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Team 3 Ron Capalbo Beth Keighley Brittany Russo Matthew Holt

Team 3 Ron Capalbo Beth Keighley Brittany Russo Matthew Holt. Sponsored by:. OUR SPONSOR. Primary Customer, in-house use ILC Dover designs & develops “ softgoods ” Spacesuits provide protection in environments non-conducive to human existence.

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Team 3 Ron Capalbo Beth Keighley Brittany Russo Matthew Holt

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  1. Team 3 Ron Capalbo Beth Keighley Brittany Russo Matthew Holt Sponsored by:

  2. OUR SPONSOR • Primary Customer, in-house use • ILC Dover designs & develops “softgoods” • Spacesuits provide protection in environments non-conducive to human existence. • No room for error  Continual Improvements in Technology LUNAR DUST TESTER • Global Problem: • Regolith (Lunar Dust) is harsh on current engineering materials • ILC Dover would like a means to test candidate spacesuit materials

  3. PROJECT SCOPE • Global Scope: To design & fabricate a fixture to apply specific mechanisms in a dust challenged environment to candidate spacesuit materials and assemblies to simulate activity during lunar outpost missions. • Team 3’s Scope: To design and fabricate a fixture that can apply impact & randomness in a sand & aggregate-challenged environment to representative materials (Goretex, Thinsulate, Coated Fabric, & Felt) that provides repeatable, qualitative & quantitative results In addition, Team 3’s duties include: • Develop Test Article Configuration • Develop Test Plan • Demonstrate Fixture & Results with ILC

  4. MECHANISMS Research & Discussion lead to… • Abrasion-fraying, ∆ thickness & appearance • Adsorption- ∆ in surface appearance, noticeable layer of deposited material • Impact- ∆ in appearance, thickness, texture • Penetration-how much one material breaches the barrier of another

  5. WANTS/NEEDS/CONSTRAINTS • Needs:Constrained By: • Low Cost $5,000 Maximum Budget • Repeatable Operator Independency Achieving Comparative Results • Relatively Compact Must Fit Comfortably on a Bench Top • Wants: • Simplistic Operation • Leak-Proof Operation • Worry-Free Manufacturability

  6. BENCHMARKING Tester ≈ 3’ Tall x 2.5’ Wide • RoTap in U of D Geology Dept. • Targets Impact and Adsorption • Preliminary Tests Conducted on Representative Materials To Verify Mechanism Occurrence Drum ≈ 24” long by 20” Diameter • Johnson Space Center TMG Tester • No Detailed Information • Hollow Drum-No variable Internal Geometries

  7. Metrics & Target Values

  8. CONCEPT GENERATION 1) Convertible Tumbler  sideways to upright position Pros: Targets Impact, Modifiable Cons: Relatively Long Setup Time Due to Change in Positioning 1 2)Upright drum: Employed pendulum motion & air circulator Pros: Circulates Particles in Random, Effective Manner w/ No Motion of Containment System Needed Cons: Expensive to Design b/c of Pendulum, Difficult to Find Circulator Compatible with Simulant (Highly Abrasive) 2 3) Sideways Tumbler with Interchangeable Drums Pros: Modifiability, Manufacturability, Repeatability, Lower Cost (No Custom Parts Needed) Cons: Hard To Validate Which Mechanism or Combination of Mechanisms Are Occurring 3

  9. CONCEPT SELECTION Synchronous Belt • Modifiable Tumbler • Simplistic Compared to Other Concepts Generated • Commercial Hardware w/ Minimal Lead Times • Operator Independent Design • Modifiability • Targets all 4 Mechanisms Separately or in Combination • Can Conduct Randomized Testing Allows “Real-Life” Simulation • Manufacturability • Commercial Hardware-Minimized Assembly Times Idler Arm (Not Pictured) Idler Shaft 1 HP Motor Bearings 80/20 Frame Wheels (x4) Drive Shaft (x2)

  10. FINAL MACHINE DESIGN: Details • Removable/Interchangeable Drum • Removable Window • Leak-Proof • 80/20Adjustable • Variable Speed Control • Shock/Vibration Resistant Leveling Supports • Idler Arm & Side Support Wheels • Final Cost $3680.00 • Bulk of Cost= Motor, Controller, Base Frame, & Geometry Materials

  11. FINAL CONCEPT: Analysis • A fatigue and bending analysis sized the main drive shaft at ¾” diameter. • The shaft deflection is only .007 in. • Sample Weight: Between 2 & 20 pounds. • Motor Rated for 1hp • The Maximum speed is 21RPM with speed reducer

  12. DRUM DESIGNS • The Randomizer Drum • Geometry: Drum with 3 Different Sized Internal Baffles • Allows the Material to Experience Differing Levels of All Mechanisms! • The Impact Drum • Geometry: 2 Parallel Planes Adhered to Walls of Drum • Carries the sample to the top of the drum, where it is then dropped to Achieve Impact Force

  13. PROOF-OF-CONCEPT TESTING • Hand Tests: Conducted to Compare w/ Tumbler Tests • Utilized a Force Sensor, 2 grain sizes of sand, 3 material masses, and 4 materials • Tumbler testing: 200 cycles, 3 masses, 3 speeds, 2 grain sizes, 4 materials

  14. Testing Results • Under same conditions, Tumbler Testing results matched those of Controlled Testing (Hand Tests) • Tumbler Test Trials w/ Equivalent Parameters Yielded Consistent Results • Working Curves Effects of Damage due to Parameter Variation • Motor Consistency • Specimen Mass Gain within 10% Error Bound.

  15. PATH FORWARDFUTURE DRUM DESIGN & TESTING IDEAS 1 • The Abrasion Drum • Geometry: circumscribed square within the drum • Allows sample to slide down each wall, maximizing friction force 2 • The Penetration Drum • Ridged inner ring all the way around drum • Creates vibratory cutting • FabricationControlled TestsComparative Damage Scale

  16. Thank youTeam 3Questions/Comments

  17. Appendix • Complete Metrics & Target Values

  18. Motor Sizing

  19. FINAL CONCEPT: Analysis Summary

  20. Mechanism Definitions • Abrasion: The wear or damage to a material caused by the repeated effects of sliding, scraping, or rubbing. It can be characterized by changes in the appearance, thickness, or texture of a material coating or the cutting and consequent fraying of material fibers. Damage is usually consistent over a large area with evidence of striations indicating direction(s) of motion. • Impact: The wear or damage caused by a single blow or the repeated effects of striking or colliding with a fabric surface. It can be characterized by changes in the appearance, thickness, or texture of a material coating or the cutting and consequent fraying of material fibers. Damage is usually limited to discrete locations within the area of impact(s). • Penetration: The piercing or passing into or through a fabric or enclosing mechanism. This can be characterized by observing how much material breaches the barrier of the material or enclosure. • Adsorption: The ability of a fabric to retain or accumulate material on the surface during and after exposure. This can be characterized by a change in the surface appearance or color of the fabric as well as an observable layer of material deposited on the surface.

  21. Test Materials Composition • Goretex- A waterproof, high-performance, breathable fabric made from polytetrafluoroethylene and other fluoropolymer products. Urethane coating and porous membranes make it impenetrable to liquid water. Tightly woven. • Thinsulate- A synthetic fine fiber used for thermal insulation purposes. Thinsulate fibers are much thinner compared to the polyester fiber competition. • Felt- Felt is a non-woven cloth and is made by matting, condensing, and pressing fibers. Felts are usually made from pure wool fibers. • Coated Fabric- A fabric with synthetic coating.

  22. Total Cost

  23. Working Curves

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