6.2 Computer-Aided Simulation of Automated
6.2.2 Computer-Aided Simulation on Automated
The mathematical modeling of gas leakage in chemical gas charging process can be expressed as follows (White 2003):
VGLẳB ΔP N
1
Δt VC
T ð6:2ị Here,VGL—leakage rate of gas, B—unit conversion constant,ΔPNẳhNPFFPNIIi
— final pressurePFdivided by final gas deviation constantNFminus initial pressurePI
divided by initial gas deviation constantNI,Δ1t—time duration in minutes to build a Fig. 6.12 Computational modeling of deflection profile in liquid filling mechanism
94 6 Automated and High-Speed Manufacturing System
stabilized pressure,VC—tubing string volume above container, andT—temperature in container.
This mathematical equation can be modeled and analyzed by computer-aided 3D modeling and numerical simulation, with analytic result expressed in Fig.6.15.
The computational simulation result indicates that this newly designed chemical gas charging system has strong sealing capability and even very small gas leakage under high pressure can be reasonably ignored.
To perform computer-aided structural analysis, the following mathematic equa- tion is applied to define the load or the force increment in the computational simulation (White 2003):
FLoadẳPGasSArea ð6:3ị Here, FLoad—load or force applied to the component, PGas—maximum gas pressure, andSArea—gas charging area.
The computer-aided structural analysis can assist this new system design with analytic results on some critical parts including container fixture mechanism, plug delivery mechanism, plug insertion mechanism, and sealing plug feeding unit represented in Figs.6.16,6.17,6.18,6.19,6.20,6.21,6.22, and6.23.
Fig. 6.13 Computational modeling of stress profile in ultrasonic welding mechanism
6.2 Computer-Aided Simulation of Automated and High-Speed. . . 95
Fig. 6.14 Computational modeling of deflection profile in ultrasonic welding mechanism
0.00016 0.00014 0.00012 0.00010 0.00008 0.00006 0.00004 0.00002 0.00000
0 20 40 60 80 100 120 140 160 180 200 220 Gas Pressure (psia)
Gas Leakage (cc/min)
240 260 280 300 320 340 360 380 400 420 440
Fig. 6.15 Gas leakage vs. gas pressure
96 6 Automated and High-Speed Manufacturing System
The computer-aided simulation and analysis in Figs.6.16and6.17display the stress and deflection of container fixture mechanism in this new automated and high-speed viscous liquid filling system. The analytic results state that the maxi- mum stress of 24,692.52 psi in this container fixture mechanism is less than the material yield strength of 36,300 psi and maximum deflection of 0.11857 in. is within material allowable deflection limit.
The computer-aided simulation and analysis in Figs.6.18 and 6.19 show the stress and deflection of plug delivery mechanism in this new automated and high- speed viscous liquid filling system. The analytic results demonstrate that the maximum stress of 21,072.31 psi in this plug delivery mechanism is less than the material yield strength of 36,300 psi and maximum deflection of 0.08751 in. is within material allowable deflection limit.
The computer-aided simulation and analysis in Figs.6.20and6.21indicate the stress and deflection of plug insertion mechanism in this new automated and high- speed viscous liquid filling system. The analytic results state that the maximum stress of 13,766.81 psi in this plug insertion mechanism is less than the material yield strength of 36,300 psi and maximum deflection of 0.07182 in. is within material allowable deflection limit.
The computer-aided simulation and analysis in Figs.6.22and6.23present the stress and deflection of plug feeding unit in this new automated and high-speed Fig. 6.16 Computational simulation of stress profile in container fixture mechanism
6.2 Computer-Aided Simulation of Automated and High-Speed. . . 97
Fig. 6.17 Computational simulation of deflection profile in container fixture mechanism
Fig. 6.18 Computational simulation of stress profile in plug delivery mechanism
Fig. 6.19 Computational simulation of deflection profile in plug delivery mechanism
Fig. 6.20 Computational simulation of stress profile in plug insertion mechanism
Fig. 6.21 Computational simulation of deflection profile in plug insertion mechanism
Fig. 6.22 Computational simulation of stress profile in plug feeding unit at bowl exit
viscous liquid filling system. The analytic results state that the maximum stress of 7,216.14 psi in this plug feeding unit is less than the material yield strength of 36,300 psi and maximum deflection of 0.01819 in. is within material allowable deflection limit.
Based on computer-aided simulation in Figs.6.16,6.17,6.18,6.19,6.20,6.21, 6.22, and 6.23, the maximum stresses produced in all critical parts including container fixture mechanism, plug delivery mechanism, plug insertion mechanism, and sealing plug feeding unit are all less than the material yield stress and also relevant maximum deflections of these parts are within allowable limits of the materials. The above computational simulation shows the good performance of this new automated and high-speed chemical gas charging system with superior sealing capability in normal pressure and neglected gas leakage in high gas pressure. This new gas charging system can be potentially applied in high speed and fully automated manufacturing process with the cost-effective features due to simplified and less tolerance-controlled system design.
Fig. 6.23 Computational simulation of deflection profile in plug feeding unit at bowl exit 6.2 Computer-Aided Simulation of Automated and High-Speed. . . 101