Team Members & Role:

Benjamin Zamachaj: Team Lead

Graham Buckton: Design Lead

Peter Chen: Analysis Lead

Samira Lopez: Evaluation Lead

Om Naik: Fabrication Lead

Abstract: The UMass Building and Construction Technologies (BCT) department has identified the need for a better method of producing residential insulation panels made from recycled straw and wooden framing. Their current process suffers from serious limitations including long production times, heavy reliance on manual labor, and inconsistencies from cycle to cycle that produce non-uniform panels. To address these challenges, this project focuses on the design of a power and control system that automates key process requirements and ensures a uniform panel density of 7 lbs/ft³. The final proposed solution includes a motor-operated roller chain that moves a compressor head along the length of the panel, compressing a 2-inch section of straw to targeted density with each pass. A servo motor, outfitted with an encoder and controlled by a programmable logic controller and servo drive, is used to accomplish precise and repeated operations. The system’s chain drive mechanism uses a keyed shaft with a drive sprocket on either side of the panel frame to provide a straight and even motion profile. The system requires an average operating speed of 2 inches per second, necessitating the use of a gearbox that optimizes the motor’s torque output while maintaining speed for efficiency. Safety was also a large consideration for this project, requiring the implementation of emergency stops, proper guarding, and limit switches. Although several other competitors have developed similar systems for producing straw panels, each is a highly customized, expensive, and unique solution for that company. Where all other competitors have designed stationary assemblers, the BCT department requires a transportable design. This would enable the assembler to be readily moved by trailer from one job site to another, greatly increasing its versatility.

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