1. P10229: Composites Autoclave Brian Cario: ME Matt Brady: ME Matt DiFrancesco: ME Brandon Allen: EE John Mink: EE

2. 2 Detailed Design Review Agenda Project Background Project Objectives Functional Risk Mitigation Pressure Vessel Design Stand Design Structural Finite Element Analysis RG&E Pressure Vessel Proposal Heating and Circulation Design Insulation Finite Element Analysis Plumbing and Pressurization Design Electrical Design Controls and Software Design Budget and Bill of Materials Preliminary Test Plan Next Steps Desired outcome: approve final design raise awareness of funding situation

3. 3 Background: Purpose of an Autoclave Device for Curing Components Made of Composite Materials Under Heat and Pressure High-Strength, Low Mass Very Low Void Ratio 10x Wet Layup Image Courtesy directindustry.com

4. 4 Project Objectives Senior Design 1Senior Design 2 TasksConcept Generation and Selection Complete Pressure Vessel Construction Detailed Design, Ready for Construction Test Pressure Vessel Spec Stock PartsFinal Assembly Test Autoclave DeliverablesComplete Autoclave DesignComplete, Operable Autoclave Partially Built Pressure VesselManual for Operation Some Parts Obtained

5. IDRisk ItemEffectCauseLikelihoodSeverityImportanceAction to Minimize RiskOwner Describe the risk briefly What is the effect on any or all of the project deliverables if the cause actually happens? What are the possible cause(s) of this risk? 1 to 5 L*S What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring? Who is responsible for following through on mitigation? 1Inadequate BudgetEnd product will be incompleteInitial estimated cost is insufficient5525 Leverage other groups, colleges, departments for extra support Deliver product with reduced functionality Entire Team 8 Autoclave releases too much heat into the surrounding room Surrounding room will get too warm for occupants to safely work Inaccurate insulation calculations and research 248 Complete a thorough heat analysis with Pro E, ensure that external temperature remains below 125F Matt D. Surface of vessel might cause injury if touched 9 Door is not completely fastened to the vessel during operation Pressure will be lost from vessel Improper fastening of door3412 Clear instructions on proper closure and fastening of door. Team Air from room may be replaced with HOT N2 Gas Sensor system for detecting improper closure which will prevent operation if improperly closed 10Autoclave requires too much power to heat Heating system will not be able to function as needed Excess heat loss into vessel and surroundings 4520 Explore alternatives for vessel design to minimize heat loss Matt D. Try adding some insulation to inside of vessel 11Autoclave experiences overpressure Pressure vessel structure is compromisedMechanical failure of inlet valve 122 Add blow-off valve to vessel Matt B. Potential danger to room occupantsSoftware failureSet inlet regulator to max desired pressure 12Autoclave experiences over Temperature Damage to pressure vesselExcess current draw248Current-limiting fuseBrandon Damage to workpiece(s) Thermocouple failure248Have multiple thermocouples within vesselJohn/Brandon Software failure155Have thermal fuse (450-500F) within circuitBrandon 13Circulation motor fails Uniform temperature is not maintained withing vessel Mechanical failure133 Multiple air thermocouples to detect non-uniform air temperature, with software to turn off system Matt D. Damage to workpiece(s) 14Autoclave is unstable Personnel injury Weight of pressure vessel 248Design wide, low standBrian Vessel damage High Center of Gravity Bulding damage

6. Controls Flowchart

7. User Interface Screenshots

8. Circuit Diagram

9. Stand Design

10. Pressure Vessel Model

11. Pressure Vessel FEA Model

13. Structural FEA Summary

15. FEA Summary ComponentMax Stress (psi)MaterialYield Strength (psi)Factor of Safty Pressure Vessel (@150 psi)11547.9API 5L X42 Steel Pipe420003.64 Rear End Cap (@150 psi)5557.84Plain Carbon Steel320005.76 Front Door (@150 psi)9418.75Plain Carbon Steel320003.40 Front Door Hinge7620.28A36 Carbon Steel360004.72 Front Door Hinge Pin6430.97A36 Carbon Steel360005.60 Tank Flanges (@150 psi)3258.99Plain Carbon Steel320009.82 Tank Support Straps7763.87A36 Carbon Steel360004.64 Vertical Stand Supports519.81A36 Carbon Steel3600069.26 Horizontal Stand Supports1460.53A36 Carbon Steel3600024.65 Flange Bolts32971.8Grade 8 (1.25" Diameter)12000036.39 Based on bolt torque of 650 ft-lbf per RGE specification

16. Heating and Circulation

18. Insulation FEA- External Only 94 lbf/(in-s) = 67kW

19. Insulation FEA-Internal Added 15.2 lbf/(in-s) = 8.6 kW

20. Steady State Surface Temp Outer Surface Temp: 80-110°F

21. Steady State Heat Flux 0.425 lbf/(in-s) = 385W

22. Plumbing Schematic

23. Facilities Validation Proposed location: composites lab 230V 3-phase power supply available in lab Met with Neil Kromer (building 78 manager) on 2-5-10, no foreseeable problems with installation

