1. 1 Composite Generator Enclosure PROJECT 99.12 New Castle Design Associates

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 diesel engine 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 Metrics and Target Values Years of Exposure10 yrs / 3000 hrs Tg350F / 800F Weight15 lbs Cost$200 Sound Level35 dBA reduction Drop Test4 ft Stackable5 units high Time to Access10 min Time to Start1 min

7. 7 System Benchmarking Open Tubular Frame Westerbeke Clamshell Enclosure Honda Super Quiet Generators Fisher Panda Generators Previous UD NCDA Enclosure

8. 8 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

9. 9 Functional Benchmarking Sound Suppression Accessibility Ventilation/Heat Rejection Stackable Rolling Carrying Weather Exposure Ease of Starting

10. 10 Physical Model Testing 1 Sound Testing Temperature Testing Unenclosed/ Enclosed Load/ No Load Enclosed Forced Convection

11. 11 Physical Model Testing 2 The Equipment Sound Test

12. 12 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

13. 13 Concept #1 6 removable access panels Advantages Easy Access Disadvantages Not Structurally Sound “Hand Buggy” Style Advantages Easy to Use Outdoors Disadvantages Increases Height

14. 14 Concept #2 “Clam Shell” Design Advantages Easy Access Disadvantages Large Stress Concentrations 4 Dolly wheels Advantages Easy to Roll on Smooth Floors Disadvantages Difficult to Use Outdoors

15. 15 Concept #3 Sliding Side Door Access Advantages Easy to Use Disadvantages Limited Access Multiple roller wheels Advantages Easy to Use on Smooth Floor Disadvantages Difficult to Use Outdoors

16. 16 Concept #4 2 Piece Shell Access Advantages Easy to Use Disadvantages High Stress on Latches

17. 17 Final 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, Foam Core

18. 18 Final Concept Hinged Starting Panel Removable Top Panel Recessed Wheel Multiple Handles

19. 19 Schedule

20. 20 Budget To Date: Materials: ………………………...$20.00 Miscellaneous:…………………....$60.00 Predicted: Materials:………………………..$580.00 Miscellaneous:…………………....$45.00 Total Spent:……………………...$705.00 Total Remaining:……………….$2045.00

21. 21 Est. Engineering & Shop Hours Build Mold……………………………120 Make Enclosure………………………..80 Testing…………………………………40 Reevaluate/Redesign…………………160

22. 22 Conclusion Present Design Future Work FEA Build & Test Prototype