Tractor Roof
Agriculture Award
Molder: Composite Products, Inc.
Moldmaker: Delta Mold, Inc.
Designer: John Deere Southeast Engineering Center
OEM: John Deere Commercial Products
Cab Sub-Assembly: John Deere Waterloo Works
Description
Tractor Cab Roof for Mid-sized Utility Tractor. The Tractor Cab Roof is part of an original climate-controlled cab intended for workers who spend a large amount of time using the tractor, as well as for those who desire the comforts of protection from the outdoor elements.
Why is this Part Innovative?
This part is innovative because it is part of a system that is unique to this size of commercial utility tractors. The climate controlled cab needed a Roof that was strong enough to enable multiple components to be assembled to it, while possessing aesthetic properties that did not need any expensive secondary finishing. The Roof is the backbone of the cab system as it houses such items as the HVAC system, the radio, the interior and exterior lights, the exterior roof, and the interior headliner. It also has many features such as deep, thin ribs, out of draw ribs, fastener and attachment systems, and other designed-in features that allowed for the elimination of many purchased components in the assembly. This design, coupled with the direct in-line compounding process, allows for fiberglass reinforcements into these features so that the full properties of fiberglass reinforced polypropylene could be utilized. Many of these deep draw features could not have been obtained using other long-fiber material processing methods.
This part is also an integral part of a system that is fully sealed from the outside atmosphere, so that dust particles and other irritating contaminants are kept outside the cab, and fresh air is continuously filtered into the cab. The composite design also allowed for noise reduction that is second to none in the industry, thereby further increasing the comfort of the operator.
This part also utilizes a unique molding technique that reduces material waste along with tool cost and part price. This technique essentially eliminates the excess material a transfer mold would normally generate (similar to the runner system in an injection mold), by designing the transfer gate into a functional area of the part. This design allows for a material savings of at least 10% per part, and a tool savings of approximately 10% as well.
Process
Direct In-Line Reinforced Thermoplastic Transfer-Compression Molding was chosen for significant economic savings while achieving superior performance, design flexibility, and aesthetics.
Design
Design was done using CAD
Mold flow analysis
Finite element analysis
Tooling
Steel
Number of Cavities: 1
Molded in Texture: Yes
Transfer compression mold that contained the puck and runner system as “part-of-the part”, a unique concept to minimize material waste, tool size, and ultimately tool and part cost.
Material
Polypropylene and 30% Glass Filler was chosen as long glass fiber reinforced polypropylene results in a high-performance composite that is economically advantageous.
Finishing
Unfinished
