UNR Capstone team, Shoe Inn Rebooted (SIR), is developing a manufacturing process for shoe cover cartridges that fill automatic shoe cover dispensers. SIR’s sponsor company, Shoe Inn, sells and distributes automatic shoe cover dispensers and various types of shoe cover cartridges to businesses that operate clean rooms. While Shoe Inn markets their dispensers as “Faster Easier and Safer”, the shoe covers themselves are much more expensive than shoe covers that don’t utilize a dispenser. In an effort to allow Shoe Inn to be more competitive in their market, SIR is developing a more efficient process for producing shoe cover cartridges to reduce the overall cost.
The semi-automated track and jig will consist of a 6-foot long track, made out of hexagonal tubing, with two acme screws (augers) inset. There will also be a jig that is made of the same hexagonal tubing that will hold the final assembled shoe cover cartridges.
Figure 1: 3D model of the track design used for the proof of concept.
Figure 2: 3D model closeup of the clip tubes and the augers that were inserted into the track.
Figure 3: 3D model of the Shoe Inn Rebooted jig design.
Proof of Concept
For the Proof of Concept, three main components were built, assembled, and tested: the auger, track system, and jig. The track was assembled with the auger in place to address SIR’s concerns associated with jamming, shearing, and smooth conveyance of shoe covers down the assembly line. Tolerances were tight due to the size of the components being assembled; because of this, SIR had to ensure that the assembly jig and track were aligned. The results from the POC proved that the augers would convey the shoe covers down the track without jamming and that the interface between the jig and track was aligned correctly for the shoe covers to transition with ease.
Figure 4: Completed shoe cover cartridge.
Figure 5: Shoe cover clip that is used to weave the shoe covers together and move them down the track.
Figure 6: Proof of Concept track.
Figure 7: Proof of Concept jig and track interface.
Design Overview and Manufacturing of the Shoe Cover Cartridge Assembly Line (SCCAL)
The Shoe Cover Cartridge Assembly Line (SCCAL) was designed to expedite the manufacturing process and packaging of shoe cover cartridges. The final design exceeded expectations in both safety and speed by featuring fully encased augers, safety guards in place for all moving components, OSHA approved warning labels and utilizing selected motors to ensure a reliable, repeatable, and fast operation.
Figure 8: End of one auger being milled to accommodate bushing and gear for belt drive system.
Figure 9: Troy squaring up the track assembly.
Figure 10: Troy and Tyler attaching a small aluminum plate to SCCAL track assembly.
Figure 11: Tyler milling out a small section of the track assembly. This opening will allow for the belts to be attached to the augers in order to rotate them.
Figure 12: Belt drive assembly.
Figure 13: Samar wiring up the motors after assembly is complete so the team can begin testing.
Figure 14: 3D CAD model of the final SCCAL structural design.
Figure 15: 3D CAD model of the final SCCAL.
Figure 16: 3D CAD model of the motors, cover, and warning label.
Figure 17: Close up of 3D CAD model of the gears on the augers and motors.
Figure 18: Close up of gates inside the tubes of the assembly jig used to keep the clips from pulling out.
Figure 19: The final prototype of the SCCAL.
Testing of the SCCAL
To test the SCCAL, Shoe Inn Rebooted (SIR) had to come up with project specifications to meet. The most important specification was that one shoe cover cartridge had to be built to completion in 30 minutes or less. Most of our testing was proving our SCCAL prototype would do this.
Table 1: SCCAL project specifications.
Figure 20: Shoe covers being weaved together and being conveyed down the track during the testing process.
Figure 21: Transfering the woven shoe covers onto the assembly jig.
Figure 22: Shoe covers being compressed and bound.
Figure 23: Removal of the completed shoe cover cartridge.
Figure 24: Completed shoe cover cartridge.
Table 2: Project specifications, testing verification and validation, and item closure (was the requirement met).
The SCCAL not only met our project specifications but surpassed our expectations by completing a full shoe cover cartridge in 25 minutes.
Meet the Team
Tyler is a senior mechanical engineering student at UNR and an avid outdoorsman. Graduating in May 2016, he plans on staying in the Reno/Tahoe area to work as an engineer and continuing to pursue his many outdoor hobbies.
Maureen is a senior mechanical engineering student. She received her first degree, a BSBA in Finance, from Old Dominion Univeristy in Norfolk, VA where she was also on the university’s sailing team. Maureen’s first love is sailing but also enjoys skiing and hiking in the Sierras. She is looking forward to a career in mechanical engineering after graduation, where her goal is to make a long-lasting impact on the world.
Troy is graduating in May with a degree in mechanical engineering. After graduation, he will start work as an engineer at Cognito Motorsports, where he will continue his passion for offroad action sports.
Samar is a student double majoring in electrical and mechanical engineering. He will be graduating in May 2016. His goal is to do great engineering work that will have a lasting impact on society. His main focus is in energy and renewable systems. He knows he will be a great engineer for any company.
Born and raised in Reno, Nevada. Justin has a great love of the outdoors and athletics. After graduation, he hopes to work for an engineering company that manufactures mountain bikes, or water sports equipment. He will fill his free time with travel, music, family, and friends.