Automated Trim Assembly
Problem
One of the Calendars at the factory was supposed to be used to make large rolls of tape and be able to adjust the width of the rolls. The blade assembly was broken in that the blades could no longer move and it was creating problems for the operators. I was tasked with designing a new blade system that would last longer and could adjust the blade position more effectively.
Considerations
Design that is sturdy, reliable. Has to withstand recoil from the blades
Dimensions fit inside the calendar cage
Blades must be adjustable to the widths specified by the operators
Easily manufacturable by the maintenance team
Would be a bonus to use materials from the existing frame
Solution
The most important component in the design was to find an effective way to adjust the blades as the frame would be designed around the blade system. I found a ball screw linear actuator and rail system online that would be sturdy enough to handle the recoil of the blades, while also providing acceptable adjustability and precision. The website provided a variety of sizes which would be ideal to fit inside the calendar cage. The linear actuator is shown to the left.
Through communication with the engineering team and operators, the components of the frame were designed in a way that would be convenient to build for the maintenance team and also preserved materials. The components and assembly were designed using OnShape, with the drawings shown to the left.
Result
Using OnShape Assembly, the complete 3-D model of the blade assembly was created. I made a drawing for the overall design and passed that along to the maintenance team including the part drawings so that construction could begin. My design was then built and installed into the calendar with everything working as anticipated including the blade adjustment. The complete drawing is shown.