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?