Senior Design Project Final Presentation
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Transcript of Senior Design Project Final Presentation
Final Design PresentationFinal Design PresentationSenior Design ProjectSenior Design Project
Team Mata-Door (L6)Team Mata-Door (L6)
12/3/200912/3/2009
Final Design Presentation Final Design Presentation OutlineOutline
PersonnelPersonnel
ScheduleSchedule
Problem BackgroundProblem Background
System OverviewSystem Overview
OptimizationOptimization
Detail Analysis of each partDetail Analysis of each part
Safety InterlockSafety Interlock
TestingTesting
Cost AnalysisCost Analysis
RecommendationsRecommendations
ConclusionConclusion
PersonnelPersonnel
Final Design Presentation Final Design Presentation Personnel – Mitchell W. M. RieckPersonnel – Mitchell W. M. Rieck
Hobbies: Ultimate Frisbee Collegiate SportsCampus Crusade for Christ
Team Role: Fearless LeaderWelder
Experience: 4 years ME coursework2 internships in manufacturing industry
Final Design Presentation Final Design Presentation Personnel – Jason RoysterPersonnel – Jason Royster
Hobbies: Hiking, Whitewater rafting, traveling, gaming, music, cars, and just about any sport.
Team Role: WelderFE Analyst
Experience: 4 Months Risk Management Consultant(CNA Insurance Company)5 years of course work at NCSU-MAE
Final Design Presentation Final Design Presentation Personnel – Edwin RivasPersonnel – Edwin Rivas
Hobbies: Running, Basketball
Team Role: TreasurerStrut Expert
Experience: 4 years MAE courseworkSociety Hispanic Professional Engineers
Final Design Presentation Final Design Presentation Personnel – James PittmanPersonnel – James Pittman
Hobbies:Riding MotorcyclesSailing
Team Role: SpokesmanEMI Specialist
Experience:4 rotations as a co-op with US Airways4 years of MAE course work
Final Design Presentation Final Design Presentation Personnel – Guang “G” YangPersonnel – Guang “G” Yang
Hobbies: Playing table tennis Video gamesTravel
Team Role: Design DirectorUtility
Experience: 4 years MAE coursework
Final Design Presentation Final Design Presentation Personnel – Jeremy ReidPersonnel – Jeremy Reid
Hobbies:Anything with a motor, fishing, sports, motocross
Team Role: MachinistVP CAD operations
Experience: 4 years MAE 1 year co-op at ATI Industrial Automation 2 years Wolfpack Motorsports Baja Co-Captain -drivetrain component design for WM Baja Car
ScheduleSchedule
Final Design Presentation Final Design Presentation ScheduleSchedule
Final Design Presentation Final Design Presentation Problem BackgroundProblem Background
Objective: Objective: Design, build and test an access system for a ground Design, build and test an access system for a ground based radar array. It must be easy to open, highly accessible and based radar array. It must be easy to open, highly accessible and rugged.rugged.
Most Important Constraints:Most Important Constraints:– Must be sealed from environment and provide EMI shielding of Must be sealed from environment and provide EMI shielding of
60 dB 60 dB – Minimal loose hardwareMinimal loose hardware– Secure latch mechanismSecure latch mechanism– Must be cost effectiveMust be cost effective– Able to handle some load, with overall weight <150lbsAble to handle some load, with overall weight <150lbs– Non by-passable safety interlockNon by-passable safety interlock
Final Design Presentation Final Design Presentation System OverviewSystem Overview
AdvantagesAdvantages
3 door system3 door system
