen on the following page.

64
Exhibition
On the 10th of April the annual Engineering Exhibition was held in Cork Institute of Technology.
The public come into the exhibition to see a large variety of different innovative ideas, and
companies came to find new graduates for their facilities and to observe the projects that

65
were undertaken. It was a chance to show off months of hard work and to present the design
clearly to lecturers and fellow students.
When I was asked to explain my design to members of the public it was good preparation for
the presentation because I had to assume they had no knowledge whatsoever of the project,
what it was intended for and the solution I came up with.
A positive and enthusiastic attitude was very important in keeping people’s attention and
intriguing them further. I designed a poster to make my stand pleasant to the eye and to draw
people in and find out exactly what project I had undertaken.
The picture below shows my stand on the day of the exhibition. I had all the relevant
information laid out on the stand. The software I used to programme the rig was displayed
on my laptop as well as the plastic mould for the cake bases. The mould gave a visual to the
problem at hand and helped explain the situation Silver Pail was in. I was there for any
questions people had about my project throughout the day.
Figure 12.2 Engineering Exhibition Stand

66
13. Discussion and Conclusion
The aim of the project was to come up with a solution to the major problem that was had in
Silver Pail. The problem was that too many cakes were being wasted or rejected due to an
excessive amount of bacteria present on the cakes. As part of the scope of my project, it was
required to find the source of the problem. The problem was sourced to the removal of the
plastic mould on the production line. At this stage in the production line there was a large
amount of manual handling involved with the cakes which was not the optimum situation. It
was then necessary to come up with an automated way of removing this plastic mould from
the cakes. The design that was decided on was an automated rig that would separate the
plastic mould off the ice cream itself using suction grippers. The condition for this solution to
be successfulwas the icecream cakes were to be dipped in liquid nitrogen which in turn broke
the bond between the plastic mould and the ice cream.
The rig was designed using AutoDesk Inventor. This software allowed me to designthe rig and
design how it would move and operate. The rig was designed to be able to remove the plastic
mould from the cake at a force of 24 Newton’s, and immediately discard the mould in awaste
bin provided behind the automated rig.
All the necessary pneumatic parts had to be chosen carefully into the design of the rig.
Choosing these parts were an important part of the project as they parts are vital to the
operation of the rig. Quotes were obtained for these parts so that the costing of the rig could
be estimated.
I feel that my project was a huge success, I have been to the factory in Silver Pail since
completing my project and they are extremely happy with my solution. They have yet to
decide if they will be taking the design any further and thanked me for my time and efforts I
put into this project.

67
Appendix A
(Materials Specification)

68
Stainless steel
Description
The material
Stainless steels are alloys of iron with chromium, nickel, and - often - four of five other elements. The
alloying transmutes plain carbon steel that rusts and is prone to brittleness below room temperature
into a material that does neither. Indeed, most stainless steels resist corrosion in most normal
environments, and they remain ductile to the lowest of temperatures.
Fe/<0.25C/16 - 30Cr/3.5 - 37Ni/<10Mn + Si,P,S (+N for 200 series)
Image
_
Caption
One the left: Siemens toaster in brushed austenitic stainless steel (by Porsche Design). On the right,
scissors in ferritic stainless steel; it is magnetic, austenitic stainless is not.
General properties
Price * 4.59 - 5.06 EUR/kg
Yield strength (elastic limit) 170 - 1e3 MPa
Tensile strength 480 - 2.24e3 MPa
Compressive strength 170 - 1e3 MPa
Fatigue strength at 10^7 cycles * 175 - 753 MPa
Mechanical loss coefficient (tan delta) * 2.9e-4 - 0.00148
Thermal properties
Melting point 1.37e3 - 1.45e3 °C
Minimum service temperature -272 - -271 °C
Thermal conductor or insulator? Poor conductor

