T hermocoupl e Socket Connections Re-design to reeduce Carbo … · T Re the req ADV Facu...
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T Re the req ADV Facu Thermo e-desig Sub quireme VANCED ulty of A ocoupl gn to re David Eco mitted ents of for t D ENG Art’s, En Dec e Sock educe James o Engin in parti Leeds the Deg INEER nvironm cember ket Co Carbo Raistri eering al fulfilm Metrop gree of RING MA ment an r 2012 onnecti on Foo ick ment of politan U ANAGE nd Tech ons otprint f Univers EMENT hnology 1 sity T y
Transcript of T hermocoupl e Socket Connections Re-design to reeduce Carbo … · T Re the req ADV Facu...
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2
Authorship Declaration
I, David James Raistrick, confirm that this dissertation/assignment and the work
presented in it are my own achievement.
Where I have consulted the published work of others this is always clearly
attributed;
Where I have quoted from the work of others the source is always given. With the
exception of such quotations this dissertation is entirely my own work;
I have acknowledged all main sources of help;
If my research follows on from previous work or is part of a larger collaborative
research project I have made clear exactly what was done by others and what I
have contributed myself;
I have read and understand the penalties associated with Academic Misconduct.
I also confirm that I have obtained informed consent from all people I have
involved in the work in this dissertation following the School's ethical guidelines
Signed:
Date: 21 December 2012
Student ID No: 33153272
3
Abstract
This report has been published from the investigations of Eco engineering.
Following PAS2050 methods an existing component has been analysed and its
carbon footprint calculated. From the results of this it could be identified which
areas contributed the largest to the carbon footprint and what could be changed
to make the product more environmentally friendly.
4
Contents
1.0 INTRODUCTION ........................................................................................ 6
2.0 EVALUATION OF CARBON FOOTPRINT ................................................ 9
3.0 PRODUCT RE-DESIGN ........................................................................... 14
4.0 MANUFACTURING .................................................................................. 18
5.0 CONCLUSION .......................................................................................... 22
5
List of Figures
Fig1 LBBCThermoclave 6
Fig2 Typicallayoutofthermocoupleconnections 7
Fig3 Typical6wayconstructionofthermocoupleinterfaceconnections 8
Fig4 ProcessMapforTheromcouplesocketmanufacture 9
Fig5 Materialspecificationsfor1component6wayplate 10
Fig6UmbertoLayoutoforiginalproduct 11
Fig7 Chartedresultsfromoriginalproduct 11
Fig8ModelInput/Outputmaterialsfororiginalproduct 12
Fig9Summaryfororiginalproduct 12
Fig10Materialspecificationfor1re‐designed6waythermocoupleplate 14
Fig11UmbertoLayoutofre‐designedproduct 15
Fig12 Chartedresultsfromre‐designedproduct 15
Fig13 ModelInput/Outputmaterialsforre‐designedproduct 16
Fig14 Summaryforre‐designedproduct 16
Fig15 ModelDesignImage1 18
Fig16 ModelDesignImage2 19
Fig173DPrintingmachine 19
Fig18Modelprintingphase 20
Fig19Printedmodelview1 20
Fig20Printedmodelview2 21
1.0Wit
rep
piec
pro
in t
Avi
bek
Aco
Fig
Bar
The
75%
crea
typi
0 Introd
thin the ae
airingairc
ce of air c
cedureenf
the world
iationAdm
keptfor2y
ommonma
1 LBBCT
rG)
esemachin
%ofairfram
ate an arti
ical tempe
duction
erospace in
craftcompo
craft equip
forcedand
. “Europea
ministration
yearsonev
achineused
Thermocla
nesareuse
mecompon
ificial contr
erature soa
ndustry va
onentsthro
pment car
regulated
an Aviatio
n(FAA)”. T
verypartfo
dwithinthe
ave(25m
ed for curin
nentstoday
rolled envi
ak at 178C
6
arious mac
oughoutth
rries a ver
byatleast
on Safety
Theseregu
ortractabili
eaerospac
long, 4m
ng carbon
y.Thermoc
ironment,
C is requi
chines are
eworld.A
ry strict m
toneofthe
Agency (E
ulationssti
ity.