Opens verticallyOpens vertically
140140˚ requirement˚ requirement
Major Design AspectsMajor Design Aspects
FrameFrame
DoorDoor
LatchLatch
HingeHinge
Initial Considerations
OptimizationOptimization
Final Design Presentation Final Design Presentation Frame Weight OptimizationFrame Weight Optimization
Final Design Presentation Rib Weight OptimizationRib Weight Optimization
Thickness .5inx.5in .75inx.75in 1inx1in1/16" # of bars Weight (lb) # of bars Weight (lb) # of bars Weight (lb)
1 0.446 1 0.683 1 0.9212 0.891 2 1.367 2 1.8423 1.337 3 2.050 3 2.7634 1.782 4 2.733 4 3.6845 2.228 5 3.416 5 4.6056 2.674 6 4.100 6 5.5267 3.119 7 4.783 7 6.4468 3.565 8 5.466 8 7.3679 4.010 9 6.149 9 8.288
10 4.456 10 6.833 10 9.209
1/8"1 0.832 1 1.307 1 1.7822 1.664 2 2.614 2 3.5653 2.495 3 3.921 3 5.3474 3.327 4 5.228 4 7.1305 4.159 5 6.536 5 8.9126 4.991 6 7.843 6 10.6957 5.823 7 9.150 7 12.4778 6.654 8 10.457 8 14.2599 7.486 9 11.764 9 16.042
10 8.318 10 13.071 10 17.824
1/4"1 1.426 1 2.377 1 3.3272 2.852 2 4.753 2 6.6543 4.278 3 7.130 3 9.9824 5.704 4 9.506 4 13.3095 7.130 5 11.883 5 16.6366 8.556 6 14.259 6 19.9637 9.982 7 16.636 7 23.2908 11.408 8 19.013 8 26.6189 12.833 9 21.389 9 29.945
10 14.259 10 23.766 10 33.272
Final Design Presentation Weight and Dimensions AnalysisWeight and Dimensions Analysis
Frame
Item Material Density (lb/in3) Width (in) Height (in) Depth (in) Thickness (in) Weight (lb) Quantity Total Weight (lb)
Frame tubing (short) Aluminum 6061-T6 0.098 81 3 2 0.125 9.43 4 37.71
60.49Frame tubing (long) Aluminum 6061-T6 0.098 2 124 2 0.125 11.39 2 22.79
Door
Item Material Density (lb/in3) Width (in) Height (in) Depth (in) Thickness (in) Weight (lb) Quantity Total Weight (lb)
Door Panel Aluminum 6061-T6 0.098 83 39.33 0.0625 - 19.99 3 59.98
86.13
outside ribbing (vertical) Aluminum 6061-T6 0.098 1 36.83 1 0.125 0.79 6 4.74
outside ribbing (horizontal)
Aluminum 6061-T6 0.098 80.5 1 1 0.125 1.73 6 10.35
inside ribbing Aluminum 6061-T6 0.098 80.25 0.5 0.5 0.125 0.74 15 11.06
Strut 1.50 6 9.00 9.00
Hinge
Item Material Density (lb/in3) Width (in) Height (in) Depth (in) Thickness (in) Weight (lb) Quantity Total Weight (lb)
Bracket (base) Aluminum 6061-T6 0.098 1.5 4.5 0.25
-
0.17 6 0.99
5.82
Bracket (arms) Aluminum 6061-T6 0.098 0.25 1.5 2.25 0.068 12 0.82
Pin (base) Brass 0.3 diameter (in) 1.1 0.1 0.029 6 0.17
Pin (cylinder) Brass 0.3 diameter (in) 0.9 1.75 0.334 6 2.00
Support Bar Aluminum 6061-T6 0.098 0.38
5.32 1.5
0.12 6 0.731.68 0.5
diameter (in) 0.9
Support Pad Aluminum 6061-T6 0.098 2 3.75 0.25 0.18 6 1.10
Latch
Item Material Density (lb/in3) Width (in) Height (in) Depth (in) Thickness (in) Weight (lb) Quantity Total Weight (lb)
Latch Catch (base) Aluminum 6061-T6 0.098 1.25 0.75 0.25
-
0.023
15
0.34
5.04
Latch Catch (catch) Aluminum 6061-T6 0.0982 0.75 0.25 0.037 0.55
1 0.4 0.25 0.010 0.15
Latch Handle Aluminum 6061-T6 0.098 8 1 0.25 0.195 15 2.92
Latch Pad Aluminum 6061-T6 0.098
1 1 0.25 0.0245
15
0.37
diameter (in) 0.5 0.25 0.0048 0.07
Latch Post Aluminum 6061-T6 0.098 diameter (in)0.5 0.25 0.0048 15 0.07
0.75 0.875 0.0379 15 0.57
Total Weight 166.48 lb
ModelingModeling
Detailed Design Review Detailed Design Review System OverviewSystem Overview
Final Design Presentation Door AnalysisDoor Analysis
Final Design
Post-optimization modeling
FBD
Ansys
Final Design Presentation Door AnalysisDoor Analysis
The maximum deflection is 0.04 in.
The maximum elastic strain is 0.00038(in/in)
The maximum stress is 3776.2 psi.
