Heavy Duty Conveyor Belt Module

Project Description

I was responsible for the initial design exploration for the Intralox Series 1600 Heavy Duty Edge (S1600HDE) module. This design was aimed at addressing contimatination risks associated with the current Series 1600 Edge module, which occasionally fails due to improper belt disassembly during routine cleaning.

Three S1600 Edge Modules (Non Heavy-Duty Edge)

Design Process

Part 1: Transposing a HDE

The edge design from the larger Series 800 Heavy Duty Edge (pictured) was selected as the starting point for the S1600HDE. A scaled-down duplicate of it was modeled in CREO Parametric onto an existing S1600 model.

Part 2: Rod Insertion Force Calibration

To minimize rod insertion force and maximize strength, the minimum edge length was determined using simplified 3D printed prototypes by measuring their respective rod insertion forces (RIF) and multiplying them by a printed-to-molded coefficient calculated using RIF's of existing injection molded products and their 3D printed counterparts.

Part 3: 3D Printing Prototypes

Several prototypes with various differences, including mirrored and non-mirrored copies and copies with and without enlarged first links were modeled and 3D printed.

Part 4: Qualitative Testing

The ease of use of a few prototypes was evaluated by several volunteers with varying levels of assembly and disassembly experience. Among the prototypes was the Series 800 Heavy Duty Edge for use as a baseline. Their feedback was used to choose a prototype to move forward with.

Part 5: Final Adjustments

Final adjustments including the implementation of an insertion guide which doubled as a structural enhancement and guard for the first link were implemented.

Final Prototype

Relevant Skills

CREO Parametric | Design for Injection Molding | Sanitary Design | 3D Printing | Presentations

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