The rice transporter robot hopper was optimized through finite element analysis to maximize carrying capacity within the design constraints. Initially, the uniformly thick hopper displaced 0.686mm under load, exceeding the 0.5mm limit. Multiple wall thicknesses between 2.28-2.49mm reduced displacement to 0.4997mm. Confirming calculations matched applied loads and stresses, validating the analysis. Further optimizations could increase volume by designing in sections or modifying brackets and motor placement.
Study of Different Parameters on the Chassis Space Frame For the Sports Car b...IOSR Journals
The concept of Finite Element Analysis of a chassis space frame has been highlighted in this project.
The topic has constrained the study of the chassis space frame. Complex assemblies are to be avoided, for
sports car. The model of the chassis space frame is built using CATIA V5 and then imported to ANSYS CLASSIC
11.0 to find its finite element module. To perform a torsion and Bending Test on the computational prototype
chassis to determine its torsional stiffness. To incorporate a design improvement study and note the effects on
the global torsional stiffness of the chassis. The stress ,strength and degrees of freedom of the chassis will be
investigated. The body shape is fixed and therefore the overall external shape of the chassis must not be altered.
The engine bay must remain as open as possible to allow a variety of engines to be fitted
prepared by Shubham Bhargava and Arnav Tapan from Medi-Caps University, Indore and IIT ,Bombay respectively.
For more info Contact me - bhargavashubham17@gmail.com
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
Study of Different Parameters on the Chassis Space Frame For the Sports Car b...IOSR Journals
The concept of Finite Element Analysis of a chassis space frame has been highlighted in this project.
The topic has constrained the study of the chassis space frame. Complex assemblies are to be avoided, for
sports car. The model of the chassis space frame is built using CATIA V5 and then imported to ANSYS CLASSIC
11.0 to find its finite element module. To perform a torsion and Bending Test on the computational prototype
chassis to determine its torsional stiffness. To incorporate a design improvement study and note the effects on
the global torsional stiffness of the chassis. The stress ,strength and degrees of freedom of the chassis will be
investigated. The body shape is fixed and therefore the overall external shape of the chassis must not be altered.
The engine bay must remain as open as possible to allow a variety of engines to be fitted
prepared by Shubham Bhargava and Arnav Tapan from Medi-Caps University, Indore and IIT ,Bombay respectively.
For more info Contact me - bhargavashubham17@gmail.com
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
Range of IBC Precision Products for Support of Ball Screws
Fields of application of 60° super precision angular contact ball bearings and units: Rigid but fairly low-friction assembly of ball screws or satellite screws for conversion of rotary movement into linear movement (among others, also in worm gears for rotating tables or in tailstocks). To Know More Visit:http://www.carterbearings.co.uk/wp-content/themes/default/downloads/ibc/IBC_Ball_Screw_Support_Bearings.pdf
A brief slideshow outlining the creative journey taken thus far in improving the ts_17 halfshafts and tripods in an attempt to achieve better race car performance.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
we using lathe bed choose different materials and using creo and ansys we conclude some results that which material is best, also we remove some materials in order to reduce cost and weight.
Design, Development & Analysis of Loopwheel TechnologyABHISHEKPUND
In today’s world, Bicycles are the most favorite choice when it comes to causes like health, pollution, and the environment. Researches have been done in order to make the ride comfortable. This undertaking report introduces the Loop wheel. The purpose of our project was to reduce shocks on uneven roads, improve shock Absorption & take a smooth ride. Loop Wheel is a suspension system, Built to Experience a smooth ride on uneven roads by reducing shocks! So we replaced Spokes by 3 carbon springs. If we are riding on uneven roads, the spring can move in between Hub and Rim. As it's gone past a bump or bad road then the spring which is been touched to the surface will get compressed and others get to expand! So the whole impact power gets distribute in the wheel and the rider will feel nothing about that impact.
WELCOME
Good Morning, I am Nagarajan from INDIA doing material handling
equipment manufacturing, supplying and exporting, I always used to dream
something innovative way to develop concepts and ideas in my field of
engineering
So for I have designed various components for the cranes, For example
gearboxes, Electrical wire rope Hoists, electrical safety circuits and accessories.
