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Composite Generator Enclosure

Composite Generator Enclosure. PROJECT 99.12 New Castle Design Associates. Team 12. Composite Generator Enclosure. Members:. Justin Schaffer Tom Winward Noel Goldstein Jeremy Freeman. Customer:. Center for Composite Materials. Advisor:. Dr. Michael Keefe. Mission:.

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Composite Generator Enclosure

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  1. Composite Generator Enclosure PROJECT 99.12 New Castle Design Associates

  2. Team 12 Composite Generator Enclosure Members: • Justin Schaffer • Tom Winward • Noel Goldstein • Jeremy Freeman • Customer: Center for Composite Materials • Advisor: Dr. Michael Keefe • Mission: It is our goal to design and construct a prototype portable generator enclosure made from composite materials that successfully satisfies all the wants and constraints defined by our customers, and to have a prototype built by April 1999. • Approach: We will first identify customers and their wants. We will also attempt to find all current technology in use for sound reduction and in the area of composites. Then concepts will be developed based on the information gained during our benchmarking. The best design will be determined by comparing our concepts with customer wants and constraints. Next we will begin a process of prototype design and evaluation, culminating with the production of a prototype part. This prototype is then to be further developed by CCM to fit the D Star generator.

  3. Background • Army needs portable generator for use in remote locations • D-Star Engineering designing lightweight diesel engine • Team 12 to design a prototype enclosure • CCM to finish development for pre-production model

  4. Changes in Objective Design a proof of concept prototype • Must fit currently available generator • Must be adaptable to fit D-Star’s design • Must meet operating constraints predicted for D-Star generator design

  5. Problem • Lower noise level • Increased portability • Increased durability The generators currently available need the following modifications:

  6. Customers • D-Star Engineering • U.S. Army • New Castle Design Associates • Safety Organization (NFPA) • Army Soldier • Home Owners • Construction Industry • Outdoor Entertainment • RV Owners • Emergency Services

  7. Will not break Thermally Stable Quiet Portable Stackable Ease of Operation Longevity Ease of Maintenance Cost Prioritized Wants

  8. Constraints • Maximum Size • Maximum Weight • Primary Materials • 15”x16”x30” • 25 LBS • Composites

  9. Metrics • Years of Exposure • Glass Transition Temperature • Weight • Cost • Sound Level • Drop Test • Stackable • Time to Access • Time to Start

  10. System Benchmarking • Open Tubular Frame • Westerbeke Clamshell Enclosure • Honda Super Quiet Generators • Fisher Panda Generators • Previous UD NCDA Enclosure

  11. System Level Best Practices • Years of Exposure Painted Metal • Tg N/A • Weight Open Frame • Cost Open Frame • Sound Level Enclosed Box • Drop Test ? • Stackable N/A • Time to Access Open Frame • Time to Start Electric Start

  12. Functional Benchmarking • Sound Suppression • Accessibility • Ventilation/Heat Rejection • Stackable • Rolling • Carrying • Weather Exposure • Ease of Starting

  13. Target Values for Metrics • Years of Exposure 10 yrs / 3000 hrs • Tg 350F / 800F • Weight 15 lbs • Cost $200 • Sound Level 35 dBA reduction • Drop Test 4 ft • Stackable 5 units high • Time to Access 10 min • Time to Start 1 min

  14. Concept #1 • 6 removable access panels • “Hand Buggy” style

  15. Concept #2 • 4 Dolly wheels • “Clam Shell” access

  16. Concept #3 • Multiple roller wheels • Sliding Side Door Access

  17. Concept #1: Concept #2: Concept #3: Initial Concept Evaluation • One Person • All-around Access • Two Person • Complete top access • Side access • Easy to Roll around OTHER AREAS OF FUTURE ANALYSIS Structural Evaluation (Finite Element Analysis) Detailed Vent/ Louver Design (Air Flow/ Acoustical Study)

  18. ACTUAL TO DATE Schedule 1

  19. DETAILED TO NEXT PRESENTATION Schedule 2

  20. Budget • Materials: ……………………….$500.00 • Tools: ………………………….$1000.00 • Travel: ………………………….$250.00 • Miscellaneous:. .……………….$1000.00

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