Shanghai Tobacco Machinery Co. LTD (STMC) would like to increase packing efficiency, cut down energy consumption, and reduce noise and vibration in the tobacco packaging line by focusing on improvements to its hard-pack packing machines. Central to this is the enhancement of the multi-station rotating plate, a component integral to the speed and reliability of the packaging process.
The project aims to innovate a lightweight rotating plate by optimizing its geometry and analyzing its static and dynamic behavior. Through Finite Element Analysis (FEA), dynamic characterization, and the incorporation of algorithm development, the team will craft a design that balances the weight and inertia reduction with deformation. The goal is to achieve a structure that is not only lighter but also maintains rigid standards: minimizing elastic deformation to under 0.02 mm, decreasing the moment of inertia by 20%, and reducing plate weight by 30%. These improvements are expected to significantly lower energy consumption, noise, and vibration while increasing machine efficiency and preserving the high precision necessary for consistent quality assurance.
Our team investigated three strategies for achieving a lightweight design: topology optimization, advanced materials, and additive manufacturing. Using a Quality Function Deployment (QFD) chart, we determined that moment of inertia and maximum deformation are the most critical engineering specifications. We employed a weighing matrix based on their advantages and disadvantages and selected topology optimization as the final concept design approach.
We developed three parameterized models and designed an optimization algorithm to refine the parameters. The algorithm consists of import, meshing, preprocessing, simulation, visualization, and output analysis of torque and deformation. By iteratively comparing results against target goals, it updates the parameters until optimization is achieved. The algorithm was first tested on an example plate and validated using ANSYS software for accuracy and precision. We will use the algorithm to optimize our plate design between DR3 and DR4. Finally, we will use ADAMS to perform dynamic analysis for final verification.
Additionally, we updated the project timeline to extend the optimization and analysis, outlined each team member’s responsibilities, and calculated the budget. The budget for the project is calculated to be zero. In conclusion, our team strives to create a novel approach to designing a lightweight rotating plate for the tobacco hard-packing machine by integrating mechanical engineering and artificial intelligence, to both accelerate STMC's machinery and foster its energy efficiency and productivity.