Among these, my Drum rope guide design, Cross pulling prevention
Mechanisms, hypocycloid limit switches are very famously accepted in my
colleagues organizations
This time I have developed micro headroom JIB crane, which has been
proposed to a customer, who long time has requested, Since they are operating
cargo goods transportation business, they have very tough time to load or
unload heavy parcels from the container lorry. Inside the container , headroom
clearance will be less than 10 feet, so any normal type Crane equipments cannot
handle this type of operations efficiently. Every time they would hire mobile
crane vechile to load/unload their goods, it is time consuming and costly too
I developed this idea and proposed them, by the way of implementing MICRO
HEAD ROOM hoist, All mechanical parts like motor, Gearbox, Drum, Guides
and Breaks are kept on rear side , While the boom and trolley along with hook
would extrude in to the container. It seems sounds and innovative, we are
waiting foe the clearance from their management to go ahead to produce.
Just I want to share my ideas with you for improvements and your valuable
opinions, please share if you like this
Thanks
Nagarajan.B +91 9791222047 ( CEO)
rajanihoistandcranes@gmail.com
Friday, March 8, 2019
The Cement Lathe,Jenny,Multimachine and Drill together...create a full-scale machine shop – or a small factory or trade school. Plus, the Genny can provide power for a village. And, they can be built using leftover materials available anywhere junked cars exist.
Design of half shaft and wheel hub assembly for racing carRavi Shekhar
The Half - Shaft and Wheel Hub of Formula One racing car was designed taking into consideration one of the popular model of Redbull racing car. The various dimension of shaft and hub were altered to attain maximum factor of safety.
Range of IBC Precision Products for Support of Ball Screws
Fields of application of 60° super precision angular contact ball bearings and units: Rigid but fairly low-friction assembly of ball screws or satellite screws for conversion of rotary movement into linear movement (among others, also in worm gears for rotating tables or in tailstocks). To Know More Visit:http://www.carterbearings.co.uk/wp-content/themes/default/downloads/ibc/IBC_Ball_Screw_Support_Bearings.pdf
A brief slideshow outlining the creative journey taken thus far in improving the ts_17 halfshafts and tripods in an attempt to achieve better race car performance.
CADmantra Technologies Pvt. Ltd. is one of the best Cad training company in northern zone in India . which are provided many types of courses in cad field i.e AUTOCAD,SOLIDWORK,CATIA,CRE-O,Uniraphics-NX, CNC, REVIT, STAAD.Pro. And many courses
Contact: www.cadmantra.com
www.cadmantra.blogspot.com
www.cadmantra.wix.com
we using lathe bed choose different materials and using creo and ansys we conclude some results that which material is best, also we remove some materials in order to reduce cost and weight.
Design, Development & Analysis of Loopwheel TechnologyABHISHEKPUND
In today’s world, Bicycles are the most favorite choice when it comes to causes like health, pollution, and the environment. Researches have been done in order to make the ride comfortable. This undertaking report introduces the Loop wheel. The purpose of our project was to reduce shocks on uneven roads, improve shock Absorption & take a smooth ride. Loop Wheel is a suspension system, Built to Experience a smooth ride on uneven roads by reducing shocks! So we replaced Spokes by 3 carbon springs. If we are riding on uneven roads, the spring can move in between Hub and Rim. As it's gone past a bump or bad road then the spring which is been touched to the surface will get compressed and others get to expand! So the whole impact power gets distribute in the wheel and the rider will feel nothing about that impact.
WELCOME
Good Morning, I am Nagarajan from INDIA doing material handling
equipment manufacturing, supplying and exporting, I always used to dream
something innovative way to develop concepts and ideas in my field of
engineering
So for I have designed various components for the cranes, For example
gearboxes, Electrical wire rope Hoists, electrical safety circuits and accessories.
