Production Technique glass door report
Jeroen Egberts
Edwin Tensen
Joep Looman
Christian Rovers
Gertjan Vons
Yannis Chatzikonstantinou
Titelpage Title: Date:
Glass door report 01-04-2010
Course: Code:
Production Technique AR1B090
Docent:
Peter van Swieten Kees Baardolf
Studenten:
Yannis Chatzikonstantinou Jeroen Egberts Joep Looman Christian Rovers Edwin Tensen Gertjan Vons
Production Technique “Best Kees”
7000126 1549553 1375008 1176978 1547275 1520725
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Table of content Titelpage........................................................................ 2 Table of content............................................................. 3 Prefix............................................................................. 4 Designproces................................................................. 5 Hinge......................................................................... 5 Designproces................................................................. 6 Handle...................................................................... 6 Designproces................................................................. 7 Lock........................................................................... 7 Shop drawings............................................................... 9 Hinge......................................................................... 9 Shop drawings............................................................. 10 Handle.................................................................... 10 Building process.......................................................... 11 Hinge....................................................................... 11 Building process.......................................................... 12 Building process.......................................................... 13 Lock . ...................................................................... 13 Handle.................................................................... 13 Final product............................................................... 15
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Prefix This report is written for the course AR1B081”Product Design”. During this course every student needs to make a design for an innovative façade for an office room. This office façade should take the architectonic, building physics, environmental and functional qualities into account. The design of the façade has to be worked out from the conceptual phase till the final design. After the first presentation 50% of the designs are selected and will be worked out further till shop drawings in couples of 2 students. After a second presentation one design out of the 50% is chosen, this winning design need to work out every single part of the design. The winning design was made by Maxim Eekhout and Axel van Zalingen. The total group of students are divided in 4 groups; The curved wall-, the floor-, the door- and the ceiling group. Each group worked out every part of the design on production level, because every part of the design will be produced in reality by the students. Our group is the “door group”, we designed every single part of the door, from the glass doorplate itself till the smallest part of the hinge that’s carrying the weight of the whole door. After doing researches and calculations we designed shop drawings which we needed to order the materials and getting started with the production of the parts.
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Designproces Hinge
The first design was the result of the research to the requirements of the hinges and the bearings. To adapt the hinges to various size difference the hinge had to be adjustable in all the different directions, on top of that the hinge should be able to tilt when necessary. In the first stages of the design of the hinge the idea was to use 3 bearings, 1 for the horizontal stress (gravity) and two for the vertical stress(the moment). The discovery of another type of bearing; the slide bearing changed a lot in the design of the hinge. The slide bearing(gleitlager) can both get the vertical forces and the horizontal forces, this way the hinge is more simple. The only requirement for the slide bearing is an very precisely manufactured shaft around the bearing, if the shaft isn’t the right size the bearing will wear much faster. The adjustability of the hinges is very important so a lot of time was spend on this subject. The adjustment of the x and the y direction is easy to design, but the ability to tilt and adjust in the z direction is more complex. The designs consisted out of a round plate with three screw-threads with nuts, with the nuts the plate could also be adjusted when the hinge was already under pressure. In the final design the round adjusting plate was changed to the a triangle, the reason for this was that the triangle plate takes less space around the hinge. In that stage the available space for the hinge in the floor was unknown, so an aim of the design was to make the hinges as compact as possible. The weakest point of the hinge was calculated by special computer program, the results were good, but to make sure the hinge would never fail the axle was enlarged. Production Technique “Best Kees�
First sketch
Ball bearing
Slide bearing
Adjustable in 3 directions
Final design
Adjustments after calculation
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Designproces Handle