Factor of Safety: XXX:1
Final Design Presentation Final Design Presentation Hinge AnalysisHinge Analysis
•External•Aluminum 6061-T6 •Brass Pin (main wear item)•Split Ring
Final Design Presentation Final Design Presentation Hinge AnalysisHinge Analysis
Final Design Presentation Final Design Presentation Hinge AnalysisHinge Analysis
The maximum deflection is 5.403e-5 in.
The maximum elastic strain is 2.259e-5(in/in)
The maximum stress is 225.9 psi.
Factor of Safety: XXX:1
Final Design Presentation Final Design Presentation Hinge AnalysisHinge Analysis
The maximum deflection is 4.51e-4 in.
The maximum elastic strain is 3.43e-5(in/in)
The maximum stress is 343 psi.
Factor of Safety: XXX:1
Final Design Presentation Final Design Presentation Latch AnalysisLatch Analysis
•External
•Custom made
•Compressive
•Rides on bearing-National Precision
Final Design Presentation Final Design Presentation Latch AnalysisLatch Analysis
Final Design Presentation Final Design Presentation Latch AnalysisLatch Analysis
The maximum deflection is 2.13e-4 in.
The maximum elastic strain is 2.70e-5(in/in)
The maximum stress is 728.48 psi.
Factor of Safety: XXX:1
*Prototype Catch
Final Design Presentation Final Design Presentation Latch AnalysisLatch Analysis
The maximum deflection is 0.024 in.
The maximum elastic strain is 4.84e-4(in/in)
The maximum stress is 4840.4 psi.
Factor of Safety: XXX:1
Final Design Presentation Final Design Presentation Strut AnalysisStrut Analysis
Final Design Presentation Final Design Presentation Struts AnalysisStruts Analysis
•It offers 40 lb force
•Working Temp. -40°C to +80°C
Final Design PresentationFinal Design PresentationSafety InterlockSafety Interlock
Normally Closed Normally Closed Magnetic Contact Magnetic Contact SwitchSwitch– Within the operational Within the operational
temp. range.temp. range.
Magnet Contact Switch
Schematic
Final Design PresentationFinal Design PresentationTestingTesting
Final Design Presentation Final Design Presentation Gasket AnalysisGasket Analysis
Combined Weather and EMI shielding sealCombined Weather and EMI shielding seal
•Solid silicon rubber weather sealSolid silicon rubber weather seal•Provides acceptable protection Provides acceptable protection throughout temperature rangethroughout temperature range•Seals attached with adhesive for easy Seals attached with adhesive for easy replacement with no toolsreplacement with no tools•Spira-Shield CMS-0623Spira-Shield CMS-0623
Final Design Presentation Final Design Presentation Material SectionMaterial Section
Combined weather and EMI Combined weather and EMI shielding sealshielding seal
• Spiral Tin/Lead Plated Spiral Tin/Lead Plated Beryllium Copper EMI gasketBeryllium Copper EMI gasket
• Offers >120 dB shielding Offers >120 dB shielding between 1MHz – 1GHzbetween 1MHz – 1GHz
Aluminum Door Surface and Box Tube Aluminum Door Surface and Box Tube FrameFrame
Pros:Pros:•Good EMI shielding propertiesGood EMI shielding properties•Light WeightLight Weight•Strong enough for our applicationStrong enough for our application•InexpensiveInexpensive
Cons:Cons:•Difficult to weldDifficult to weld
Detailed Design Review Detailed Design Review Cost AnalysisCost Analysis
• Total Cost of a door built by the Team Matadoors: Priceless• Total Cost in dollars: $2,602.80
Final Design Presentation Final Design Presentation RecommendationsRecommendations
Higher Compression/Thicker GasketHigher Compression/Thicker Gasket
Use notched latch catchUse notched latch catch
Weld the hinge platesWeld the hinge plates
Use laser cutter or water jet to cut Use laser cutter or water jet to cut the framethe frame
Use CNC machine to cut latches Use CNC machine to cut latches and hingesand hinges
Analyze smaller frameAnalyze smaller frame
Final Design Presentation Final Design Presentation ConclusionsConclusions
Meets or exceeds ALL the Meets or exceeds ALL the
requirementsrequirements– 140140– -40-40˚C ˚C /+71/+71˚C˚C– 80 knot winds80 knot winds– EMI proofEMI proof– All parts recessed within frameAll parts recessed within frame
Easy to operateEasy to operate
LightweightLightweight
Simple design for maximum Simple design for maximum
effectivenesseffectiveness
May we answer any questions?