Among these, my Drum rope guide design, Cross pulling prevention
Mechanisms, hypocycloid limit switches are very famously accepted in my
colleagues organizations
This time I have developed micro headroom JIB crane, which has been
proposed to a customer, who long time has requested, Since they are operating
cargo goods transportation business, they have very tough time to load or
unload heavy parcels from the container lorry. Inside the container , headroom
clearance will be less than 10 feet, so any normal type Crane equipments cannot
handle this type of operations efficiently. Every time they would hire mobile
crane vechile to load/unload their goods, it is time consuming and costly too
I developed this idea and proposed them, by the way of implementing MICRO
HEAD ROOM hoist, All mechanical parts like motor, Gearbox, Drum, Guides
and Breaks are kept on rear side , While the boom and trolley along with hook
would extrude in to the container. It seems sounds and innovative, we are
waiting foe the clearance from their management to go ahead to produce.
Just I want to share my ideas with you for improvements and your valuable
opinions, please share if you like this
Thanks
Nagarajan.B +91 9791222047 ( CEO)
rajanihoistandcranes@gmail.com
Friday, March 8, 2019
The Cement Lathe,Jenny,Multimachine and Drill together...create a full-scale machine shop – or a small factory or trade school. Plus, the Genny can provide power for a village. And, they can be built using leftover materials available anywhere junked cars exist.
Design of half shaft and wheel hub assembly for racing carRavi Shekhar
The Half - Shaft and Wheel Hub of Formula One racing car was designed taking into consideration one of the popular model of Redbull racing car. The various dimension of shaft and hub were altered to attain maximum factor of safety.
DATE: 2019.05
- Design of a gearbox as a power transmission system
- Calculation of mechanical design parameters
- Mechanical design process
- Bearing selection from a given catalog
- Using ISO standards for a mechanical design process
In this project, a suitable gearbox is designed, and bearings are selected for the given prime mover in a screw conveyor machine. Screw conveyors are used for granular material transporting applications such as wheat. The granular medium can be transported efficiently to any desired position, ie. horizontal, vertical or sloped position.
Designing Engineers, Lmtd.A Pseudonym for ME 154 A divi.docxsimonithomas47935
Designing Engineers, Lmtd.
A Pseudonym for ME 154
A division of Mechanical Engineering Dept.
03 June 2016
To: Project Engineers
From: Michael Jenkins, Engineering Manager
Re: Design Project 5 (Design of a small speed reducer)
A large commercial customer from Mexico has approached us about submitting a bid for an order of 1000
small speed reducers. These speed reducers are to accept an input of 2.25 kW at a shaft speed of 2000 rpm
and will have a reduction ratio of 3.15:1 with the output shaft rotating in the same direction as the input. The
input and output shafts are to be on opposite sides of the casing and are to be parallel to each other. The
external parts of the shafts are solid, circular pieces of standard sizes and will have standard square key ways.
There will be no significant axial load placed on the shafts from external sources. The shafts will overhang
the face of the casing by 3 times the shaft diameter. The external loads will be applied by flexible couplings
which transmit only torque to the shaft. The power source is an electric motor and the driven load will be
smooth in nature. Reversal of the input rotation is anticipated on occasion. Any necessary lubrication should
be by grease packed into the casing (no liquid lubricants!). Minimal maintenance may be expected in use.
Your job is to design the internal workings of the speed reducer (e.g., gear set, chain and sprocket, etc) along
with associated shafts and bearings. Also design a suitable casing, being sure to allow for assembly, mounting
to convenient flat surfaces, and sealing of any grease. Provide a complete set of your final design calculations
and a set of component and assembly drawings. Describe your design process in your final FORMAL report.
Be sure to list and defend assumptions and major design decisions. Describe alternative designs which were
considered, giving reasons for their rejections. Include materials selection and manufacturer and part numbers
for any purchased parts (e.g. bearings).
Note, if an "off-the-shelf" speed reducer is selected, the above requirements are not obviated and your final
report shall include design calculations to confirm the vendor's design.
Provide a list of parts, approximate cost of each part, and method of fabrication (or procurement). Also
provide an estimate of the assembly time.
