PAINT SHOP TRACK BEAM SYSTEM

Joel Escobales

Fabian Robinson

Kyle Lindsay

EML 4905 Senior Design Project

Florida International University

Department of Mechanical Engineering

Miami, FL

• Self-contained, full-service

aircraft landing gear

overhaul facility

• Repair and overhaul landing

gear, wheels, brakes, and

accessories for 43 different

types and subtypes of

commercial and military

aircraft

Allen Aircraft Radio Landing Gear Services

BOEING 777 MAIN LANDING GEAR OUTER CYLINDER

Length ≈ 10 ftWeight ≈ 1300 lbs

CURRENT PAINT SHOP

CURRENT PAINT SHOP CONFIGURATION

3 Paint Booths(Paint Booth #2 is NOT accessible from track beam)

2 Small

Ovens

Design Alternate 1, 2, 3Design Alternate 4

DESIGN ALTERNATES

Pros

• Spacious design

• Larger oven space

• Multiple options

Cons

• Production stoppage

• Two paint booths

Pros

• Larger oven space

• Three paint booths

• Multiple options

Cons

• Limited production

• Paint booth at each

oven entrance

Pros

• Least expensive

design

• Quick

implementation

Cons

• Limited oven space

• Limited future

improvement

Pros

• Larger oven space

• Does not halt

production

Cons

• Longest construction

• Most expensive

alternate

#1 #2 #3 #4

PROPOSED PAINT SHOP LAYOUT (#4)

Section Length (in) Description1 180 Straight2 48 Switch3 108 Straight4 94.25 60" Radius Quarter Circle5 228 Straight6 48 Switch7 94.25 60" Radius Quarter Circle8 156 Straight9 94.25 60" Radius Quarter Circle

10 72 Straight11 48 Switch12 94.25 60" Radius Quarter Circle13 156 Straight14 94.25 60" Radius Quarter Circle15 120 Straight16 94.25 60" Radius Quarter Circle17 108 Straight

Section Length (in) Description18 48 Switch19 94.25 60" Radius Quarter Circle20 120 Straight21 48 Switch22 72 Straight23 48 Switch24 228 Straight25 94.25 60" Radius Quarter Circle26 180 Straight27 94.25 60" Radius Quarter Circle28 516 Straight29 94.25 60" Radius Quarter Circle

TOTAL

3474 inches of track beam290 feet of track beam187 feet straight track beam

6 48" switch10 60" radius, 90° Curve

PROPOSED PAINT SHOP LAYOUT

Support Trusses are placed:

• At the center of each curved section

• Before and after each switch

• On straight sections so the longest

unsupported section of track beam is no

greater than 12’

Cross Beams

Qty Length (in) Total Length (ft)

27 108 243

Vertical Supports

Qty Length (in) Total Length (ft)

54 102 459

TRACK BEAM ANALYSIS

Maximum Shear Force = ±2,724 lbs

Maximum Bending Moment = 16,056 lb-ft

Choosing a Design

Factor (DF):

• Important to account for

larger components of the

future

• Must cover any

unaccounted for forces

• Depends on purpose and

owner’s specifications

It was agreed to use DF of

4.0 for the track beam

system analysis.

TRACK BEAM ANALYSISActual Stresses

Allowable Stresses

Stress Check

Stress Level and

Case

Allowable Compression

Stress

Allowable Tension Stress

Allowable Shear Stress

Allowable Bearing Stress

1 0.60Fy 0.60Fy 0.35Fy 0.75Fy

A992 SteelFy = 60 ksi 30 ksi 30 ksi 17.5 ksi 37.5 ksi

Combined Stress Ratio

Vertical Deflection

TRACK BEAM ANALYSISLocal Flange Bending Stresses

Underside of flange at flange-to-web transition – Point 0:

Underside of flange directly beneath wheel contact point – Point 1:

Topside of flange at flange-to-web transition – Point 2:

Resultant Biaxial Stresses (0.66Fy = 33 ksi)

TRACK BEAM SELECTIONW6x16

• Track beam analysis was performed on all

Standard (S) and Wide (W) Flange I-Beams

available on the U.S. Market (ASTM A992 Carbon

Steel)