69
Specific heat capacity 450 - 530 J/kg.°C
Electrical resistivity 64 - 107 µohm.cm
Optical properties
Transparency Opaque
Processability
Castability 3 - 4
Formability 2 - 3
Machinability 2 - 3
Weldability 5
Solder/brazability 5
Eco properties
Embodied energy, primary production * 80.3 - 88.8 MJ/kg
CO2 footprint, primary production * 4.73 - 5.23 kg/kg
Recycle True
Supporting information
Design guidelines
Stainless steel must be used efficiently to justify its higher costs, exploiting its high strength and
corrosion resistance. Economic design uses thin, rolled gauge, simple sections, concealed welds to
eliminate refinishing, and grades that are suitable to manufacturing (such as free machining grades
when machining is necessary). Surface finish can be controlled by rolling, polishing or blasting.
Stainless steels are selected, first, for their corrosion resistance, second, for their strength and third, for
their ease of fabrication. Most stainless steels are difficult to bend, draw and cut, requiring slow cutting
speeds and special tool geometry. They are available in sheet, strip, plate, bar, wire, tubing and pipe,
and can be readily soldered and braised. Welding stainless steel is possible but the filler metal must be
selected to ensure an equivalent composition to maintain corrosion resistance. The 300 series are the
most weldable; the 400 series are less weldable.
Technical notes
Stainless steels are classified into four categories: the 200and 300 series austenitic (Fe-Cr-Ni-Mn)
alloys, the 400 series ferritic (Fe-Cr) alloys, the martensitic (Fe-Cr-C) alloys that also form part of the
400 series, and precipitation hardening or PH (Fe-Cr-Ni-Cu-Nb) alloys with designations starting with
S. Typical of the austenitic grades of stainless steel is the grade 304: 74% iron, 18% chromium and 8
% nickel. Here the chromium protects by creating a protective Cr2O3 film on all exposed surfaces, and
the nickel stabilizes face-centered cubic austenite, giving ductility and strength both at high and low
temperatures; they are non-magnetic (a way of identifying them). The combination of austenitic and
ferritic structures (the duplex stainless steels) provide considerably slower growth of stress-induced
cracks, they can be hot-rolled or cast and are often heat treated as well. Austenitic stainless steel with
high molybdenum content and copper has excellent resistance to pitting and corrosion. High nitrogen
content austenitic stainless steel gives higher strength. Superferrites (over 30% chromium) are very
resistant to corrosion, even in water containing chlorine. More information on designations and
equivalent grades can be found in the Users section of the Granta Design website,
www.grantadesign.com
Phase diagram

70
_
Most stainless steels are alloys of iron (Fe) with chromium (Cr) and nickel (Ni). This is the ternary phase
diagram, at a temperature of 800 C, for those three elements. The position of AISI 302 stainless steel
(Fe-18%Cr-8%Ni) is shown.
Typical uses
Railway cars, trucks, trailers, food-processing equipment, sinks, stoves, cooking utensils, cutlery,
flatware, scissors and knives, architectural metalwork, laundry equipment, chemical-processing
equipment, jet-engine parts, surgical tools, furnace and boiler components, oil-burner parts, petroleum-
processing equipment, dairy equipment, heat-treating equipment, automotive trim. Structural uses in
corrosive environments, e.g. nuclear plants, ships, offshore oil installations, underwater cables and
pipes.
Links
Reference
ProcessUniverse
Producers
Values marked * are estimates.
No warranty is given for the accuracy of this data

