P10229: Composites Autoclave

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

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 2

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 3 Image Courtesy directindustry.com

4. Senior Design 1 Senior Design 2 Tasks Concept Generation and Selection Complete Pressure Vessel Construction Detailed Design, Ready for Construction Test Pressure Vessel Spec Stock Parts Final Assembly Test Autoclave Deliverables Complete Autoclave Design Complete, Operable Autoclave Partially Built Pressure Vessel Manual for Operation Some Parts Obtained Project Objectives 4

5. Functional Level Risk Mitigation

6. Controls Flowchart

7. User Interface Screenshots

8. Circuit Diagram

9. Stand Design

10. Pressure Vessel Model

11. Pressure Vessel FEA Model

12. Pressure Vessel FEA Model

13. Structural FEA Summary

14. Structural FEA Summary

15. FEA Summary 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

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