Your design teams should not exceed five, nor be less than two persons. One person shall be designated as the
lead. The lead, rather than the group collective, is responsible for communicating with me. I expect periodic
progress reports as follows:
Friday, 03 June 2016: Gant chart showing major tasks and anticipated completion dates (hard + soft copies)
Tuesday, 07 June 2016: Brief milestone report indicating a preliminary design compared to
alternative designs and selection rationale (hard + soft copies)
Thursday, 09 June 2016: Draft of final report including organization, l.
Jaw crusher kinematics simulation and analysisIJRES Journal
Jaw crusher is a kind of the relatively new compound pendulum jaw crusher, it has two crushing chamber and has an inverted crank rocker mechanism. The design is mainly to meet the following requirements: 1, crusher capacity 30-50t / h. 2, the maximum grain size of the material feed 120mm. 3, the largest nesting size should not exceed 30mm. According to the design requirements we design the complex dual-chamber pendulum jaw crusher. Design study of the current status of the development of the jaw crusher and the future trend of development, and the design parameters of the detailed calculations. And the most important is the use of ADAMS software crusher kinematics simulation and analysis .
The standard disc brake of a 4-wheeler model was done using Autodesk Mechanical Simulation through which the properties like deflection, heat flux and temperature of disc brake model were calculated. It is important to understand action force and friction force on the disc brake new material, how disc brake works more efficiently, which can help to reduce the accident that may happen at anytime.
GEOMETRIC OPTIMIZATION AND MANUFACTURING PROCESS OF SIX CYLINDER DIESEL ENGIN...Ijripublishers Ijri
The crankshaft is that part of an engine which translates reciprocating linear piston motion into rotation. To convert the
reciprocating motion into rotation, the crankshaft has "crank" or "crankpins", additional bearing surfaces whose axis is
offset from that of the crank, to which the "big ends" of the connecting rods from each cylinder attach.
The aim of the project work is to optimize the geometry shape of 6-cylinder diesel engine crank shaft to reduce the failures
and to reduce the weight. And also this project work will provide the brief explanation of manufacturing process.
Initially literature survey and data collection will be done to understand methodology.
Design calculations will be done to get parameters of object for drafting.
3D model will be prepared according to the obtained parameters.
Analysis will be conducted on crank shaft to rectify failures by optimizing geometric shape. Also best material will be
suggested by analyzing and comparing results with the variation of materials.
Mold tool design will be done and assembly will be prepared according to that.
Cnc program will be prepared for die set using cam
Safety aspect in automotive engineering is of prime importance. Effective Braking system along with good suspension systems, good handling and safe cornering is very important for determining the performance of the vehicle. The objective of this work is to design, analyze and investigate the strength and stiffness of the brake calliper during braking operation using ANSYS Workbench 15.0This analysis is further used to identify the critical locations of low stiffness on the brake calliper and also aimed at evaluating the performance of brake calliper under severe braking conditions. Hence best suitable design is suggested based on the performance and strength criteria
A checking fixture design of corrugated pieces in Clutch assembly of automobi...IJRES Journal
Car's checking fixture is used to judge the quality of auto parts and vehicle specialized testing
equipment. It plays an important rolein the rapid and accurate detection of parts’ size accuracy, so as to ensure
the quality of the vehicle. Whether the structure and function of fixture can achieve accurate, intuitive, rapid
detection of auto parts’ requirements become a judge a decisive factor of good or bad. The corrugated piece,
steel piece, the friction piece and supporting piece in clutch assembly were stacked in accordance with the terms
of the number and the order for assembly. The same series of different models of corrugated piece soften only
have subtle differences inthickness and ripple points. According to these characteristics, based on the corrugated
points, we designed a fast and efficient online corrugated piece fixture in automobile transmission.
Design, Analysis and Manufacturing of Hydro-pneumatic Press Machineijceronline
A Hydro-pneumatic press is a press machine utilizing both air and oil in its operation and gives higher outlet hydraulic pressure with lower inlet pneumatic pressure. In this project the press is design and manufacture for pressing sleeve bearing into the circular casting part. Casting part is thick cylinder and sleeve bearing is kind of cylindrical bearing. Two actuators are used in the press one is for vertical pressing and other is for horizontal pressing. This paper includes the concept development, design, analysis and manufacturing of press machine. Various parts of the press are modelled by using Pro-E modelling software. Structural analysis has been applied on the parts of press machine by using analyzing software ANSYS.