eIndustry
m diamete
fibre comp
clave’sare
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red for 5
used for p
Anyworkca
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emajorgov
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pulatethat
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r, Max 30
ponentswh
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producing
arriedout
ing inspec
verningbo
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trecordsm
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hichmakes
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and
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12
sup
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re a
e of
6.9B
thes
Eac
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ther
The
The
The
sock
Fig
Typ
and
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BarG.ATh
seandreco
chsectiono
orded eve
rmocouple
ermoclave.
ermoclaves
e areawhic
ketconnec
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hermoclave
ordthepro
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eisdesigne
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econds thr
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etheTherm
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7
edspecifica
ghout.
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roughout
eproduct a
ouple tran
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oupleconn
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allytocrea
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nsitions ar
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rnative des
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eshownin
rmocouple
ateenviron
mperatureu
ss, to do
ed in to the
re sealed
.
sign is the
Fig1,whi
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nmentssuc
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o this sev
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ompanypo
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onstruction
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aretypeKs
nceofthese
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8
noftherm
adeupof6
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ocketassem
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supplierat
mocouplein
6socketsm
andhas2t
ringrod.
lusedforth
beenfitfor
mbliesona
theproces
tacostof£
nterfaceco
mountedin
thermocoup
heinsertsa
purposean
a6monthl
s.Every6
£75/setwh
onnection
analumin
pleinserts,
areNickel
ndfaultfre
lybasis,w
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hich20sets
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and
ee,it
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6. Newco
uationofC
withtheg
vices”
ticulture.tam
was inputte
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ssMapfor
mapfollowe
aterialsare
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merUsesco
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omponents
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omponentf
posedof
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9
Footprint
S2050“Ho
ty/hall/public
Germansof
ouplesock
ndardflow,
nfromsupp
warehous
enduser(C
for6month
(backtoste
t
owtoasses
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ftwarepack
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Customer)
hs
ep1)
ssthecarbo
2050_Guide.p
kagecalled
acture
onfootprin
dUmberto
ntof
and
10
Existing component was broken down and reverse engineered to find all the
materials used andmethods ofmanufacture. Each individual componentwas
weighedandcarbonfootprintofeachcomponentwaseithermatchedupinthe
databaseorfoundontheinternet.
Fig5 Materialspecificationsfor1component6wayplate
Material Weight(g) Amount TotalWeight(g)
NickelInsert 2 6 12
PlatinumInsert 2 6 12
InjectionMould 8 6 48
AluminiumPlate 131 1 131
BrassRod 1 1 1
TOTAL 204g
Anestimationof0.2Kwhofelectricityusageisrequiredtoassembleeach6way
plate.
Once all the informationwas collated, this could be entered into the Umberto
softwareandaprocessmapcouldbebuilt.
Fig
Um
asse
mix
mon
Fig
6Umbert
berto proc
emblyline,
x,thenship
nthsthend
7 Chart
toLayouto
cessmap fl
,thenelect
ppingphase
disposedof
tedresults
oforiginal
low, showi
tricalinput
etotheend
f.
sfromorig
11
product
ing the raw
talongwit
dcustomer
ginalprod
wmaterials
thsometra
r.Compon
duct
sbeenbro
ansportwa
nentswould
ought in to
asaddedto
dbeusedf
the
othe
for6
Fig
Fig
Out
The
0.48
Eac
20*
8 Mode
9 Summ
tcome from
ermocouple
8KgC02
chThermoc
*0.48=9.6
elInput/O
maryforo
m the Umb
epanelpro
claverequir
6CO2pers
Outputma
originalpro
erto carbo
oduced
res20pane
et
12
aterialsfor
oduct
on footprin
els
roriginalp
nt software
product
ewas that each 6 so
cket
13
Analysingtheresultssuggestedthat75%ofthecarbonfootprintwasmadeup
of the rawmaterials and over 20% in production, if these two area could be
reducedthenthecarbonfootprintofthisproductcouldbereducedsignificantly
14
3.0 ProductRe‐designUsing modern manufacturing techniques it would be possible to manufacture
thiscomponentmoreefficientlyandwithareducedcarbonfootprint.
