Hydraulic Cylinder Processing Workstation Automation

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Lin, Cuifen
Ni, Ruinan
Onyebuchi, Chukwuka
Rigby, Graham
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This report outlines all three phases of the new hydraulic cylinder assembly workstation project. These three phases are in order the project definition, concept generationand selection and the final design. The problem given to the team was to design an automated assembly station for hydraulic cylinders, dealing with the installation of the head into the tube for a variety of different cylinder models. This was done to improve efficiency and customer satisfaction.In the initial stage, the team identified the project scope and design constraints, as well as the design needs from our client, Monarch Industries. In the second phasethe team generated 28 preliminary concepts through brainstorming and external research. All concepts were categorized into four different concept groups: overall layout, torquing devices, linear motion devices and vertical adjustment devices. After weighing and comparing the concepts in scoring matrices, as well as discussing them with the client, some of our design concepts were selected which were latterly integrated with the client’s suggestions, compiling into the final design concept.The final design of this project consists of two mechanical clamping mechanisms which align the cylinder tube and head, before forcing them together or threading one over the other. Due to the clamping mechanism, the centrelines of the rod and tube are always aligned. These clamping devices are operated via two hydraulic cylinders located underneath the clamping surfaces. One clamping mechanism is forced sideways during operation by a third hydraulic cylinder. The other clamping mechanism allows the tube to rotate whist being clamped. Rotation is achieved through using a commercially obtained nutrunner. A large frame was designed in order to support the long types of cylinders.In the final phase, detailedinformation such as dimensions and connecting solutions of all devices and parts were determinedby all team members. Dimensions and material properties of different components that have a variety of sizes and shapes were calculated by following equations from textbooks. Finite Elements Analysis (FEA) was performed two critical componentsto determine that the component can withstand the forces applied on itfor its entire product life. Through preliminary FEA simulations it was determined that a redesign of certain...