Similar to Rice Transporter Robot Project Report (20)
2. 2
Table of Contents
Design Summary.........................................................................................3
Hopper .............................................................................................3
Motor plates......................................................................................3-4
Rack and Stilt Assembly....................................................................4
Rollers ..............................................................................................5
Bill of Materials ..........................................................................................6
Finite Element Analysis Setup.....................................................................7
Determining Volume and Load..........................................................7
Applying Loads and Constraints ........................................................7
Remote Load/Mass..................................................................7-8
Reaction Force........................................................................8
Finite Element Analysis Results ..................................................................9
Uniform Thickness............................................................................9
Multiple Thicknesses.........................................................................9-10
Confirming Finite Element Analysis...................................................11
Conclusion .................................................................................................12
3. 3
Design Summary
The main goal for the project was to maximize the carrying capacity of the hopper and minimize the material
needed to structurally survive the required load with a displacement less than 0.5 mm. My design includes
features that cater to both of these requirements while also considering the ease for assembly by the assembler.
Hopper:
The hopper is printed with multiple different thicknesses that optimize the displacement when under load. In
order to reduce the unsymmetrical deformation the hopper experiences at max load, the thickness of the walls
range from 2.28mm to 2.49 mm thick seen in figure 1.
Figure 1: Top View of Hopper with Thicknesses
Motor Plates:
The upper and lower motor plates are of simple design. They are CNC threaded, and are machined from only
one side which can be seen in figures 2 and 2.1. The blue circles on figure 2 represent where the plates fasten to
the hopper and the red circles represent the threaded holes that are used to attach the motor to the plates.
Figure 2 (left): Front View of Motor Plates Figure 2.1 (right): Top View of Motor Plates
4. 4
The grooves machined into the plates allow for a snug fit with the motor. The design intends that the motor will
be first fastened to the upper and lower plates before both plates are attached to the hopper.
Rack and Stilt Assembly:
Figure 3 (left): Front View of Rack and Stilt
Figure 3.1 (center): Side View of Rack and Stilt
Figure 3.2 (right): T-shape end attaching HUB-ee Wheels to Rack and Stilt
The rack and stilt assembly are fastened together by two hex nuts represented by the green circles in figure 3.
The stilt is threaded allowing for a tight assembly. To convert the rotational work done by the motor to linear
motion of the rack and stilt, the motor pinion gear is tangent to the rack. The HUB-ee Wheels are fastened to the
rack by pegs that are designed specifically for the ‘cross’ extrusion cut in the wheels. These pegs are made out
of aluminum and will need to be CNC machined due to their groove radius of 0.5mm.
Included in the hopper design are sliding brackets that support the upper and lower parts of the rack and stilt
assemblies. They have clearances for the rack addendum and help resist rotational and bending deformations of
the racks and stilts that may occur during loading.
Figure 4: Top View of Bracket Figure 4.1: Isometric View of Upper Brackets
5. 5
Figure 4.2: Front View of Lower Brackets
Rollers:
The transporter robot has rollers that help support its center of gravity when transitioning from the ground to the
top of the 20 centimeter clearance. My design, which can be seen in figures 5 and 5.1, consists of a tri-sectioned
roller design that is held and secured by 1.50 mm tabs. The reason I went with this tri-section design was
because I wanted to have multiple support points in the middle as well as on ends of the hopper.