Areatoresearch
1. Materialsused
a. Candifferentmaterialsbeused
2. Materialprocurement
a. Canmaterialsbesourcedlocally
3. Assembly
a. Canassemblybereduced
4. Transport
a. Cantheweightbereduced
b. Candistanceoftransportbereduced
5. Waste
a. Canmoreenvironmentallyfriendlymaterialsbeused
Firstly the component ismade up from several parts but really the only parts
thatneedtoexistarethethermocoupleinserts,therestoftheassemblycouldbe
madeas1piece. Soby identifyingwhatparts couldbemade into1pieceand
sourcinganalternativematerialthatwouldbefitforpurposeanewmateriallist
couldbeproduced.
Fig10Materialspecificationfor1re‐designed6waythermocoupleplate
Material Weight(g) Amount TotalWeight(g)
NickelInsert 2 6 12
PlatinumInsert 2 6 12
PrintedInterface 50 1 50
TOTAL 74g
Lab
0.1
Fig
Um
mat
Fig
bourtimen
Kwhofele
11Umber
bertoproc
terialsand
12 Chart
nowforass
ectricityusa
rtoLayout
cessmapsh
differentm
tedresults
semblywa
ageisnow
tofre‐desi
howingthe
manufactur
sfromre‐d
15
asreduced
required
ignedprod
enewflow
ringenergy
designedp
by50%an
duct
wwithalter
yinputs
product
ndisnowe
rnativeand
estimated
dreduced
that
raw
Fig
Fig
13 Mode
14 Summ
elInput/O
maryforr
Outputma
e‐designed
16
aterialsfor
dproduct
rre‐designnedproduuct
17
Measured outcome from the Umberto carbon footprint software with the re‐
designeddatainputtedwasthateach6socketThermocouplepanelproduced
0.14KgC02
EachThermoclaverequires20panels
20*0.48=2.8CO2perset
After the re‐design of the component, a saving on the carbon foot print was
reducedby
9.6–2.8=6.8CO2perset
Whichisareductionof71%
4.0Afte
des
Thi
“Sol
Max
Fig
0 Manu
er analysin
ignedprod
s start wi
lidworks”
x”wasused
15Model
ufacturing
ng the out
ductcanbe
ith using a
or “3dsMa
d.
DesignIm
g
tcome of t
processed
a 3D draw
ax” todeve
mage1
18
the Umber
d.
wing packa
elop them
rto model,
age such
model comp
a prototy
as “Autode
ponent. In
ype of the
esk Invent
this case “
re‐
tor”,
“3ds
Fig
On
Fig
16Model
completion
173DPri
DesignIm
nofthemo
ntingmac
mage2
odeltheima
hine
19
ageisloade
edintoa3D
Dprintingm
machine
Pro
Fig
On
Fig
ocesswasse
18Model
completion
19Printe
etrunning
printingp
n,themode
dmodelvi
andtimeta
phase
elwasremo
iew1
20
akentocre
ovedando
eatethenew
outcomeas
wmodelw
shown
was5hours
Fig
Thi
20Printe
sprototype
dmodelvi
ewassucce
iew2
essfulandf
21
fulfilledallcriteria.
22
5.0 Conclusion
Aims of this task were to take an existing product and calculate its carbon
footprintduringmanufacture.Thenbyreverseengineeringandre‐designingthe
productusingPAS2050inanattempttoreducetheproductcarbonfootprint.
Fromtheresultsithasbeenprovedthatasavingof71%ofthecarbonfootprint
hasbeensavedonthisproductbyusingalternativematerialsandcreatingiton
onepiecetoreduceassemblytime.