71
Age-hardening wrought Al-alloys
Description
The material
The high-strength aluminum alloys rely on age-hardening: a sequence of heat treatment steps that
causes the precipitation of a nano-scale dispersion of intermetallics that impede dislocation motion and
impart strength. This can be as high as 700 MPa giving them a strength-to-weight ratio exceeding even
that of the strongest steels. This record describes for the series of wrought Al alloys that rely on age -
hardening requiring a solution heat treatment followed by quenching and ageing. This is recorded by
adding TX to the series number, where X is a number between 0 and 8 that records the state of heat
treatment. They are listed below using the IADS designations (see Technical notes for details).2000
series: Al with 2 to 6% Cu -- the oldest and most widely used aerospace series.6000 series: Al with up
to 1.2% Mg and 1.3% Si -- medium strength extrusions and forgings.7000 series: Al with up to 8% Zn
and 3% Mg -- the Hercules of aluminum alloys, used for high strength aircraft structures, forgings and
sheet. Certain special alloys also contain silver. So this record, like that for the non-age hardening
alloys, is broad, encompassing all of these.
2000 series: Al + 2 to 6% Cu + Fe, Mn, Zn and sometimes Zr
6000 series: Al + up to 1.2%Mg + 0.25% Zn + Si, Fe and Mn
7000 series: Al + 4 to 9 % Zn + 1 to 3% Mg + Si, Fe, Cu and occasionally Zr and Ag
Image
_
Caption
The 2000 and 7000 series age-hardening aluminum alloys are the backbone of the aerospace industry.
The 6000 series has lower strength but is more easily extruded: it is used for marine and ground
transport systems.
General properties
Price * 1.88 - 2.06 EUR/kg
Yield strength (elastic limit) 95 - 610 MPa
Tensile strength 180 - 620 MPa
Compressive strength 95 - 610 MPa
Fatigue strength at 10^7 cycles 57 - 210 MPa
Mechanical loss coefficient (tan delta) 1e-4 - 0.001

72
Thermal properties
Melting point 495 - 640 °C
Minimum service temperature -273 °C
Thermal conductor or insulator? Good conductor
Specific heat capacity 890 - 1.02e3 J/kg.°C
Electrical resistivity 3.8 - 6 µohm.cm
Optical properties
Transparency Opaque
Processability
Castability 4 - 5
Formability 3 - 4
Machinability 4 - 5
Weldability 3 - 4
Solder/brazability 2 - 3
Eco properties
Embodied energy, primary production * 198 - 219 MJ/kg
CO2 footprint, primary production * 12.2 - 13.4 kg/kg
Recycle True
Supporting information
Design guidelines
The age-hardening alloys have exceptional strength at low weight, but the origin of the strength -- age
hardening -- imposes certain design constraints. At its simplest, age-hardening involves a three step
heat treatment.
Step 1: the wrought alloy, as sheet, extrusion or forging, is solution heat treated -- held for about 2 hours
at around 550 C (it depends on the alloys) to make the alloying elements (Cu, Zn, Mg, Si etc) dissolve.
Step 2: the material is quenched from the solution-treatment temperature, typically by dunking or
spraying it with cold water. This traps the alloying elements in solution. Quenching is a savage treatment
that can cause distortion and create internal stresses that may require correction, usually by rolling.
Step 3: the material is aged, meaning that it is heated to between 120 and 190 C for about 8 hours
during which the alloying elements condense into nano-scale dispersions of intermetallics (CuAl, CuAl2,
Mg2Si and the like). It is this dispersion that gives the strength.
The result is a material that, for its weight, has remarkably high strength and corrosion resistance. But
if it is heated above the solution treatment temperature -- by welding, for example -- the strength is lost.
This means that assembly requires fasteners such as rivets, usual in airframe construction, or
adhesives. Some 6000 series alloys can be welded, but they are of medium rather than high strength.
Technical notes
Until 1970, designations of wrought aluminum alloys were a mess; in many countries, they were simply
numbered in the order of their development. The International Alloy Designation System (IADS), now
widely accepted, gives each wrought alloy a 4-digit number. The first digit indicates the major alloying
element or elements. Thus the series 1xxx describe unalloyed aluminum; the 2xxx series contain copper
as the major alloying element, and so forth. The third and fourth digits are significant in the 1xxx series
but not in the others; in 1xxx series they describe the minimum purity of the aluminum; thus 1145 has
a minimum purity of 99.45%; 1200 has a minimum purity of 99.00%. In all other series, the third and
fourth digits are simply serial numbers; thus 5082 and 5083 are two distinct aluminum-magnesium
alloys. The second digit has a curious function: it indicates a close relationship: thus 5352 is closely
related to 5052 and 5252; and 7075 and 7475 differ only slightly in composition. To these serial numbers
are added a suffix indicating the state of hardening or heat treatment. The suffix F means 'as fabricated'.
Suffix O means 'annealed wrought products'. The suffix H means that the material is 'cold worked'. The
suffix T means that it has been 'heat treated'. More information on designations and equivalent grades
can be found in the Users section of the Granta Design website, www.grantadesign.com