Figure 5: Bottom View of Rollers Figure 5.1: Isometric View of Rollers and E-style ring
6. 6
Bill Of Materials (BOM)
Item
#
Part Name Manufacture Method Material
Quanti
ty
1 Hopper 3D Printed ABS 1
2 GW370 Motor Provided by Sumotor Zinc Alloy 2
3 Pinion Gear Provided by Manufacturer Aluminum 6
4 Teflon roller Provided by Manufacturer PTFE 12
5 Roller Shaft Provided by Manufacturer Steel 4
6 Reinforced E-style Retaining Ring SolidWorks Design Library Alloy Steel 8
8 Lower Motor Plate CNC (threaded) Aluminum 2
9 Upper Motor Plate CNC (threaded) Aluminum 2
10 B18.6.7M - M3 x 0.5 x 10 Indented HMS --10N SolidWorks Design Library SolidWorks Design Library 19
11 B18.6.7M - M3 x 0.5 x 13 Indented HMS --13S SolidWorks Design Library SolidWorks Design Library 17
12 B18.6.7M - M3 x 0.5 x 4 Indented HHMS --4N SolidWorks Design Library SolidWorks Design Library 8
13 B18.6.7M - M3 x 0.5 x 8 Indented HHMS --8N SolidWorks Design Library SolidWorks Design Library 16
14 Upper Sliding Bracket CNC (threaded) Plastic 8
15 Clamping Sliding Bracket CNC (threaded) Plastic 8
16 Pinion Shaft CNC Steel 2
17 B18.2.4.1M - Hex nut, Style 1, M3 x 0.5 --D-N SolidWorks Design Library SolidWorks Design Library 28
18 Rack Waterjet cut Plastic 4
19 Stilt Waterjet cut Aluminum 4
20 HUB-ee Wheels Provided by Manufacturer Provided by Manufacturer 4
21 HUB-ee Pegs CNC Aluminum 4
Table 1: Rice Transporter Robot Bill of Materials
7. 7
Finite Element Analysis Setup
Determining Volume and Load:
After completing the assembly of the rice transporter robot, I isolated the hopper component to calculate the
internal volume. This internal volume is the deciding factor on the rice carrying capacity of the hopper. To do
this, I suppressed all the holes, and created a surface to cover the hopper. The hopper was then broken into two
regions, creating default and volume configurations that can be found in the SolidWorks hopper part. Using the
mass properties solver in SolidWorks, I found the initial volume before optimization to be 11,335,724.44 mm3.
The density value used for dry rice (7.82x10-7 kg/m3) was obtained from aqua-calc.com. From these two values,
I was able to find the weight by multiplying the mass of 8.8645 kg by gravity (9.81 m/s2). This calculation can
be seen in figure 7 below.
Figure 7: Calculating the Load
Applying Loads and Constraints:
I opened a static analysis in SolidWorks and began applying loads and constraints to the hopper. The total rice
load of 86.961 N was applied uniformly to the bottom faces of the hopper, which can be seen in figure 7.1
below. All thickness trials were performed without the change of this load respective to the volume of the
hopper, reducing the amount of iterations needed in order to optimize the design.
Figure 7.1: Findingthe
Load
8. 8
Remote Load/Mass:
To represent the force of each motor, a remote load was applied to the holes used for fastening the upper and
lower motor plates to the hopper, see figure 8 and 8.1 below. In order to properly define this load, global
coordinates were made at the contact point between the motor powered pinion gear and the rack. In my
assembly, the y-axis is up, the z-axis is normal to the face of the hopper, and the x-axis is adjacent to the
hopper. For one motor, all translation axes were set to zero. The opposing motor only had the x-and-y
translations set to zero, because I wanted to restrict the rotation displacement without over constraining the
analysis.
Figure 8 (left): All three axes (x,y,z) translations set to zero
Figure 8.1 (right): Two axes (y,z) translations set to zero
Reaction Force:
A ‘fixed geometry fixture’ constraint was placed on the two concentric shaft bearing holes that connect the
motorized pinions to their opposing counterparts. This constraint simulates the reaction force of the connecting
shaft acting on the hopper when load is applied. To do this, I applied a split line to the bearing holes shown in
figure 9 below.
Figure 9: Pinion Shaft Reaction Force Surface
9. 9
Finite Element Analysis Results
Uniform Thickness:
Before performing the static analysis, I created a 7 mm fine curved base so the hopper could run properly. The
first trial analyzed the initial uniform hopper thickness of 2mm and obtained a displacement result of 0.686 mm
that can be seen in figure 10 and 10.1 below.
