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New Castle Design AssociatesPROJECT 99.12
TEAM 12Composite Generator Enclosure
TEAM 12Composite Generator Enclosure
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Composite Generator Enclosure• Team 12 • Justin Schaffer
• Tom Winward• Noel Goldstein• Jeremy Freeman
Members:
• Partner: Center for Composite Materials• Advisor: Dr. Michael Keefe
• Mission: It is our goal to design and construct a prototype portable generator enclosure made from composite materials that successfully satisfies all the wants and constraints defined by our customers, and to have a prototype built by April 1999.
• Approach: We will first identify customers and their wants. We will also attempt to find all current technology in use for sound reduction and in the area of composites. Then concepts will be developed based on the information gained during our benchmarking. The best design will be determined by comparing our concepts with customer wants and constraints. Next we will begin a process of prototype design and evaluation, culminating with the production of a prototype part. This prototype is then to be further developed by CCM to fit the D Star generator.
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Background
• Army needs portable generator for use in remote locations
• D-Star Engineering designing lightweight, high power diesel generator
• Team 12 to design a prototype enclosure
• CCM to finish development for pre-production model
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Customers
• D-Star Engineering• U.S. Army• New Castle Design Associates• Safety Organization (NFPA)• Army Soldier• Home Owners• Construction Industry• Outdoor Entertainment• RV Owners• Emergency Services
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Wants and Constraints
• Will not break• Thermally Stable • Quiet• Portable• Stackable
•Ease of Operation•Longevity•Ease of Maintenance•Cost
15” x 16” x 30” 25 LBS Composites
•Maximum Size•Maximum Weight•Primary Materials
Constraints
Wants
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Benchmarking
System Level• Open Tubular Frame
• Westerbeke Clamshell Enclosure
• Honda Super Quiet Generators
• Fisher Panda Generators
• Previous UD NCDA Enclosure
Functional• Sound Suppression• Accessibility• Ventilation/Heat Rejection• Stackable• Rolling• Carrying• Weather Exposure• Ease of Starting
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System Level Best Practices
• Years of Exposure Painted Metal• Tg N/A • Weight Open Frame• Cost Open Frame• Sound Level Enclosed Box• Drop Test ?• Stackable N/A• Time to Access Open Frame• Time to Start Electric Start
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Metrics and Target Values
• Years of Exposure 10 yrs / 3000 hrs• Tg 350F / 800F• Weight 25 lbs• Cost $200• Sound Level 60 dB / 65 dB max • Drop Test 4 ft• Stackable 5 units high• Time to Access 10 min• Time to Start 1 min
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Physical Model Testing1
• Sound Testing
• Temperature Testing
• Unenclosed/ Enclosed Generator• Load/ No Load
• Enclosed• Forced Convection
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Critical Concepts
• Stackable
• Access to interior
• Portable
• Quiet, Longevity, Cost, Will not break, Thermally stable
Rectangular
Panels (removable, hinged, sliding)
Handles, Wheels
Composite sandwich
Wants Concepts
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Concepts1
“Hand Buggy” Style with 6 removable access panelsAdvantages: Easy Access and Mobility
Disadvantages:Not Structurally Sound
“Clam Shell” Design with4 Dolly wheelsAdvantages: Easy to Roll on smooth surfaces, Easy Access
Disadvantages: Large Stress Concentrations
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Concepts2
Multiple roller wheels and
Sliding Side Door Access
Advantages: Easy to Use
Disadvantages: Limited Access and difficult outdoor mobility
2 Piece Shell Access
Advantages: Easy to Use
Disadvantages: High Stress on Latches
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Concept Selection
Mobility
Access
Composite Structure
Hand Buggy Style with Additional Handle
Multiple Panels at Critical Locations
Ciba Resinfusion 8605 Epoxy, E-Glass and Kevlar Fibers, Phenolic Foam Core
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• Phenolic Foam Core did not hold up structurally in initial sample tests
• Further research led to the testing of a Balsa Wood Core
S.C.R.I.M.P.
CIBA RESINFUSION 8607
Composite Structure Selection
Kevlar 49
E-Glass
Phenolic Closed Cell Foam Core
Kevlar 49
E-Glass
Balsa Wood Core
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Composite Lay Up2
• Samples made and tested with varying numbers of layers of fabric around balsa wood core
3 Point Bend Test Drop (Impact) Test
Test Samples
y
• Best Lay Up: 2 layers of Kevlar 49, and 2 layers of E Glass.
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Final Concept
Hinged Starting Panel
Removable Top Panel
Recessed
Wheels
3 Recessed Handles
Kevlar 49 (2), Balsa Wood, E-Glass (2)
Sandwich Structure
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Concept Testing1
• Sound Reduction:– Maximum 64.5 dB sound level in open
parking lot, measured at 7m.
• Temperature:– 160-170 oF inside
• Size:– 15”x16”x30”
• Weight:– 22 Pounds without louvers, handles and
wheels (These will add approximately 8 pounds)
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Concept Testing2
• Drop Test:– 4 ft. Off loading dock onto asphalt; sustained only
minimal damage• Access Time:
– 30 sec. to remove starting door, and replace– 5 min. to remove top cover to access engine and
replace• Stackable:
– Supported 400 pounds on top
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Prototype BudgetMaterials
• MOLD–Wood & Miscellaneous (including Bondo Body Filler, Paint, Sand Paper, Screws, etc…)
• SCRIMP–Ciba Resin–Kevlar–E Glass–Phenolic Foam–Balsa Wood–SCRIMP Materials (including Vacuum Bag, Tubing, Tacky Tape, Peel Ply, & Distribution Medium)
• OTHER–Film and Developing–Decibel Meter
TOTAL
Team Cost
• $ 399.68
• $ 0.00• $ 105.00• $ 671.25• $ 181.30• $ 414.00• $ 167.51
• $ 30.00• $ 30.00
• $ 1,998.74
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Est. Engineering & Shop Hours
• Fabrication:
– Wooden Model...16
– Mold…………..400
– Test Panels……..60
– SCRIMP………200
– Finishing………..15
– Testing…………...6
TOTAL………..697
• Research&Development:
– Benchmarking..…….40
– Customers/Wants…..20
– Foam Core Design....40
– Balsa Core Design....70
– Shape………..……..65
– Mat’l Procurement…20
TOTAL………..….255
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Projected Production Costs
• Kevlar:
• E-Glass:
• Balsa Wood:
• Resin:
• 4 yards
• 3 yards
• 3 1/2 sheets
• 1 gallon
• $ 70.00
• $ 16.11
• $ 41.40
• $ 73.93
Total: $ 201.44