grp04_208_f15_final

Design of a Water Cooler
Objective: The objective of this project was to effectively design, model, and create drawings
for a 3-chambered drink cooler/jug which addresses various issues in today’s current models.
Design Requirements: The drink cooler should have the following attributes:
 3 vertical chambers – 1 designed for ice, 2 designed for liquid (different drinks)
 An internal design which allows complete emptying without tipping
 A drainage system which removes melted ice from ice chamber
 A separate chamber which catches melted water and can be emptied
 A manufacturing process and accompanied marketing scheme which would coincide to
meet consumer demand.
Design Solution: The drink cooler is designed around a complex internal structure which forms
the three chambers required. The cylindrical internal volume contains three vertical dividers
which separate it into three primary compartments. The compartments are unequally spaced,
though, allotting 25% of the volume to the ice chamber and 37.5% of the volume to each of the
liquid chambers. This set-up is best described by the simplified representation (top view) of the
internal structure shown in Figure 1 below.
Figure 1 - Simplified Top View of Internal Structure
The bottom surface of each chamber is structured in a way which directs liquid toward the spout
to avoid the need to tip the jug to empty it. This was accomplished using three separate parts for
the respective chambers. The bottom plates of the drink chambers feature a “v-shaped” contour
to direct liquid. The bottom plate of the ice chamber is sloped to direct ice toward the ice door.
The bottom plate of the ice chamber also features numerous holes which drain melted ice.
Because of the shape of the bottom plate, the cooler is required to have space underneath the

bottom plates in order to maintain cylindrical shape. Our design makes use of this space as a
drainage chamber, holding water which has drained in from the ice chamber. A threaded stopper
plugs the drainage hole located in the bottom of the cooler. The drainage system is shown below
in Figure 2.
Figure 2 - Drainage System
Due to the complicated nature of the internal structure of our design, the project was
forced to take a unique position on manufacturing and marketability. The only way to adequately
manufacture the inner workings of this cooler would be by welding together stamped and formed
sheet metal. The sports drink cooler would then be marketed as a “heavy duty” or “super duty”
cooler given the robust nature of the inner chambers.
Other features include a screw top lid with an accompanied threaded rim and an
insulating layer of solid polyurethane. The extra layer of insulation is required due to little
thickness in the polypropylene outside shell and the low specific heat of the internal aluminum.
All components inside the insulation are made of aluminum sheet metal. The cap and threaded
rim system is made of polypropylene with exception to screws and nuts from the standard
library. Other minor parts (i.e. flange pieces, drainage stopper, etc.) are machined of steel. Also,
the outer shell is made of polypropylene. All polypropylene parts are to be injection molded.
The spouts themselves, which control the release of liquid, are to be purchased from an
outside vendor. The “Oasis White Water Cooler Faucet Belled with Male Threads” from
Freshwater Systems [1] will be used, and the nozzle flange parts have been modeled to
appropriately mate with this model. See Figure 3 below for final design pictorial view.

Figure 3 - Top Level Assembly of Sports Drink Cooler
Modeling Techniques: Most of the components in the Sports Drink Cooler model were simple
and required only extruded solids, extruded cuts, rounds, holes, and cosmetic threads. The three
screws and nuts are standard library parts in which the parameters were updated for the
assembly. There were a few interesting modeling features that were used during the process of
modeling the required components. The first was the thread feature in both the cap and threaded
rim parts. These two parts contain threads that must mate together. These parts necessitated the
modeling of physical threads because there was not a cosmetic thread large enough to properly
designate them. Modeling the threads on the cap and threaded rim parts was done using the
helical sweep tool. Another interesting feature that had to be used during the modeling process
was the extrusion and manipulation of quilts. This process was implemented for the modeling of
the drink and ice section bottoms. These parts contained very unique geometry that required the
combination of two separate quilts which were then trimmed to the proper size and shape by
projecting an outline sketch and trimming the excess solid.
Assessment: Model Quality: Model quality checks have been performed on the assembly, and
there were no significant discrepancies found. Table 1 describes the specific areas that were
checked and the results of the quality assessment. Based on these checks the Sports Drink
Cooler CAD models are of an acceptable quality level.

