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Background
Background
An assembly was needed to prevent items from dropping during transfers into an existing accumulation area. I was tasked with designing two end caps that would prevent items from leaving the area and assist in directing catching them during transfers.
Process
Process
I began by sketching potential solutions
After getting a concept approved, I moved to Creo to design the parts that would be needed
One side of the area required more coverage from the funnel, so I started with that side
Due to the flexible nature of the polycarbonate I was using I added supports with leveling feet
The polycarbonate pieces were attached together with 16 gauge steel brackets which I laser cut, painted, and bent in house to precise angles. Slots were added for easy alignment
The first panels were hand cut and drilled using templates which I printed out on the company's large format plotter, this allowed me to space the holes accurately over a large area
Due to the prohibitively long printing times of the original brackets for the leveling supports, I made sheet metal versions which were quicker to make and much stronger
The first assembly was installed easily on one end of the area. The supports eliminated the need to hold up the whole assembly while it was being attached, which sped up the process
Using what I had learned from the design, build, and installation of the first end cap, I designed one for the other side
The other end cap was designed with the same system of brackets and panels
This side did not need to extend as far out, so supports were not needed, instead I added a bent section across the back panel for additional stiffness. Also, Acrylic was used instead of PC for it's stiffness.
To speed up the second build, I sent out for the panels to be cut using an online service. This improved precision and quality of the final product
Results
Results
Both end caps were completed from concept to installation within a few weeks
The installation of both assemblies greatly reduces the chance of items leaving the area and should prevent drops in the future
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