Problem The current device is too heavy and bulky. Due to this fact, it is not portable enough for the Electrodynamic employees. Workers are unable to carry the racks back and borth and load them in and out of the oven without the risk of injury. The rack still needs to fit all the size and temperature constraints.
Design Statement Design and test a lighter, durable, cost, and work effective test rack that is easy to handle and store.
Constraints The distances between the units in the fixture must be maintained in order to allow the largest and the smallest flange configurations to load side by side. Non-Magnetic materials with the exception of hardware must be used in the fixture configuration. Test Panel: Size: 20” Wide X 21” Deep X 4” Height (With component installed) / Equivalent to TN-2588 Orientation: Units to be inserted into fixture in a vertical orientation. The holding fixture shall be horizontal when used in testing. Fixture shall accommodate for two (2) handle lift and carry
Observations This object is used for Electrodynamics employees to test the counters they distribute. Both the counters and the test rack need to be able to withstand extreme temperatures and still function properly, and during this testing the counters are placed on the test rack.
Statistics Compared to the previous design, our design ways about two pounds less. It
Decision Matrix Size Design Functionality Weight Construction Effectivenes Ideas s Totals Phenolic 3 3 3 1 3 13 with solid front Phenolic 3 3 4 4 3 17 with bars Phenolic 3 3 2 1 3 12 with bars and handles on the sides
Standards for the Matrix Size Constraints 1. Test rack does not and will not fit all the size constraints given by the engineers from Electrodynamics. 2. Test rack does not fit all the size constraints given, but could be easily modified to do so. 3. Test rack fits all the size constraints given by the engineers from Electrodynamics. Functionality (Temperature and Magnetic constraints) 1. Due to one or more of the materials, the test rack will not be able to last through one cycle of testing or will provide inaccurate data because of magnets. 2. All the materials will be able to withstand the conditions of the testing environment and will not provide inaccurate data, but they may deteriorate during storage. 3. All the materials used will be able to withstand the conditions of the testing environment, won’t deteriorate during storage, and will not provide inaccurate data. Weight 1. The test rack exceeds the weight of the original. 2. The test rack is the same weight as the original. 3. The test rack reduces the weight of the original by a marginal amount. (1/2 – 2 lbs.) 4. The test rack significantly reduces the weight of the original. (More than 2 lbs.) Design Effectiveness 1. The test rack can’t be transported, filled, or stored easily. 2. The test rack can only do one of the following things easily: transported, filled, stored. 3. The test rack can only do two of the following things easily: transported, filled, stored. 4. The test rack can be transported, filled, AND stored easily. Construction 1. The test rack can’t be reasonably constructed because of the basic design. 2. The test rack design is reasonable, but can’t be constructed with the given materials. (i.e. metals won’t shape the way you want) 3. Both the test rack design and the chosen materials allow for reasonable construction.
Caculations AChoosing a material These are 3 options that can all be used in the testing conditions. The main concern is weight. Calculations using the dimensions of the original horizontal bar: 42.5cm x 2.5cm x .5cm = 53.125 cm cubed ORIGINAL ALUMINUM 53.125 cm. cubed X 2.70 g/cm cubed (density of aluminum) X 1 lb/453g = .317 lbs per bar .317 lbs X 9 bars = 2.85 lbs total PHENOLIC LAMINATED SHEETS best material to use-lightest and still durable and fits temperature constraints 53.125 cm. cubed X 1.40 g/cm cubed (density of phenolic) X 1 lb/453g = .164 lbs per bar .164 lbs X 9 bars = 1.47 lbs total GAROLITE 53.125 cm. cubed X 1.73 g/cm cubed (density of phenolic) X 1 lb/453g = .203 lbs per bar .203 lbs X 9 bars = 1.83 lbs total