by dean mckinstry national diploma project electro plating fixture
TRANSCRIPT
Design Brief
I am going to produce a fixture for electro plating increasing productivity at T.J plating's production for one product line
ProcessElectroplating is the process of plating one metal onto another, most commonly for decorative purposes or to prevent corrosion of a metal.
Major Design Parameters
Increase productivity
Fisher engineering parts
Mass is 1.1kg
25mm clearance between parts
Set up by one person
Offers flexibility
Major Customer Requirements
The costumers main demand is the quantity per dip, which means he is wanting a fixture that will support more work and he also wants a quicker set up time. The main purpose of his demand is to boost production.
Product Design Specification
When I was at the factory I was able to get lots of information such as:
The type of acid that is used for plating is hydrochloric acid
The bath is 400mm wide and the rail used to hold the jig is 2400mm long.
The product I will be working with is 45mm box section and 1080mm long and the spacing between hooks will have to be 80mm apart for a high quality plating job.
The motor used for the crane is 5hp.
The maximum load the crane can withstand is 1000kg
Testing
I have come up with a testing frame which will allow me to test different fixtures out to see which design could work the best
Concepts
The limitation is, this will be difficult to set up because its hanging, fixture would need to be balanced on the frame
This design is balanced but it doesn’t have any fixed positions, it possibly hasn’t got enough circulation
This is the best solution but I wanted to try and improve it to be easier to manufacture.
Concept selection
• Simple to make• Welded frame • Fits to existing
hanger• Uses no tools to
secure
• High stress and high loading may mean its difficult to lift
Design development
Modular i.e. 3 sections
Make 1 section
750mm long sections
Capacity of 54/3
Loading gantry is 54 x 1.1kg i.e. 59.4Kg, fully loaded
Spacing of 80mm meaning 50mm circulation
Detailed Design
Demand is 1500 parts plated per week
Cost £2,50 per part per job
Demand is 250 per working day
18 per batch, 3hour cycle time
16 hours per working day
Old capacity – 14 x 18 units = 252 per day
1512 per week
New capacity 14 x 54 units = 756 per day
5 day week = 3780
6 day week = 4536
Or no night shift i.e. 8am to 4pm
54 x 6 x 6 = 1944 parts plated on a 6 day week
I.e. night shift wages reduced by 8 x 6 x £15=£720 per week
Productivity
• Output increased by 150%
• Saving over £35000 per year on labour
18 units at £2.00 = £3646 units at £2.00 = £92
Profit increased by £56 per batch
At R1F x D= MCM= ACM2.4 R2= 103 x 0.075m + 206 x 0.825 + 206 x 1.575 + 103 x 2.325= 7.725 + 169.95 + 324.45 + 239.4752.4R1= 741.6 NmR1= 309N