24. RG&E Proposal

25. Funding Commitments to Date $2000 – ME Department $1500 – MET Department $500 – BAJA Team

26. Bill Of Materials Part I Electrical DescriptionPart NumberSourceQuantityUnit PriceTotal Price High Temperature WireTBDGoodman's50' roll$27.50/50ft$27.50 Back Panel (22”x22”)N/APlastics Lab9Free DC RelaysN/APlastics Lab3Free Din-rail/TerminalsN/APlastics Lab9Free High Current Bulkhead Connector1575Pave Technology Co1$90.00 9 #22AWG Bulkhead Connector1588Pave Technology Co2$115.00$230.00 Thermistor502JH1kUS Sensor5$10.00$50.00 3-Phase 45A RelayGA312D45ZCrouzet1$132.29 22 AWG Red Wire22awgRedChrome Glow50ft$0.25/ft$12.50 22 AWG Black Wire22awgBlackChrome Glow50ft$0.25/ft$12.50 3-Phase 240V Safety Switch7524K22McMaster1$83.89 Subsystem Total$638.68 Pressure Vessel and Stand DescriptionPart NumberSourceQuantityUnit PriceTotal Price 2" x 2" x 1/4" (48" length) A36 HR Angle SteelN/ARochester Steel and Surplus13$9.00/ Section$117.00 24" x 48" (3/16 thick) A36 HR Sheet SteelN/ARochester Steel and Surplus1$45.00 Titan 6" Casters with full brake5500398Tractor Supply4$29.99$119.96 1.25" x 1' A36 HR Steel BarR12Metals Depot1$12.01 Rust-Oleum Hammer Black Paint170995Lowes2$14.98 /qt$29.96 5/16 - 18 x 1" Hex Bolts48872Lowes1$3.18 /25$3.18 5/16 - 18 Hex Nuts40958Lowes1$4.51 /25$4.51 2' x 2' x 1/2" A36 Steel PlateP112Metals Depot1$125.76 2' x 8' x 3/64" 3003 Aluminum SheetS3040Metals Depot3$40.96$122.88 1/8" x 1/8" Aluminum Rivet45309Lowes1$4.94 /100$4.94 Tested RG&E Vessel Parts and Labor-RG&E1$3,700.00 Includes ~$2500 in parts Gas Cylinder Clamp2283T12McMaster1$40.12 Mesh for Part Rack9243T381McMaster1$59.02 Door Hinge Bushing2938T62McMaster2$4.65$9.30 Door O-Ring9396K418McMaster2$22.91$45.82 Subsystem Total$4,439.46

27. Controls DescriptionPart NumberSourceQuantityUnit PriceTotal Price Pressure TransducerPX91N0-10KSVOmega1 $860.00 Standard Power Supply iDRN-PS-1000Omega1 $150.00 3-Phase Circuit BreakerQO340Schneider-Electric1 $240.00 Relay 501-00010 MPJA1 $19.95 ComputerEL1600-01eMachines1 $229.99 DAQNI USB-600National Instruments1 $169.00 Subsystem Total$1,668.94 Pressurization DescriptionPart NumberSourceQuantityUnit PriceTotal Price Nitrogen Regulator7897A12McMaster1$137.88 Inlet Solenoid Valve10M61Magnatrol2$153.00$306.00 Blow-off Valve4673K71McMaster1$104.23 36" Nitrogen Inlet Hose5676T846McMaster1$66.39 1.5"x3/8" Pipe Bushing4638K575McMaster1$5.13 6 feet 3/4" Copper Tube8967K8McMaster1$25.27 3/4" NPT Compression Fitting5272K294McMaster1$11.85 3/8" MxF Stainless Braided Hose5676T342McMaster1$41.26 3/4" x 3/8" Reducing Tee44605K468McMaster1$4.25 3/4" NPT Nipple7736K114McMaster1$13.47 2"x3/4" Pipe Bushing44605K295McMaster1$6.53 3/8" Pipe Nipple7727K162McMaster2$3.47$6.94 1-200psi hi-temp Pressure Gauge4010K116McMaster1$108.58 3/8" Pipe Tee44605K402McMaster2$6.09$12.18 1.5" Pipe Elbow MxF44605K138McMaster1$7.11 Subsystem Total$857.07 Heating, Circulation, and Insulation DescriptionPart NumberSourceQuantityUnit PriceTotal Price Mineral Wool Insulation, 2"x2'x4' qty. 6N/AATS Acoustics3$34.00$102.00 4kW Straight Incoloy tubular heating elementsTHE04061Tempco3$131.05$393.15 bulkhead connectors for heating elements?Tempco3$34.95$104.85 5-blade fan, 1000CFM, CW rotation2UJU3Grainger1$19.71 1/50 HP 115VAC Motor for fan58459Drill Spot1$38.46 5/16" shaft seal13125K76McMaster1$20.13 3/8" flanged bearing for fan shaft9440T18McMaster1$1.56 1"OD,.5"ID steel tube for fan shaft supportT21250Metals Depot1ft$9.01 3/8" 1018 steel rodR238Metals Depot2ft$2.46 1/4" shaft coupler6412K11McMaster1$5.44 Galvanized steel plug for blower shaft mount7739K188McMaster1$6.00 1x3x11ga. Steel Tube for motor mountT13111Metals Depot2ft$6.96 11 gage steel sheet for heating element mountsS111Metals Depot1ftx2ft$21.40 Subsystem Total$731.13 Autoclave Total$8,335.28

28. Funding Options Current funds: $4000: Pressure Vessel, Incomplete Stand, Completely designed system $4500: Complete Pressure Vessel and Complete Stand $6000: Complete Pressure Vessel, Stand, Heating System, and Pressurization System $8500: Complete Autoclave as Designed Design will have all the basic functionality of commercial unit at 1/10 the cost

29. Preliminary Test Plan Pressure Vessel: Hydrostatically Tested by RGE Heating: Physically Tested at ambient Pressure Electrical: Simulated then Physically Tested as a system Controls: Extensive Simulation then Physically Tested Pressurization: Physically Tested to ensure safety Detailed Test Matrices to Follow in MSD 2

30. Next Steps Determine level of funding and resulting functionality – By 2-24-10 Meet with funding sources to discuss options Investigate MSD II Deliverable options Order custom and long-lead-time parts based on funding Commission RGE to begin Vessel Fabrication Begin Fabrication of Stand, Hinge, and Blower Parts as funding permits