Ingot Loading Apparatus to Mitigate Workpace Injuries

Overview

The Team consists of Four Students from The Pennsylvania State University, and two students from Shanghai Jiao Tao University. The team was sponsored by PCC Structurals, a world leader in investment casting manufacturing of various super alloy materials. The project issued by PCC Structurals is to modify a manufacturing process that loads ingots into crucibles, and places the pair in a melting box on a raised platform.

Objectives

The proposed solution to the problem covers all stages of the process, from the unloading of the ingots and crucibles from their initial shipment, to the loading of the coupled pair into the final box for melting. The team aims to increase workplace safety by eliminating pinch point hazards, and ensuring maximum lifting standards are adhered to. The team also aims to increase the quality of the casting by minimizing the amount of ceramic that contaminates the melting process. This will be accomplished by eliminating ingot movement and scraping inside the crucible.

Approach

– Participate in Weekly Student, and Staff Meetings

– Conduct bi-weekly sponsor zoom teleconferences with the sponsor to ensure the solution is agreeable at all stages

-Split the entire manufacturing process in 3 separate stages, and design a cohesive solution for each.

-Purchase materials and conduct testing on a small-scale prototype

-Conduct engineering analysis to ensure efficient, and safe design

-Pivot deliverables and scope as necessary to accommodate any unforeseen challenges (COVID-19)

Outcomes

The team has created a 3D design in Solid Works as a theoretical solution for PCC Structurals factory floor. The design will eliminate hazards, and protect factory workers from lifting any ingots that are too heavy. The design will maintain peak melting rates, and will enable a higher level of efficiency on the factory floor. The team’s design meets all customer needs, and target specifications