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The Leader in Lightweight Technology

The Leader in Lightweight Technology. Consolidated Metco. Annual Sales FY2002: $238 Million Employees: 1,157 Headquarters: Portland, Oregon History Company roots are in the truck business… Started by Consolidated Freightways-1964 Freightliner/Daimler Benz 1981 LBO-1987 Varlen -1989

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The Leader in Lightweight Technology

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  1. The Leader in Lightweight Technology

  2. Consolidated Metco • Annual Sales FY2002: $238 Million • Employees: 1,157 • Headquarters: Portland, Oregon • History • Company roots are in the truck business… Started by Consolidated Freightways-1964 • Freightliner/Daimler Benz 1981 • LBO-1987 • Varlen -1989 • Amsted-1999 • ESOP Company with 9 Operating Companies/ $2.1B Sales • 50% Ownership in Maxion Brazil (Steel Foundry/ Fifth Wheel)

  3. D B AIMLER ENZ

  4. Manufacturing Locations Clackamas,OR 180 Employees 65,000 sq. ft. St. Thomas,Ontario Canada 10 Employees 10,000 sq. ft. Portland, OR 200 Employees 166,000 sq. ft. Etowah, TN 10 Employees 60,000 sq. ft. Monroe, NC 350 Employees 300,000 sq. ft. Bryson City, NC 165 Employees 182,000 sq. ft. Cashiers, NC 165 Employees 96,000 sq. ft. Monterrey, Mexico 150 Employees 68,000 sq. ft.

  5. Recognized Quality Supplier Eaton CorporationQuality First PACCAR Preferred Supplier FreightlinerMasters of Quality Daimler BenzVDA Approved Meritor PreferredSupplier Honeywell Preferred Supplier TS 16949 Monroe, Etowah, Clackamas, Rivergate, Bryson City, Cashiers Approved

  6. The Leader In Lightweight Technology

  7. Major Processes & Products • Aluminum • Semi-permanent Mold • Low Pressure • Die Casting • Machining and Assembly • Hubs • Fifth Wheels • Castings • Fuel Water Separators • Plastics • Structural Foam • Gas Assist • Injection Molding • Thermoforming

  8. Hubs

  9. Brake Drums

  10. Plastics

  11. Die Castings

  12. Permanent Mold Castings

  13. Simplex Fifth Wheels

  14. Fifth Wheel • Approximately 26,000 units sold per year (15% market share) • Standard at Freightliner, Volvo, Mack • Two models: Simplex & Simplex II • Over 60% of units are sliders • Product development includes two new slider models • Production located in Monroe, NC • Testing and development in Portland, OR

  15. Simplex Fifth Wheels Simplex Simplex II Standard with a left hand, straight pull release Optional Touchloc pneumatic unlocking system Vertical Load Capacity: 50,000 lbs Trailing Load Capacity: 150,000 lbs Vertical Load Capacity: 70,000 lbs Trailing Load Capacity: 200,000 lbs

  16. ConMet Test CenterCapabilities • Rotating Bending Hub Fatigue Testing • Seal Abrasion Testing • Fifth Wheel Vertical and Fore/Aft fatigue testing • Fifth Wheel Ultimate Rollover Testing • Component Fatigue Testing

  17. Hub Fatigue Testing

  18. Seal Abrasion Testing

  19. Fifth Wheel Fatigue Testing

  20. Fifth Wheel Rollover Ultimate Test

  21. Rollover Ultimate TestResults

  22. Why we test our Fifth Wheels

  23. Capstone Project Outline • The purpose of this project is to conceptualize, analyze, design and build a test fixture for testing the ultimate strength of heavy truck fifth wheels in the draw bar load case.   • This project will incorporate all elements used in Mechanical Engineering from design, analysis (FEA), prototyping (working with local machine designers), and data acquisition.

  24. Drawbar Load Case Defined Fdrawbar = 150K to 200k

  25. Drawbar Load Case

  26. Capstone Project Outline • Conceptualize and Brainstorm design ideas • Paper design chosen design • Model and Analyze design with Solid Modeling & FEA • Perform prototyping (using local vendors) • Assemble and build Drawbar Tester (ConMet test lab) • Test the machine for proper functionality • Perform destructive test and collect results • Write report • Perform presentation

  27. Questions?

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