73
Phase diagram
_
The 2000 series of wrought aluminum alloys are based on aluminum (Al) with 2.5 - 6% copper (Cu).
This is the relevant part of the phase diagram.
Typical uses
2000 and 7000 series: aerospace structures, pressure vessels, ultralight land-based transport systems;
sports equipment such as golf clubs and bicycles.
6000 series: cladding and roofing; medium strength extrusions, forgings and welded structures for
general engineering and automotive such as connecting rods.
Links
Reference
ProcessUniverse
Producers
Values marked * are estimates.
No warranty is given for the accuracy of this data

74
Appendix B
(Industrial Products)

77
Appendix C
(FESTO Products Data Sheets)

83
Appendix D
(Joining Methods and Specifications)

86
Bolt Grade Markings and Strength Chart
HeadMarking
Grade and
Material
Nominal
Size Range
(inches)
Mechanical Properties
Proof
Load
(psi)
Min. Yield
Strength
(psi)
Min. Tensile
Strength
(psi)
US Bolts
No Markings
Grade 2
Low or mediumcarbon
steel
1/4 thru 3/4 55,000 57,000 74,000
Over 3/4 thru
1-1/2
33,000 36,000 60,000
3 Radial Lines
Grade 5
MediumCarbon Steel,
Quenched and
Tempered
1/4 thru 1 85,000 92,000 120,000
Over 1 thru 1-
1/2
74,000 81,000 105,000
6 Radial Lines
Grade 8
MediumCarbon Alloy
Steel, Quenched and
Tempered
1/4 thru 1-1/2 120,000 130,000 150,000
Stainlessmarkingsvary.
Moststainlessisnon-
magnetic
18-8 Stainless
Steel alloy with17-19%
Chromiumand 8-13%
Nickel
1/4 thru 5/8
40,000 Min.
80,000 –90,000
Typical
100,000 –
125,000
Typical
3/4 thru 1
40,000 Min.
45,000 –70,000
Typical
100,000
Typical
Above 1
80,000 –
90,000
Typical

87
HeadMarking
Classand
Material
Nominal
Size Range
(mm)
Mechanical Properties
Proof
Load
(MPa)
Min. Yield
Strength
(MPa)
Min. Tensile
Strength
(MPa)
Metric bolts
8.8
Class 8.8
MediumCarbon Steel,
Quenched and
Tempered
All Sizes below
16mm
580 640 800
16mm- 72mm 600 660 830
10.9
Class 10.9
Alloy Steel,Quenched
and Tempered
5mm - 100mm 830 940 1040
12.9
Class 12.9
Alloy Steel,Quenched
and Tempered
1.6mm-
100mm
970 1100 1220
Stainlessmarkingsvary.
Moststainlessis non-
magnetic.
Usuallystamped A-2
A-2 Stainless
Steel alloy with17- 19%
Chromiumand 8-13%
Nickel
All Sizes thru
20mm
210 Min.
450 Typical
500 Min.
700 Typical
Tensile Strength: The maximum load in tension (pulling apart) which a material can withstand before breaking or fracturing.
Yield Strength: The load at which a material exhibits a specific permanent deformation.
Proof Load: An axial tensile load which the product mustwithstand without evidence ofany permanent set.
1MPa = 1N/mm2 = 145 pounds/inch2

