Team WRAPR

Certain information has been redacted to preserve intellectual property while still presenting the student project.

Porvair is working on innovating various aspects of their manufacturing processes in order to better accommodate the needs and requests of current and future clients. In regards to this, Porvair has offered a project to a talented team of future mechanical engineers at Boise State University in order to provide them with a viewpoint of a real world engineering project. The project explores analyzing a current manufacturing operation and developing a set of process improvements. Porvair requests a device to automate aspects of the process, thus reducing contamination and improving on the production rates of Porvair’s filtration products.

Porvair is a company who specializes in high-quality filtration products. [Redacted]
[Redacted]. A device is desired to automate aspects of the process to reduce human interaction, thus reducing contamination and improving on the production rates of Porvair’s filtration products.

1. OSHA Standard 1910.94

• www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.94
• This OSHA standard covers workplace ventilation needs.

2. OSHA Standard 1910.212

• www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.212
• This OSHA standard covers shielding in machinery and how it should be used to protect the operator.

• [Redacted]
• [Redacted]

Device addresses one of our issues – the application of a linear thermal seal. Could have useful info on heat application, pressure, etc.

Pros:

• Very similar to one of the operations in the manufacturing process
• Simple and straightforward

Cons:

• Doesn’t address wrapping or circumferential seals
• Heated surface degradation

Investigating the methods used for precisely controlling the temperature of the extruder hot end on a 3D printer could yield methods applicable for controlling the temperature of our sealing surfaces.

Pros:

• Model for active temp control
• Common enough for numerous solutions and approaches

Cons:

Precise and/or active temp control may not be necessary

Induction Sealing Machine: The Ultimate Guide

While our method of applying heat will very likely be different, some other properties such as pressure applied or materials used may be relevant.

Pros:

• Very similar application – seal applied thermally
• Pressure applied during sealing process
• Analogous materials

Cons:

• Very different heat source, very unlikely we will use induction

www.mcmaster.com/packing-tape-dispensers/

Tape dispensers of various designs could inspire designs for cutting and wrapping methods.

Pros:

• Designs could have insight for wrapping and cutting mechanisms
• Relatively simple, compact

Cons:

• Tendency to jam/break
• Not “clean” cut edges

• Major goal is to reduce the amount of human touch points to a minimum, ideally to 3 or less
• Budget should be kept at a minimum, ideally less than $500.
• Must not contaminate the filter or create large divots that can negatively impact the filter.
• Operated by a single technician

• For the safety of the operator, the temperature of the [Redacted] film must be maintained [Redacted] [Redacted].  Higher temperatures, [Redacted] may release toxic fumes.
•  Max Tension for [Redacted] is [Redacted],  [Redacted]. The thickness and width of tape rolls is needed to accurately predict this.
• Pressure, geometry of heating element, and rotation mechanism should not tear or damage the [Redacted] film

The amount of cuts and heat seals will be the same but will be more accurate and consistent.

• Safety of Device
• Usability
• Simplicity
• Consistency

• Production rate
• Production quality
• Operational cost of device
• Capital cost of device
• Consistency/up time
• Sales, acquiring new customers

• Safety of Filter
• Performance
• Consistency
• Lifespan
• Costs

• Safety while maintaining/repairing
• Ease of maintenance
• Availability/Documentation of parts

• Availability of documentation
• Modularity

Spec A

Various heating elements: soldering iron, hot knife, clamp heating element, long blade seal, number of heating elements

Different angles of heating element

Different pressures

Spec B

Will guard rail prevent hands from contacting heating elements

Spec C

Visually examine seal quality

Testing remaining flap strength, possibly with Instron machine

Check consistency of seal quality between each filter

Spec D

Count touch points during operation

Spec E

Black light testing for contaminants

Spec F

Visual inspection for divots

Spec G

Place cores into machine to see if they fit properly

Slide the second heating element over to ensure it accommodates cores.

Slide longitudinal heating element across to ensure there is enough room to accommodate cores.

Spec H

Time the filter wrapping process

How many can we do in an [Redacted]

Spec I

Can the process be done with one technician or will other help be needed

Spec K

Place each tape roll on the dowel to see if they both fit and able to roll out tape

1. Heating devices need to not interfere with the wrapping process.
2. Rotating core at speeds/pressure could create tearing/stretching
3. Holding wrap in place for first axial seal
4. Guaranteeing that wrapping feed is tight enough to avoid slack but loose enough to prevent stretching
5. Creating enough tension in the wrap to avoid wrinkles or excess, but not enough to stretch or tear material.
6. Cutting material in such a way as to no stretch or pull, must cut straight across.
7. Keeping the area with core open enough to allow safe installation and removal of cores.
8. Applying adequate pressure from thermal heating devices for appropriate seals