Starting point for the design was to create a long, slightly curved door handle, heavy enough to open a door of nearly 500 kg with. If the door handle would be too light, the handle would possibly bend. To avoid that problem, a 2 m long RVS beam with a rectangular profile of 50 x 20 mm was chosen, in which a slight curvature would be rolled. The design and the connection with the glass door were tuned with this squared profile. Until in the very end of the design process the group needed to cut some extra costs. At this point a RVS tube with a diameter of 35 mm and a wall thickness of 2 mm was introduced since this tube was already in stock. Obviously, this had major consequences for the designed connection of the handle to the door. This connection now took place through cylinders sticking in the tubes, welded around, clamped to the glass with the possibility to screw the bolts more (or less) tight, hence controlling the clamping force. In the previous scenario, the rectangular profile would have been fixed to the handle from within, this way not leaving any connecting bolts in sight. The choice for a round profile also meant that the end of the cylinder sticking in the tube had to be smaller than the end that had to clamp the glass plate. This was because the small end had to fit inside the tube with a diameter of 35 mm (therefore we gave the cylinder a diameter of 25 mm) while the holes in the glass plate were already fixed and ordered. These holes were 20 mm wide. To create a margin we designed these flanges to become 40 mm wide with a thickness of 5 mm so the cylinder could not possibly break at the seam between body and flange under too much tension when opening the door with some force. The steel pin sticking through the holes in the glass and inside the cylinders to clamp the glass between the flanges was designed in such a way that you could adjust the whole through adjustment bolts. The bolts and matching slots were of a different size so that by first fixing the smaller bolt (M4) in the shallower slot, the whole would be tightened when the bigger bolt (M5) was screwed because it would automatically search for the middle of the slot. Between the cylinder and the glass where was of course a rubber layer for protection but also allowed for some tolerance when clamping the glass plate. Between the steel pin and the edge of the glass round the holes a layer of POM (with the same thickness as the glass) is introduced. This is a hard plastic that prevents the steel pin sticking through the POM from shifting. This way avoiding damage to the glass or even worse, building up high point loads around the edges. Production Technique “Best Kees�
Glass door
Horizontal section
Vertical section 6
Designproces Lock The initial specification for the lock was for a mechanism that would be concealed within the floor construction (First design iteration). In it’s initial state, the design was based on an eccentric curved element that would push a steel plate by rotating, as shown on the right. It’s rotation would be initiated by a common keypad that would be placed on the same axis of the rotating eccentric part. This design had the advantage that no forces from the clamping plate were transmitted to the keypad, therefore minimizing the risk of damaging it. However, this solution suffered from that it restrained the glass panel on a single point, therefore imposing a significant bending stress First design iteration on the panel in case of lateral forces being applied to it. A second, similar mechanism concealed in the ceiling construction was considered so that a second restraining point could be added, but the operation of both mechanisms using a single keypad was nearly impossible to design using mechanical means. An alternative was considered to use electric boltlocks, but no commercial system was found that satisfied all design constraints (securing plate dimensions, power requirements etc.). The design proposal that followed was based on a mechanism that was re-positioned within the side profile on which the glass panel rested when the door was closed. This offered the advantage that with a simple mechanism, multiple points of contact, or even a continuous surface could be designed, therefore minimizing the point stresses on the glass panel. Design proposal Production Technique “Best Kees”
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The first version of this design was also based on an eccentric ellipse-shaped plate that pushed sideways a long corner profile which was used to secure the door. However, a drawback of this design was that the force required to push the profile was too much to be handled by he turn of a key in the keypad and could therefore damage the keypad or the key itself. A second version was designed with point supports, which also suffered from the same drawback. The final iteration of the design improved on this aspect by implementing a different arrangement: A standard cabinet lock was connected with two long metal tubes, flattened at their ends, which were in turn joined with steel plates at the top and bottom of the side profile. A part of each plate was shaped as a corner and protruded out of the profile. When rotated, the cabinet lock pushed the tubes which in turn pushed the plates upwards and downwards respectively, therefore releasing the door. The guides on which the plates move were designed so as a diagonal movement of the plates could be allowed, avoiding wear on the glass plate and allowing a better clamping. Access to the mechanism was made possible by providing a removable area at the side of the profile facing towards the inside of the office. This final design iteration also offered the advantage of hiding almost the whole of the mechanism from view. The only part visible from outside the office would be the clamps when securing the door. Production Technique “Best Kees�
3D picture of the proposal
horizontal section
Glass door
vertical sections
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Shop drawings Hinge To build the hinge properly shopdrawings where made. Every single part was drewn in AutoCAD and the dimensions were added sothat there was a drawing in the workshop with all the possible dimensions. If everyone who was working on the hinge use this drawing, all the parts should fit. And if someone who wasn’t involved by the desingn process needs to manufacture a part for the hinge he can make them properly by using the shopdrawings.
bolt m12
Y-direction Steel plate 10mm thickness
axis X-direction Steel plate 12mm thickness
gleitlager cilinder bolt m16
Z-direction
cilinder
Y-direction bolt m10 Z-direction Steel plate 10mm thickness
Gleitlager JFM-3038-30
Axis made of steel
X-direction
UNP80
Cilinder
Parts Production Technique “Best Kees”
Side view Glass door
Front view 9
Shop drawings Handle
These shop drawings are used during the built of the handle. With these drawings the shapes and the sizes of the different products where clear. We only need six different parts to assemble the handle: • The handle bar • The spacers between glass an handlebar • The axis which clamps the glass between the spacers • rubber rings to prevent the steel to touch the glass • Pom rings to put in the holes of the glass • Adjustment bolts to connect the pieces.
