1. 1 New Castle Design Associates PROJECT 99.12

2. 2 Composite Generator Enclosure Team 12 Justin Schaffer Tom Winward Noel Goldstein Jeremy Freeman Members: Partner: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. 3 Background Army needs portable generator for use in remote locations D-Star Engineering designing lightweight, high power diesel generator Team 12 to design a prototype enclosure CCM to finish development for pre- production model

4. 4 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

5. 5 Wants and Constraints Will not break Thermally Stable Quiet Portable Stackable Ease of Operation Longevity Ease of Maintenance Cost  15” x 16” x 30”  25 LBS  Composites Maximum Size Maximum Weight Primary Materials Constraints Wants

6. 6 Benchmarking System Level Open Tubular Frame Westerbeke Clamshell Enclosure Honda Super Quiet Generators Fisher Panda Generators Previous UD NCDA Enclosure Functional Sound Suppression Accessibility Ventilation/Heat Rejection Stackable Rolling Carrying Weather Exposure Ease of Starting

7. 7 System Level Best Practices Years of ExposurePainted Metal T g N/A WeightOpen Frame CostOpen Frame Sound LevelEnclosed Box Drop Test? StackableN/A Time to AccessOpen Frame Time to StartElectric Start

8. 8 Metrics and Target Values Years of Exposure10 yrs / 3000 hrs Tg350F / 800F Weight25 lbs Cost$200 Sound Level60 dB / 65 dB max Drop Test4 ft Stackable5 units high Time to Access10 min Time to Start1 min

9. 9 Physical Model Testing 1 Sound Testing Temperature Testing Unenclosed/ Enclosed Generator Load/ No Load Enclosed Forced Convection

10. 10 Physical Model Testing 2...The Equipment Sound Test...

11. 11 Critical Concepts Stackable Access to interior Portable Quiet, Longevity, Cost, Will not break, Thermally stable  Rectangular  Panels (removable, hinged, sliding)  Handles, Wheels  Composite sandwich WantsConcepts

12. 12 Concepts 1 “Hand Buggy” Style with 6 removable access panels Advantages: Easy Access and Mobility Disadvantages: Not Structurally Sound “Clam Shell” Design with 4 Dolly wheels Advantages: Easy to Roll on smooth surfaces, Easy Access Disadvantages: Large Stress Concentrations

13. 13 Concepts 2 Multiple roller wheels and Sliding Side Door Access Advantages: Easy to Use Disadvantages: Limited Access and difficult outdoor mobility 2 Piece Shell Access Advantages: Easy to Use Disadvantages: High Stress on Latches

14. 14 Concept Selection Mobility Access Composite Structure  Hand Buggy Style with Additional Handle  Multiple Panels at Critical Locations  Ciba Resinfusion 8605 Epoxy, E-Glass and Kevlar Fibers, Phenolic Foam Core

15. 15 Phenolic Foam Core did not hold up structurally in initial sample tests Further research led to the testing of a Balsa Wood Core S.C.R.I.M.P. CIBA RESINFUSION 8607 Composite Structure Selection Kevlar 49 E-Glass Phenolic Closed Cell Foam Core Kevlar 49 E-Glass Balsa Wood Core

16. 16 Composite Lay Up 2 Samples made and tested with varying numbers of layers of fabric around balsa wood core 3 Point Bend TestDrop (Impact) Test Test Samples y Best Lay Up: 2 layers of Kevlar 49, and 2 layers of E Glass.

17. 17 Final Concept Hinged Starting Panel Removable Top Panel Recessed Wheels 3 Recessed Handles Kevlar 49 (2), Balsa Wood, E-Glass (2) Sandwich Structure

18. 18 Concept Testing 1 Sound Reduction: –Maximum 64.5 dB sound level in open parking lot, measured at 7m. Temperature: –160-170 o F inside Size: –15”x16”x30” Weight: –22 Pounds without louvers, handles and wheels (These will add approximately 8 pounds)

19. 19 Concept Testing 2 Drop Test: –4 ft. Off loading dock onto asphalt; sustained only minimal damage Access Time: –30 sec. to remove starting door, and replace –5 min. to remove top cover to access engine and replace Stackable: –Supported 400 pounds on top

20. 20 Prototype Budget Materials MOLD –Wood & Miscellaneous (including Bondo Body Filler, Paint, Sand Paper, Screws, etc…) SCRIMP –Ciba Resin –Kevlar –E Glass –Phenolic Foam –Balsa Wood –SCRIMP Materials (including Vacuum Bag, Tubing, Tacky Tape, Peel Ply, & Distribution Medium) OTHER –Film and Developing –Decibel Meter TOTAL Team Cost $ 399.68 $ 0.00 $ 105.00 $ 671.25 $ 181.30 $ 414.00 $ 167.51 $ 30.00 $ 1,998.74

21. 21 Est. Engineering & Shop Hours Fabrication: –Wooden Model...16 –Mold…………..400 –Test Panels……..60 –SCRIMP………200 –Finishing………..15 –Testing…………...6 TOTAL………..697 Research&Development: –Benchmarking..…….40 –Customers/Wants…..20 –Foam Core Design....40 –Balsa Core Design....70 –Shape………..……..65 –Mat’l Procurement…20 TOTAL………..….255

22. 22 Projected Production Costs Kevlar: E-Glass: Balsa Wood: Resin: 4 yards 3 yards 3 1/2 sheets 1 gallon $ 70.00 $ 16.11 $ 41.40 $ 73.93 Total: $ 201.44

23. 23 Conclusion Our final design has met and exceeded most wants and constraints placed by our customers. Areas for improvement include decreasing the weight and using a better method to lay-up the composite fabrics.