Figure 10: 0.686 mm displacement Figure 10.1: 3.905 MPa Max annotation
The max annotation stress shown in figure 10.2 is 3.905 MPa. The tensile strength of ABS is 13 MPa, which
means that the factor of safety of my design is around 3.329. This is more than twice the design requirement of
a 1.5 factor of safety.
Multiple Thicknesses:
With the displacement result of the uniform thickness trial being 0.186mm over the threshold of the 0.5 mm
displacement design constraint, I decided to use the multiple thickness shell feature to reinforce specific
sections of my hopper. I selected four faces. I set a thickness of 2.28mm for the top face, 2.41mm to the max
displaced face, 2.4mm to the one adjacent to it, and 2.35 mm to the bottom face.
Figures 11 and 11.1: Views of multi-thickness faces
10. 10
The result from the multi-thickness hopper was a displacement of 0.5144 mm which can be seen from figure 12.
This showed that the multi-thickness feature helped in reducing the displacement experienced by the whole
hopper.
Figure 12: Multiple Thickness Trial 1
With this data, I was able to better determine the increase of thicknesses needed to reinforce the hopper. I
decided to increase the thicknesses as follows: top face maintained at 2.28 mm, the max displaced face from
2.41 to 2.49 mm, adjacent face from 2.4 to 2.46 mm, and maintained the bottom face at 2.40 mm. The change in
thickness size resulted in a displacement of 0.4997 mm which is below the design threshold of 0.5 mm
displacement seen in figure 13. The stress plot max annotation resulted in 3.425 MPa, which is a factor of safety
of 3.796, more than twice the design requirement seen in figure 13.1.
Figure 13: Displacement of 0.4997 mm Figure 13.1: 3.425 MPa stress max annotation
This optimized design resulted in a volume of 11,238,169.27 cubic millimeters.
11. 11
Confirming Finite Element Analysis:
To confirm the reaction force on the pinion shaft holes, I performed a stress hand calculation that can be seen in
figure 14. For the calculation, it was assumed that the reaction force of 63.7 N is distributed between the two
holes, so 31.851 N was used for the force of one bearing hole.
Figure 14: Stress at Shaft Hole
Using the probe feature in the stress plot, I selected the split line plane for the hole and received a stress result
of 2.344 MPa. This value is very similar to the hand calculation, solidifying the bearing holes were set up
correctly.
Figure 14.1: Reaction Stress
To determine if the whole finite element analysis was correct, I confirmed the force applied by the remote
load/mass of the motors and the upward reaction force from the pinion shaft bearing holes by adding them
together. Their total equaled the initial load of 86.961 N which can be seen in figures 15 and 15.1 below.
Figure 13 (left): Reaction Force Values Figure 15.1 (right): Remote Load/Mass Force
12. 12
Conclusion:
My final design resulted in a displacement of 0.4997 mm when under an 86.931 N load and holds
11,238,169.27 of dry rice. The design is simplistic, and easy to assemble. If I was able to lift some of the
manufacturing constraints, I would design a hopper that was made up of multiple sections instead of one part.
This way, I could create each section of the hopper using the current envelope size of 8x8x12 inches. It could
potentially increase the carrying capacity by about four times the current volume. Also, if the 250 mm wide
envelope design constraint would be waived, I would’ve not created the wheel wells.
If I was able to work on the design further, I would create the brackets to push the stilts out a bit a more. When
designing, I was cautious on how wide my final design would be. I ended up being 4.8 mm short of the 250 mm
constraint. This was a missed opportunity in maximizing the volume. I would also make the brackets more
supportive and robust in order to support the stilt/rack assemblies in this change. Along with this, I would
increase the thickness of the motor plates to allow the motor to be fastened farther away from the hopper. This
would reduce the displaced volume of the motor relative to the hopper. As far as the multi-thickness changes
go, I did a lot of guess and check for this design. I would take more time or perform a design study next time to
make sure that every thickness addition to the hopper was optimal.