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Building process Hinge Glass clamps higher thickness on the bottom of the clamp The bottom of the clamp, the flange, has become thicker from 6- 12 mm. First there was made some estimation about the dimensions of the flange. It was dimensioned on 6 mm, but after some calculations from some people of DEMO. They calculated the flange has to at least 10 mm to stay in the right position without any deflections. Gladly Kees could make some arraignments with someone of a steel company to exchange a present for a part of stainless steel for the clamp. All steel plates have more thickness In the design everything was dimensioned on steel plates of 10 mm thickness. These plates were big enough to care all the loads of the glass plane. In the workshop of Kees there was already a lot of steel in stock so this way there could be some saving on the budget we had to deal with. The only thing about the steel plates, were the thickness of 12 mm instead of 10 mm.
Glass clamps
Steel plates have more thickness
Bolts in clamp
Different material in clamp
Bolts in the glass clamps The clamp that must hold the glass plane on the right place is designed with a M12 bolt in the middle of the 150*150 mm plates. In front this was enough to hold the glass plane in place, but during the production of the clamp we thought it will not held of the door is turning. That’s why we changed the design of the clamp a bit. Under the clamp were the flange is of the hinge there are put four M6 conic bolts in the clamp for the hinge for the under part and four M5 conic bolts in the upper hinge. Different material between the glass and the glass clamps In the first designed there were some POM polymer parts on the side and under the glass plane. The use of POM is to protect the brittle glass for the stainless steel clamp. If the glass gets in touch with the stainless steel the glass will probably break in a lot of pieces. Production Technique “Best Kees”
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Building process Conic bolts changed to normal bolts The changes of the conic bolt to the normal bolts was because of the loads they can carry. Conic bolts will have the property to go somewhere because they are conic and forced to ‘slide’ out of the clamp. Finally there is decided to use a normal bolt because of the straight shape of it. This bolt can take the vertical forces of the glass plane much better in comparison with the conic bolt. Widen of the axle In the documentation of the slide bearing there was standing some measurements about the width of the axes that has to go in it, but when the axe was put in the bearing it wasn’t the right dimension. That’s way a second batch of two axes has to be made with the right measurements. Extra adjustment option in top hinge In the top hinge there was designed it just has to be fixed on the concrete beam without any adjustable parts in it. During the design process there has been made a decision to make some adjustable parts in the upper hinge because it could be necessary. The adjustable parts were in line of the way of the moment the glass will make towards the hinge and in the Z-direction, because of the difference in height of the floor to the beam. In the end it was good that there was some possibilities to adjust the hinge because it was very difficult to do it just by the under hinge.
Conic bolt changed to normal bolt Widen of the axel
Bracket to attach to the concrete beam The bracket that attaches the hinge to the beam is also developed new because of the cable gutter in front of the beam. There is designed a steel plate around the gutter. It was not able to remove the gutter, because there are a lot of cables in it which not easily can be removed or replaced.
Extra adjustment top hinge Production Technique “Best Kees”
Glass door
Bracket concrete beam 12
Building process Lock
In the end the whole office would be locked so there was no need to apply an extra lock on to the door. Therefor the designed lock is never built.
Handle
The production of the door handle started with making the 4 cylinders. All dimensions were final, put on paper and printed so anyone could do the job. The cylinders had to be made one-by-one out of a RVS bar of 40 mm round. Smoothening the sharp edges always finishes the products. Inside the cylinders a cavity was created with a chuck of 10 mm round. This is the space the steel pins would fit in. After finishing the cylinders, the 2 steel pins were developed. They had to be made so that they would exactly fit inside the cavities in the cylinders. The edges were smoothened so that they would fit more easily. By continuously calibrating it was possible to work very precisely. This was important because by the position and depth of the slots in the pin had to be very accurate to safeguard the adjustment possibilities. The milling of the matching holes in the cylinders and the tapping of the thread inside therefore also had to be very accurate. However, even after working so precisely there was still a difference of several millimeters in the distance between the flanges of the two sets if the bolts would be completely screwed in. This is where the created possibility to adjust did its work. The bigger bolt did not have to be screwed in completely to clamp the whole.