88
Appendix E
(Quotations)

93
Appendix F
(Safety)

104
Appendix G
(GX Developer Programme)

105
GX Developer PLC Programming Software
GX Developer supports allMELSEC controllers from the compact PLCs of the MELSEC FX series
to the modular PLCs including MELSEC System Q. This software shines with a simple, intuitive
interface and a short learning curve.
Features
Standard programming software for all MELSEC PLCs
Comfortable prompting under Microsoft Windows
Ladder Diagram, Instruction List or Sequential Function Chart
Changeable during operation
Powerful monitoring and test functions
Offline simulation for all PLC types
No hardware needed
GX Developer supports the MELSEC instruction list (IL), MELSEC ladder diagram (LD) and
MELSEC sequential function chart (SFC) languages. You can switch back and forth between IL
and LD at will while you are working. You can program your own function blocks (MELSEC
QnA/QnAS/System Q series), and a wide range of utilities are available for configuring special
function modules for the MELSEC System Q. And "configure" is the operative word here - you
no longer need to program special function modules, you just configure them.

106
The package includes powerful editors and diagnostics functions for configuring your MELSEC
networks and hardware, and extensive testing and monitoring functions to help you get your
applications up and running quickly and efficiently.
You can also test all of your program's key functions before they are implemented with the
GX Simulator offline simulation mode.
GX Simulator also enables you to simulate all your devices and application responses for
realistic testing.

107
Appendix H
(Engineering Drawings)

114
Extra drawing

115
14. References
Behealthy24.com, (2014). What to Expect From Freezing Your Moles with Liquid
Nitrogen | BeHealthy24.com. [online] Available at:
http://behealthy24.com/moles/freezing-liquid-nitrogen/ [Accessed 8 May.
2014].
BOC, (2011). Safety Data Sheet Nitrogen, Refrigerated, Liquid. 1st ed. [ebook]
Available at: https://www.boconline.co.uk/internet.lg.lg.gbr/en/images/tg-
8348-nitrogen-liquid-v1.3410_39604.pdf [Accessed 8 May. 2014].
CES Package, 2014
Metric & Multistandard Components Corp, (2000). FULL THREAD HEXAGON
HEAD SCREWS. 1st ed. [ebook] Available at:
http://www.metricmcc.com/catalog/ch1/1-2.pdf [Accessed 8 May. 2014].
Mitsubishielectric.com.au, (2014). GX Developer PLC Programming Software -
Mitsubishi Electric. [online] Available at:
http://www.mitsubishielectric.com.au/2204.htm [Accessed 8 May. 2014].
MSDS. (2014). 1st ed. [ebook] Available at: http://www.weld-
techproducts.com/msds_sheets/Esab%20Stainless%20TIG%20Rod%20MSDS
.pdf [Accessed 8 May. 2014].
Safetysupplywarehouse.com, (2014). www.safetysupplywarehouse.com. [online]
Available at: http://www.safetysupplywarehouse.com [Accessed 8 May.
2014].

116
Shl-group.com, (2014). Automation | Auto Injectors, Pen Injectors & Drug
Delivery Devices - SHL Group. [online] Available at: http://www.shl-
group.com/en/capabilities/automation.html [Accessed 8 May. 2014].
Snow, T. (2010). Application Data Sheet. [online] Available at:
http://www.tjsnow.com/supplies/cmw/w54f.pdf.
Steinel Professional, (2013). Industrial Heat Guns. 1st ed. [ebook] Available at:
http://www.steinel.net/Customized/uploads/PDFs/HG_4000_E_Data.pdf
[Accessed 8 May. 2014].
Steinel.net, (2014). STEINEL Industrial Heat Guns. [online] Available at:
http://www.steinel.net/Industrial-Heat-Guns [Accessed 8 May. 2014].

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