Integrated Cooling Solutions Working in conjunction with Worldpak LLC, to implement a cooling system within a processing machine at their Reno, NV facility. This processing machine creates a heat seal in the manufacture of flexible packaging. The processing machine is comprised of a heated platen connected to an actuator via several steel components, terminating in a hydraulic cylinder. The problem needed to be solved is premature cylinder failure which is occurring due to overheating of an internal seal from improper heat maintenance of the platen through the rest of the system. Cylinder failure is expensive in terms of rebuild costs and machine downtime. The total design timeframe is approximately six months and if the solution proves to be applicable, further implementation onto other machines will become viable.
The product must meet a variety of specifications which have been investigated and can be summarized as needing to reduce the temperature of a component to prevent thermal failure. The key design criteria are for a cylinder on a production machine with a recommended operating temperature of 285°F with a goal of 200°F; currently the component is operating at 400°F approximately. The sponsor has provided for a maximum budget of $1,200 and the component is to require minimal maintenance and down time. Our product will require no tuning because it was designed to the specifications required.
Proof of Concept
The product exists within the cooling industry of which removes heat generated by friction or electrical means to maintain the equilibrium temperature of the system it is part of. The cooling industry is growing faster than its manufacturing counterpart which leads to the competition with API Heat transfer and Lytron Total Thermal Solution, the two largest companies in the thermal management industry. By creating a SWOT analysis for each company, it was found that each company specializes in different areas of cooling components. API has a prebuilt component that is not flexible to the costumers needs, and their manufacturing is overseas which increases overall cost. Lytron Total Thermal Solutions provides the personal touch that is only possible with a smaller company. Our product’s needs are specified by our customers, unlike our competitors, who prebuild their products.
Our Proof of Concept (PoC) was developed to show the effective cooling for a scale half model of our Pivot Block Cooling System design. The purpose of the experiment is to verify that forced convection on a heatsink along with an insulation material between the test material and the heat supply will cool the material more than just a heat sink. By using a block of aluminum as a substitute for the machine pivot block component, we were able to set up a simple representation of the cooling system. Heating elements were used to heat the block from the bottom and a temperature reading was taken from the top of the block. The goal was to show that this temperature reading would be below 93C. The Pivot Block Cooling System design is symmetrical, so we can consider just half of the model. The PoC confirmed our hypothesis and demonstrated that our cooling method is effective. The combination of insulation and convection cooling on a heat sink can be applied to applications that need to cool components and stop heat from passing to other components. The next iteration of the design can use the data from this design test.
The final design is forced convective cooling system that utilizes a heat sink, fans, and insulation. The heat sink is made from Aluminum for its low cost and sufficient heat transfer properties. The heat sink fins will have the shape of cylinders 35mm long and 2.5mm x 4.5mm. The 12V fans will be included due to the higher than room temperature, semi-enclosed, operating environment. There is a thermally conductive foam film in between the heat sink and machine block to ensure proper contact and heat transfer between the two services. Rubber insulation will be machined and installed between the heated printing plate and the part above it to reduce the heat conduction up into the machine block and piston.
The purpose of the cooling system is to reduce the temperature of a seal in the piston for the machine to extend its life span. The reduction of the heat coming from the heating plate after passing through our cooling system will lower the temperature of the seals to a safe operating value. This will allow the printing press to maintain production process without interruption for longer periods of time. This will allow the sponsor company, WorldPak LLC, to have less down time and fewer delays to production.
Testing and Results
Meet the Team
Abdullah Folazkhan is from the Kingdom of Saudi Arabia, and he is an international student at the University of Nevada, Reno. The most challenging engineering project for him is building a drone from scratch to upgrade it for more advanced use. The engineering skills that he developed during the academic year is to analyze the mechanical properties of a machine to prevent future failure, improved his mathematical analyzing skills, and learned the engineering computer software’s like Matlab and SolidWorks. Abdullah’s goal now is to complete the project he is working on with the AIAA club about an advanced drone. After graduation, he is planning to gather a team when he goes back home to work on a revolutionary project.
Britt Hoashi is Senior at the University of Nevada, Reno. The most challenging engineering project Britt has worked is autonomous line following hovercraft. Britt has developed his problem-solving skills during his academic career. For example, Britt was able to analytically solve how much power a belt can transmit, with the configuration of the system. Outside of school, Britt is proud of maintaining a car his Grandfather helped him buy. Britt is from Boise, ID. Britt has the goal of graduating in Spring of 2019. In the future, Britt plans on working in industry and then later obtain a master’s degree.
Growing up in Australia, Jack Gall has dealt with many engineering challenges, most recently attempting to understand the logic behind the imperial system. As an undergraduate research assistant in Dr Yanyao Jiang’s Mechanical Behavior Lab, Jack enjoys the cutting edge research into magnesium and 3D printed stainless steel. His most challenging engineering project to date is developing a device capable of inducing ultra high strain rate grain transformation in austenitic steels. Jack is the technical advisor for the UNR SAE BAJA team, Wolf Pack Racing. Outside of university, jack enjoys skiing, cycling or anything outdoors. His interest in mechanical engineering came after learning the science behind the polymer ski boot shells. His profession over the past 10 years has been as a ski boot fitter where his clients range from recreational skiers through to world cup athletes. After graduating in May 2019, Jack will pursue a masters degree in mechanical engineering specializing in fracture mechanics and failure analysis.
Kegan Rahe is from Minden, Nevada and is a senior at the University of Nevada, Reno. Kegan graduates from the University in May 2019 with degrees in Chemistry and Mechanical Engineering. Kegan currently is an undergraduate researcher in Dr. Hadj-Nacer’s group where he studies two-phase flow in porous media. Also for Dr. Hadj-Nacer, Kegan is a teaching assistant for the instrumentation class at UNR. Outside of the University, Kegan has an internship at Neomdedical Inc. After graduation from the University, Kegan will pursue a P.h.D in Aerodynamics.
William Gregory is from Las Vegas, Nevada and a senior at the University of Nevada, Reno pursuing a mechanical engineering degree. Apart from school, William has developed his engineering skills while being a part of the ARLISS club on campus as well as participating in a machine learning research group. William has gained experience working with people and building both mechanical and software projects. He is currently working in an internship position investigating simulated drone operations. William’s goal is to graduate with an undergraduate degree in Spring 2019. After graduation, William plans to develop a career by getting a job with a local company in the field of manufacturing or robotics.