• Since the price of these standard beams are

based on the amount of material, the beam with

the smallest cross sectional area that satisfies all

conditions is the most economical choice for this

project

SUPPORT COLUMN ANALYSIS & SELECTION

Dynamic Load = (DL*DLF) + (TL*DLF)

+ LL

= 1539 lbs

DL – Dead Load

DLF – Dead Load Factor

TL – Trolley Load

LL – Lifted Load

Secant Formula

Hollow Structural Section (HSS)

Column with Eccentric Loading

ShapeBo

Design Wall

Thickness, t

Nominal

Weight

Area, A

Surface

Area

in in lb/ft in2 ft2 / ft

HSS4X4X1/2 4.00 0.500 21.63 6.36 1.19

Shape

in psi  psi

HSS4X4X1/2

0.5487

10618

67532

ASTM A500C Carbon Steel

GUSSET PLATE & BASE PLATE

ANALYSIS & SELECTIONGusset Plate (Haunch) Design Rules of Thumb• Haunch Length – 10% of total overhead beam length

• Theoretical → (108 in)(0.10) = 10.8 in• Actual → 20 in = 18.5%

• Haunch Depth – 2% of total overhead beam length• Theoretical → (108 in)(0.02) = 2.2 in• Actual → 10 in = 9.3%

Base Plate Design – LRFD Method

  

PROTOTYPE DESIGN & TESTING

Point LoadDisplacement

(in)

Below cross beams <0.0625

5” from cross beams <0.0625

4.5” from midspan 0.125

1” center and other 3”

from cross beam0.0625

SolidWorks Simulation 0.110

1:6 Scale Prototype- Load: 320 lb = 1477 lb Equivalent Load- Track beam: 24 inch Unsupported

Section- Cross beam: 18 inch- Support column: 17 inch - Base plate- Gusset plate

FINAL COST ESTIMATECategory Description Price

Area PreparationRemove hazmat room,

hoist, computer server & demolish storage closet

$48,780

MaterialsPaint booths, track / cross beam, support columns,

oven lamps, etc.

$277,12

9

FeesGeneral contractor,

engineering fee, building permits and contingency

$104,40

2

Total 

$479,091

- It is estimated that the paint

shop will pay for itself within 6

years or less

- 48 man hours will be saved

from the overhaul process for

each Boeing 777 MLG Outer

Cylinder

- Contingency is priced at 10%

of material and area

preparation

ENGINEERING CHALLENGES

• Safety

• Strength

• Efficiency

• Cost

• Space

Applicable Standards from the following organizations will be adhered

to:

• American Society of Mechanical Engineers (ASME) Code of

Ethics

• American Institute of Steel Construction (AISC)

• Crane Manufacturers Association of America, Inc. (CMAA)

• Occupational Safety and Health Administration (OSHA)

• Miami-Dade County (MDC) Building Codes

• United States Environmental Protection Agency (EPA)

• Boeing Standard Overhaul Practices Manual (SOPM)

• Boeing Component Maintenance Manual (CMM)

STANDARDS

TEAM RESPONSIBILITIES

Joel Escobales – Research

Fabian Robinson – Design

Kyle Lindsay – Development

Each member will lead a section of this

project with the assistance of the other

teammates.

TIMELINE Aug-14 Sep-14 Oct-14 Nov-14 Dec-14 Jan-15 Feb-15 Mar-15 Apr-15

Problem Definition

Literature Survey

Project Formulation

Design Alternatives

Project Management

Engineering Design & Analysis

Prototype Construction

Testing & Evaluation

Design Considerations

GLOBAL LEARNINGThings to consider when implementing this project on a global

scale:

• Language differences

• Units / measurements

• Country’s regulations and standards

• Work force

• Safety

CONCLUSION AND FUTURE WORK

• Allow AAR to safely and efficiently

move next generation of larger

airplane components through

paint shop

• Use engineering knowledge to

improve other aspects of the paint

shop including air circulation and

thermal efficiency of ovens &

lamps