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

6. 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. 7 Prioritized Wants Will not break Thermally Stable Quiet Portable Stackable Ease of Operation Longevity Ease of Maintenance Cost

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

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

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

11. 11 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

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

13. 13 Target Values for Metrics 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

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

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

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

17. 17 Initial Concept Evaluation  Concept #1:  Concept #2:  Concept #3:  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. 18 Schedule 1  ACTUAL TO DATE

19. 19 Schedule 2  DETAILED TO NEXT PRESENTATION

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