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Glass door
meeting
preparing the rubber
polishing the door handles
Final product 13
In the mean time it was possible to roll the RVS tubes. Only a slight curvature had to be developed and this turned out to be very hard, or at least very inaccurate. We first developed a wooden mould that was the guideline for the curvature. This was held next to the tube until the curvature rolled in was more or less the same. At hindsight this was not the ideal order to produce. If the curvature would have become too strong the cylinders already produced could have become too short. New cylinders would have needed to be produced or the end of the door handle would have needed to be shortened. Luckily there was enough tolerance in the distance with which the cylinders would stick inside the tubes so no harm was done. After producing the tubes with the right curvature they had to be polished. This immediately made them look very nice. It was not yet possible to create the holes in the cylinders. The distance between these holes was 1500 mm heart-to-heart in the design. But the glass was not yet delivered and you always have to expect some irregularities in the position of the holes. So this had to wait until the glass was delivered and this distance could be checked. In the mean time the RVS caps could be produced. These caps would seal the end of the tubes so no dust would accumulate inside the tubes. These caps were dimensioned in such a way that they would have to be hit in the tubes with a plastic hammer. But this too had to wait for the delivery of the door because the tube would have to be cleaned first from the inside after the holes for the cylinders would have been created. The last phase was finished when the glass door was delivered. The position of the holes was checked and translated to the matching distance of the holes in the tubes. After making the holes, the cylinders could be welded to the door handle. This is an inaccurate process but had to be performed as accurate as possible because the end of the door handle could not reach any further than the end of the flanges. The final step was to glue the rubber layers between flange and glass to the flange. This had to wait for the welding because the glue would release after the welding.
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Glass door
Conclusion In the end, the production process was a very smooth process. Mostly because the preparations were done very carefully. The design and build-up of the process allowed for irregularities, the drawings were very clear and the designer controlled and checked the process. However, there are some remarks to be made that could improve a similar process next time. First of all, the communication between project leader and executing parties, especially regarding the budget. On the very last day of the design process, the day all the work drawings had to be handed in, it was decided to replace the rectangular bar by a tube because that was already in stock and cheaper. This was solved with some extra effort on the spot, but the moment of course was very unfortunate. This problem should have been recognized earlier. The ordering of the materials was another hazard in the process. The glass door was delivered only a few days before the office had to be opened. Some steps in the production process could not be made until the door arrived. In this case that was not a major problem because the bulk of the production process was finished, but it is likely that in another case more work needs to be done at this stage. In that case it is important to have all the ordered materials at an earlier stage and especially an important part like this. Order in time is also important because you are depending on a third party that you cannot control. The third remark is the production order. It would have been more practical to start with the most inaccurate production methods, in this case the rolling of the handles. If you proceed with ever more accurate methods, the resulting deviations are easier to process. This way you can avoid producing new parts and no radical decisions have to be made under time pressure. The final focus is on the importance of tolerances. In the design several possibilities were integrated to process the resulting deviations, like the possibility to (un)screw the bolts in the slots, the flexible rubber and the positioning of the cylinders in the tubes. These tolerances were very helpful in the production process, because we have seen that no matter how accurate we have worked we are bound to end up with minor deviations from the original design. To be prepared for that saves a lot of work. 14
Final product The final product of the glass door is changed in its design in comparison with the design how it is be made. First of all the most of the parts of the glass door are made by the stuff that was available in the workshop and the stuff Kees could provide. The parts that has to be designed before we started to build the products, the hinge, the door handle and the locking mechanism, all changed during the time. Especially the locking mechanism has changed, because in the final product is has been cancelled. It was not really necessary to have a lock on the office, because the workshop is only open when Kees or Louis are in the workshop working. The door handle was almost made has it has been designed. During the designing about how it could be made it changed sometimes from a rectangular to a round shape and the other way around, but finally it has become a round shape. This was done because this was the easiest way to manufacture the small bending of the door handle. The design of the hinge was changed during the thinking about how it would be possible to take care of the hinge will hold the glass panel. When the first design was ready and calculated by DEMO the conclusion was the design of the hinge has to be optimised other ways the door would not hang for a long time. After the change of the design of the hinge the building of the hinge can be started. The things that changed from then on were the available stuff that was on the site. The main changes were the thicknesses of the steel plates, but most of the design was the same. Working together on a project was very nice to do and everybody enjoyed working together to make the design in reality. The first part were everything has to be designed was different then the realisation of the design. Things are changing during the building of the product, because there are some things you can not know in front. Like the cable gutter which not can be removed so you have think about how it could be made in site. Production Technique “Best Kees”
Glass door
“Glass door” group
complete group 15