End of DPM Presentation P08405—Novel Materials Technology Matthew Wavrek (ME)

Concept Level Project Plan Project Name Novel Materials Technology Project Number P08405 Project Family Sustainable Technologies for the Third World Track Sustainable products, systems, and technologies Start Term 2007-2 for Senior Design I End Term 2007-3 for Senior Design II Faculty Guide Dr. Benjamin Varela (ME) is confirmed Faculty Consultant Dr. Hany Ghoneim (ME) is my choice Dr. Vincent Amuso (EE) is my choice Primary Customer Dr. Ben Varela is confirmed

Mission Statement Product Description Key Business Goals The product being developed for this Senior Design project is an environmental chamber. The chamber will have to be able to sustain a static environment. At minimum, a constant vacuum and temperature regulation system will be employed by the chamber. This chamber will be used to test composite materials, foams, and other materials under development by Dr. Varela and Dr. Ghoneim. Key Business Goals The primary business goals of this product are to: provide a medium to test materials under development for Third World applications. Materials are being developed to make costs of construction and assembly in the Third World more affordable. These materials could help build up Third World economies and increase the quality of life there. Primary Market The primary market for this product is the RIT mechanical engineering department and its materials research faculty. This is a special product, a cheaper and more customizable version of current industry products, for creating a static environment to test materials under research. Secondary Market Secondary markets for this product may include future manufacturers and contractors associated with the research of Dr. Varela and Dr. Ghoneim. Another possibility for a secondary market is other small testing labs or universities who could benefit from having a static environment test chamber. Stakeholders End users-Dr. Varela and Dr. Ghonheim Suppliers-Companies that manufacture components and materials Manufacturers-RIT SD Team, RIT Students-future use in materials classes/research RIT ME Dept.-new lab and research equipment Third World countries-will use developed materials and technology

Staffing Requirements Name Discipline Role/Skills Ben Varela ME Dr. Ben Varela is the faculty guide on this project. As such, he will work closely with the team on an on-going basis to facilitate success and monitor progress. In addition to these roles, Dr. Varela will also provide aero-gel technical and testing information as well as make recommendations on the project progress and methods. Hany Ghoneim Dr. Ghoneim is one of the faculty consultants on this project. He will provide ME discipline technical support and composites related testing information so that the group may become more familiar with composites design and applications. Dr. Ghoneim will also be a resource for FEA analysis recommendations and expertise. Matthew Wavrek I am the project lead engineer for this project. The first ME student on this project will be responsible for the CAD modeling and part layouts for the project. It will be their choice which software package to use, but Pro-Engineer will be the preferred program. This student will be responsible for updating the CAD files on the team website regularly. Forrest Svingala The second ME student for this project will select the chamber materials and components. Cost/Benefit analysis will be used to select the best possible materials and components for building the chamber. Analysis to ensure part compatibility and longevity will also be performed. Rich Arlotta The last mechanical engineer will perform analysis and calculations to ensure smooth system operation. Strength, fluid flow, and stress calculations will be performed for the individual components of the system and at an overall system architecture level. Life cycle and loading scenarios will be looked at in conjunction with ME #2.

Staffing Requirements Continued TBD Student EE EE student number one will be responsible for the temperature and pressure regulation sensors in the system. Determining needed sensor characteristics will be the first responsibility of this student. Once specifications for sensors have been created, the student will choose the best sensors, available within budget, for the chamber application. Testing the sensors and integrating them into the system interface will be done with EE #2. The second project electrical engineer will design the system interface for integrating needed sensors into the testing apparatus. An interface will be created to link the power supply, vacuum pump, and chamber sensors together. This interface will most likely be a GUI done in LabView. The final EE will design a data logging and control system for the test chamber. This system will be tied into all chamber aspects: regulation of temperature and presure, recording of temperature and pressure sensor readings, and vacuum pump control/monitoring. This work may not be incorporated into the final product, but if not it will provide a base of operations for a follow-up senior design team. IE Integration of all necessary systems of the project into a final product will be the work of the IE on the team. Consulting on individual systems will be a crucial need if the IE is to have a broad knowledge of what is to be integrated and how it is to be integrated. Design for manufacture and Design for use knowledge will be provided by the IE as well as consulting for life cycle and other system based calculations for the team.

IP Considerations The work on this Senior Design project is for the betterment of aero-gels and composites research. Specific materials, applications, and designs are not integrated into the project goals. Therefore, all information gained by doing this project is not proprietary and will be openly shared in the public domain. The advancement of knowledge in these two fields in based upon the testing that the environmental chamber of this project will facilitate. **If specific research information or design concepts are conveyed to the team by Dr. Varela or Dr. Ghoneim; however, this information is expected to remain confidential.

Work Breakdown

Work Breakdown Continued

Work Breakdown Continued

Grading Scheme

Resources

Resources Continued

Customer Needs

Revised Customer Needs Key Needs Statements: *Chamber will be mobile *Chamber will sustain a vacuum *Chamber will be pressure regulated *Chamber will be temperature regulated *Chamber will conform to regulatory agency requirements *Chamber will be corrosion resistant *Chamber will be one cubic foot or less in size *Chamber will operate between -20 and 65 degrees Celsius Ideal Needs Statements: *An observation window is present in the chamber *Humidity regulation is present *Extended temperature range of -20 to 150 degrees Celsius is accomplished *An integrated control system allows operator to control temperature, pressure, and humidity as well as log data

Affinity Diagram

Metrics

Project Target Values

Risks Delayed delivery of vacuum pump Failure of chamber seals (sealing difficulties) Lack of available shop time Long time to integrate vacuum, power, and regulatory systems Best material for manufacturing chamber is too expensive Vacuum pump life cycle shortened due to harsh environment of operation (composite byproducts) Lack of enough EE students enrolled in SD1

Budget Breakdown First Estimate $8000 total project budget Vacuum pump--$4000 Chamber Materials--$1000 Sensors--$1000 Seals--$1000 Circuitry and controls--$1000 **Amounts are maximum percentage of budget

Background and Technical Research

What’s Next? Get a team together to pursue the project Sit down with team and guide/consultants to determine project objectives Adjust Scope of project to fit team profile Project will not be possible to do in full scope without all requested staffing (controls system and other parts will be follow on projects without enough EE’s)

End of Presentation ?