The Leader in Lightweight TechnologyThe Leader in Lightweight Technology

Consolidated MetcoConsolidated MetcoAnnual Sales Annual Sales FY2002:FY2002: $238 Million $238 Million Employees:Employees: 1,1571,157Headquarters:Headquarters: Portland, OregonPortland, OregonHistoryHistory– Company roots are in the truck business… Started by Company roots are in the truck business… Started by

Consolidated Freightways-1964 Consolidated Freightways-1964 – Freightliner/Daimler Benz 1981Freightliner/Daimler Benz 1981– LBO-1987LBO-1987– Varlen -1989Varlen -1989– Amsted-1999Amsted-1999

ESOP Company with 9 Operating Companies/ $2.1B SalesESOP Company with 9 Operating Companies/ $2.1B Sales50% Ownership in Maxion Brazil (Steel Foundry/ Fifth Wheel)50% Ownership in Maxion Brazil (Steel Foundry/ Fifth Wheel)

DAIMLER BENZ

Manufacturing LocationsManufacturing Locations

Portland, ORPortland, OR200 Employees200 Employees166,000 sq. ft.166,000 sq. ft.

Clackamas,ORClackamas,OR180 Employees180 Employees65,000 sq. ft.65,000 sq. ft.

Monroe, NCMonroe, NC350 Employees350 Employees300,000 sq. ft.300,000 sq. ft.

Bryson City, NCBryson City, NC165 Employees165 Employees

182,000 sq. ft.182,000 sq. ft.

St. Thomas,Ontario St. Thomas,Ontario CanadaCanada

10 Employees10 Employees10,000 sq. ft.10,000 sq. ft.

Monterrey, MexicoMonterrey, Mexico150 Employees150 Employees

68,000 sq. ft.68,000 sq. ft.

Cashiers, NCCashiers, NC165 Employees165 Employees96,000 sq. ft.96,000 sq. ft.

Etowah, TNEtowah, TN10 Employees10 Employees

60,000 sq. ft.60,000 sq. ft.

Recognized Quality SupplierRecognized Quality Supplier

PACCAR PACCAR Preferred SupplierPreferred Supplier

FreightlinerFreightlinerMasters of QualityMasters of Quality

Eaton CorporationEaton CorporationQuality FirstQuality First

Daimler BenzDaimler BenzVDA ApprovedVDA Approved

Meritor PreferredMeritor PreferredSupplierSupplier

Honeywell Honeywell Preferred SupplierPreferred Supplier

TS 16949Monroe, Etowah, Clackamas, Rivergate, Bryson City, Cashiers

Approved

The Leader In Lightweight TechnologyThe Leader In Lightweight Technology

Major Processes & ProductsMajor Processes & Products

Aluminum– Semi-permanent Mold– Low Pressure– Die Casting

Machining and Assembly– Hubs– Fifth Wheels– Castings– Fuel Water Separators

Plastics– Structural Foam– Gas Assist– Injection Molding– Thermoforming

HubsHubs

Brake DrumsBrake Drums

PlasticsPlastics

Die CastingsDie Castings

Permanent Mold CastingsPermanent Mold Castings

Simplex Fifth WheelsSimplex Fifth Wheels

Fifth WheelFifth Wheel

Approximately 26,000 units sold per year (15% market Approximately 26,000 units sold per year (15% market share)share)

Standard at Freightliner, Volvo, MackStandard at Freightliner, Volvo, Mack

Two models: Simplex & Simplex IITwo models: Simplex & Simplex II

Over 60% of units are slidersOver 60% of units are sliders

Product development includes two new slider modelsProduct development includes two new slider models

Production located in Monroe, NCProduction located in Monroe, NC

Testing and development in Portland, ORTesting and development in Portland, OR

SimplexSimplex Fifth WheelsSimplex Fifth Wheels

Simplex II

Vertical Load Capacity: 50,000 lbs

Trailing Load Capacity: 150,000 lbs

Vertical Load Capacity: 70,000 lbs

Trailing Load Capacity: 200,000 lbs

Standard with a left hand, straight pull releaseStandard with a left hand, straight pull release

Optional Touchloc pneumatic unlocking systemOptional Touchloc pneumatic unlocking system

ConMet Test CenterConMet Test CenterCapabilitiesCapabilities

Rotating Bending Hub Fatigue TestingRotating Bending Hub Fatigue Testing

Seal Abrasion TestingSeal Abrasion Testing

Fifth Wheel Vertical and Fore/Aft fatigue testingFifth Wheel Vertical and Fore/Aft fatigue testing

Fifth Wheel Ultimate Rollover TestingFifth Wheel Ultimate Rollover Testing

Component Fatigue TestingComponent Fatigue Testing

Hub Fatigue TestingHub Fatigue Testing

Seal Abrasion Testing Seal Abrasion Testing

Fifth Wheel Fatigue Testing Fifth Wheel Fatigue Testing

Fifth Wheel Rollover Ultimate TestFifth Wheel Rollover Ultimate Test

Rollover Ultimate TestRollover Ultimate TestResultsResults

Why we test our Fifth WheelsWhy we test our Fifth Wheels

Capstone Project OutlineCapstone Project Outline

The purpose of this project is to conceptualize, The purpose of this project is to conceptualize, analyze, design and build a test fixture for analyze, design and build a test fixture for testing the ultimate strength of heavy truck fifth testing the ultimate strength of heavy truck fifth wheels in the draw bar load case.  wheels in the draw bar load case.  

This project will incorporate all elements used in This project will incorporate all elements used in Mechanical Engineering from design, analysis Mechanical Engineering from design, analysis (FEA), prototyping (working with local machine (FEA), prototyping (working with local machine designers), and data acquisition. designers), and data acquisition.

Drawbar Load Case DefinedDrawbar Load Case Defined

Fdrawbar = 150K to 200k

Drawbar Load Case Drawbar Load Case

Capstone Project OutlineCapstone Project Outline

Conceptualize and Brainstorm design ideasConceptualize and Brainstorm design ideasPaper design chosen designPaper design chosen designModel and Analyze design with Solid Modeling & FEA Model and Analyze design with Solid Modeling & FEA Perform prototyping (using local vendors)Perform prototyping (using local vendors)Assemble and build Drawbar Tester (ConMet test lab)Assemble and build Drawbar Tester (ConMet test lab)Test the machine for proper functionalityTest the machine for proper functionalityPerform destructive test and collect resultsPerform destructive test and collect resultsWrite reportWrite reportPerform presentationPerform presentation

Questions?Questions?