Tube Extraction Technology

==About Colmac Coil==
Colmac Coil is a third generation, family-owned company founded in 1971 that has grown to be one of the world’s leading manufacturers in new and replacement refrigeration coil markets. They specialize in custom fin and tube heat exchangers with the majority of business focused on industrial refrigeration. Colmac Coil is based out of Colville, Washington with an additional manufacturing facility in Paxton, Illinois and a South American sales office in Guadalajara, Mexico. Their mission is to provide heat transfer and refrigeration markets worldwide with products that are innovative, built to customer specifications, and shipped on-time, with fast friendly service for the mutual benefit of customers, employees and shareholders.
===Description of Manufacturing Process===
Colmac Coil produces fin and tube heat exchangers with a hydraulic expansion process. The tubes are fed through the stamped coil sheets to form a loose assembly. Then a plug larger than the diameter of the tube is inserted and hydraulic pressure forces the plug along the tube. This expands the tubes within the stamped coil sheets forming a mechanical bond for structural support and heat conduction. 
The expansion process is not foolproof however, the tubes can rupture and require replacement. The partially expanded tube must be extracted with minimal damage to the coil pack or else the entire assembly will have to be scrapped. The Extractors have been tasked with designing a tool-set and process to quickly and effectively remove the ruptured tubes.
===Problem Details===
::* Colmac Coil will fully expand the ruptured tube from the other end to eliminate the diameter change midway
::* A winch used for later operations can be used to drag a tool down the tube
::* Tube material is 3003 Aluminum seamless and between 0.060" and .080" wall thickness
::* Tubes will be 5/8", 7/8", and 1" inner diameter and up to 30 feet in length
::* The device and process must be successful on every attempt to prevent scrap
::* Process must take less than 1 business day to complete tube removal
::* Tool must not drag or severely damage heat exchanger fins 
::* Safety is of utmost concern and extraction process should not endanger workers
==Team Goals==
::* Target removal time of less than 2 hours
::* Separate tools for each tube size
::* A safe and reliable tube removal process
==Deliverables==
::* Prototype removal tools for each tube size
::* Demonstration of tool on Colmac test coils
::* Detailed report discussing reason for choosing final design tool, tool usage and maintenance instructions, and a self-evaluation of this product
==Tool Specifications:==
::* Tool set must cost less than $6,000
::* Replacement parts must be commercially available
::* Must be able to cut a wall thickness of .060" to .080"
::* Low maintenance
::* Tool must be able to attach to existing winch cable
=Tool Prototypes=
All of these tools use the winch supplied by Colmac Coil to operate. The supplied winch is capable of a 2,000 pound pull force, less than the winches in use at Colmac Coil. The winch is attached to a platform to secure assorted sizes of heat exchangers. The team focused on developing tools for only the 7/8" tubes until a satisfactory result was achieved before attempting 5/8" and 1" extractions. All tools are machined from 1018 round stock steel. The diameter of each tool is 0.765" which allows 0.020" diametrical clearance between the tool and the sample coil tube walls.
==Initial Concepts==
Expand this section to see the development of the tools and extraction process
Tool Designs:
Image of Tool	Description of tool
 	
 	
 	
Results from Testing the Tool Designs:
Image of Pipe from Test	Description of test
 	
 	
 	
==Secondary Concepts==
Tool Designs:
Image of Tool	Description of tool
 	
 	
 	
Results from Testing the Tool Designs:
Image of Pipe from Test	Description of test
 	
 	
 	
==First Successful Extraction Method==
Step of Process:
Image of Tool Being used	Description of
 	
 	
 	
==Final Tool Designs==
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Tool Designs:
Image of Tool	Description of tool
 	
 	
 	
Results from Testing the final Tool Designs:
Image of Pipe from Test	Description of test
 	
 	
 	
