Optimizing Hanging Configurations for Powder Coating Process

Overview

A new hook design was created for Advanced Finishing USA. The new hook design addresses the issues of parts falling off the line, powder coat color imperfections, and uneven powder application. The new hook is versatile, addresses the issues, and is cost effective. Many concepts were proposed by the team, and close collaboration with the sponsor as well as concept screening and scoring methods allowed the group to develop the final hook design. The final hook design stabilizes parts, has a decreasing hook length, and multiple hanging configurations. This design also maximizes available area, parts are equidistant for even powder distribution, and hanging time is reduced.

Objectives

The project objective was to create a new hook design for Advanced Finishing USA. The new hook design has to address the issues of parts falling off the line, powder coat color imperfections, and uneven powder application.

Approach

• After visiting the powder coating line and meeting with the sponsor, the group generated CAD model concepts to address the issues.
• After concept screening, concepts 1,3, and 5 were selected for scoring.
• Concept one was chosen as the final design after concept scoring.
• After presenting the final design to the sponsor, changes were implemented into the final design.
• Stress analysis was performed in Autodesk Inventor on the final hook design to determine if the design could support the loads and stresses which it will be subject to.
• Cost analysis was also performed on the hook to show that the hook design is cost effective for the sponsor.
• No prototypes were created of the hook design, however this is an important future step towards implementation.
• After the hook is prototyped, testing will need to be performed, and the hook can be changed in response to testing.

Outcomes

As we were not able to build a prototype due to time and budget constraints, these are the expected outcomes.

• The sponsor will save money as this hook design prevents parts falling off the line, uneven powder coat distribution, and is more cost effective than the current hooks.
• Manufacturing/production times were reduced by XX hours/minutes as a result of this project
• The hook will reduce setup time as the new hook design allows for tubes to be hung much faster.