=Team Information=
	 	
	Andy Roybal 	Biography:
*Andrew is a senior studying mechanical engineering at the University of Idaho. His favorite courses have involved computer aided design software. He loves the outdoors and especially fishing and snowboarding. He is graduating May 2016.
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	Mechanical Engineering Undergraduate	Biography:
*Andrew is a senior studying mechanical engineering at the University of Idaho. His favorite courses have involved computer aided design software. He loves the outdoors and especially fishing and snowboarding. He is graduating May 2016.
*
*''
	Hometown: Idaho Falls, Idaho 	Biography:
*Andrew is a senior studying mechanical engineering at the University of Idaho. His favorite courses have involved computer aided design software. He loves the outdoors and especially fishing and snowboarding. He is graduating May 2016.
*
*''
	Email: royb9754@vandals.uidaho.edu 	Biography:
*Andrew is a senior studying mechanical engineering at the University of Idaho. His favorite courses have involved computer aided design software. He loves the outdoors and especially fishing and snowboarding. He is graduating May 2016.
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	Alan Edwards 	Biography:
*I am a senior in Mechanical Engineering. I was in the construction industry for 12 years before coming back to school to get a degree in Mechanical Engineering. I enjoy hiking, fishing, and being outdoors while spending time with my family. 
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	Mechanical Engineering Undergraduate	Biography:
*I am a senior in Mechanical Engineering. I was in the construction industry for 12 years before coming back to school to get a degree in Mechanical Engineering. I enjoy hiking, fishing, and being outdoors while spending time with my family. 
*
	Hometown: Idaho Falls, Idaho 	Biography:
*I am a senior in Mechanical Engineering. I was in the construction industry for 12 years before coming back to school to get a degree in Mechanical Engineering. I enjoy hiking, fishing, and being outdoors while spending time with my family. 
*
	Email: edwa7949@vandals.uidaho.edu 	Biography:
*I am a senior in Mechanical Engineering. I was in the construction industry for 12 years before coming back to school to get a degree in Mechanical Engineering. I enjoy hiking, fishing, and being outdoors while spending time with my family. 
*
	 	
	Lane Matteson 	Biography:
*Hi, my name is Lane Matteson and I am a senior studying mechanical engineering. My favorite classes have been fluids and thermodynamics. I have worked in the food processing industry and studied abroad in San Sebastian, Spain this past summer. In my spare time I enjoy hunting, fishing, and other outdoor pursuits. Unfortunately I had to take the Spring semester off and withdraw from the project.
*
	Mechanical Engineering Undergraduate	Biography:
*Hi, my name is Lane Matteson and I am a senior studying mechanical engineering. My favorite classes have been fluids and thermodynamics. I have worked in the food processing industry and studied abroad in San Sebastian, Spain this past summer. In my spare time I enjoy hunting, fishing, and other outdoor pursuits. Unfortunately I had to take the Spring semester off and withdraw from the project.
*
	Hometown: Homedale, Idaho 	Biography:
*Hi, my name is Lane Matteson and I am a senior studying mechanical engineering. My favorite classes have been fluids and thermodynamics. I have worked in the food processing industry and studied abroad in San Sebastian, Spain this past summer. In my spare time I enjoy hunting, fishing, and other outdoor pursuits. Unfortunately I had to take the Spring semester off and withdraw from the project.
*
	Email: matt8513@vandals.uidaho.edu 	Biography:
*Hi, my name is Lane Matteson and I am a senior studying mechanical engineering. My favorite classes have been fluids and thermodynamics. I have worked in the food processing industry and studied abroad in San Sebastian, Spain this past summer. In my spare time I enjoy hunting, fishing, and other outdoor pursuits. Unfortunately I had to take the Spring semester off and withdraw from the project.
*
	Tony Keys 	Biography:
*Tony Keys is also a senior undergraduate in mechanical engineering. His work experience includes a summer internship at the Exotic Metals Forming Company and he has been an electrical apprentice for his father’s company in Nampa, Idaho. Tony is passionate about snowmobiling, enjoys the outdoors as well as any hands-on experience. 
*''
	Mechanical Engineering Undergraduate	Biography:
*Tony Keys is also a senior undergraduate in mechanical engineering. His work experience includes a summer internship at the Exotic Metals Forming Company and he has been an electrical apprentice for his father’s company in Nampa, Idaho. Tony is passionate about snowmobiling, enjoys the outdoors as well as any hands-on experience. 
*''
	Hometown: Boise, Idaho 	Biography:
*Tony Keys is also a senior undergraduate in mechanical engineering. His work experience includes a summer internship at the Exotic Metals Forming Company and he has been an electrical apprentice for his father’s company in Nampa, Idaho. Tony is passionate about snowmobiling, enjoys the outdoors as well as any hands-on experience. 
*''
	Email: keys5218@vandals.uidaho.edu 	Biography:
*Tony Keys is also a senior undergraduate in mechanical engineering. His work experience includes a summer internship at the Exotic Metals Forming Company and he has been an electrical apprentice for his father’s company in Nampa, Idaho. Tony is passionate about snowmobiling, enjoys the outdoors as well as any hands-on experience. 
*''
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