Table 1 - Summary of CAD model quality checks and results
Area Comments
Assembly: All components were checked to ensure they were correctly and fully
constrained. There were no discrepancies found.
Parameters: Each component has been checked to ensure it contains correct parameter
names and values. All parameters were adequate.
Model-Check: The top-level assembly as well as all components were analyzed using Model
Check-Regenerative. All components excluding library parts passed with no
errors and only minor warnings. An attempt was made to resolve errors in
library parts, but no solution could be found.
Geom. Checks: No Geometry Checks were found on any part in the assembly.
Units: Each component was checked for model units and mass density. There were no
discrepancies. (All units were inch-pound mass-second).
Views: Each component was checked for standard views, including at least one
isometric view. There were no discrepancies.
Density: Each component has been checked for the correct mass-density. All parts were
assigned their respective values.
Feature Names: Each component was checked for the presence of meaningful feature names,
and there were no discrepancies found.
Functionality: All of the desired functional design goals for this assembly were met. Based on
hand calculations that were performed, the Sports Drink Cooler will hold the industry standard 5
gallons. The full exterior of the top-level assembly was also 3D printed and as a prototype. The
threaded rim fit over the shell, but the cap and the threaded rim did not fit together. Through this
prototype we discovered a fatal flaw in the thread design of our cap and were able to correct the
error resulting in a part that is completely functional.
Manufacturability: The Sports Drink Cooler is manufacturable using common industry practices
such as stamping and forming of sheet metal, drilling, turning and facing on a lathe, and injection
molding. The metal parts are to be made out of aluminum or steel, the plastic parts are to be
made out of polyethylene, and the insulation is to be made out of solid polyurethane. There is a
high likelihood that improvements in manufacturing could be made by changing material or
slightly manipulating the CAD models, but all parts are believed to be manufacturable in their
current form.
Recommendations:
1. Consider the addition of a handle or carrying system. It is realized that some sort of
handle would be required to make this product marketable, but due to the scope of the
project and the level of detail we could pursue, other facets of the design took priority.
2. The internal structure could be redesigned in a way which allows for manufacturing by
injection molding. This could allow the elimination of all aluminum parts, making the
product more marketable and less expensive.
3. A stand for the cooler could be designed so that cups can fit under the spout without
setting the cooler next to a ledge. This is a common problem in nearly all similar drink

coolers on the market which could be solved with further design. In the case of our
design, a stand would also allow for easier emptying of the drainage chamber.
Conclusion: As designed, the Sports Drink Cooler meets all design objectives. A simplified
prototype demonstrated the functionality of certain fits in the design and a full prototype would
provide further insight into the cooler’s performance. The model was designed to be attractive
and to resemble products that are currently on the market, while addressing major problems that
other competitive products contain.
Prepared by: Tim Wolfe Date: 7 December, 2014
Caleb Sundholm
Group: 4
Team Members: Tim Wolfe
Caleb Sundholm
Doug Donatelli

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2.25
X 2.80
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.88
32.00
X 2.26
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.50
112.50°112.50°
REL? EMAIL CONTACT NAME BOX PHONE
FALSE SUNDHOLMCD1@GCC.EDU CALEB SUNDHOLM 2374 717-398-8197
15-208-G04-P201 Dec-06-14
INNER SHELL
ALUMINUM 1 of 1
design drawn chk appvd
CDS CDS TPW.13 O_THICK ALL OVER
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SEE DETAIL A
SEE DETAIL B
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SCALE 0.500
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DETAIL B
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0.400
sheet
26.54
10.22
10.20
15-208-G04-P203 Dec-05-14
INTERNAL DIVIDER
ALUMINUM 1 of 1
CDS CDS DSD
.13 THICK
SCALE 0.250

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sheet
27.83
27.80
.25
15-208-G04-P202 Dec-05-14
DIVIDER ROD
ALUMINUM 1 of 1
CDS CDS TPW
SCALE 0.200

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SCALE
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2 decimal lin: 0.01
1 decimal ang: 0.5
B
0.400
sheet
10.23
67.5°
50.00°
4.16
3.00
.25
4.77
4.80
151.0°
7.39
15-208-G04-P204 Dec-06-14
DRINK SECTION BOTTOM
ALUMINUM 1 of 1
CDS CDS DSD.13 THICK ALL OVER
SYMMETRIC ABOUT
SCALE 0.250

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SCALE
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1 decimal lin: 0.1
2 decimal lin: 0.01
1 decimal ang: 0.5
B
0.400
sheet
10.37
3.25
.25
90.00°
2.90
3.80
3.00
2.50
28.2°
4.33
70.2°
9.8°
7.15
15-208-G04-P205 Dec-06-14
ICE SECTION BOTTOM
ALUMINUM 1 of 1
CDS CDS TPW
.13 THICK ALL OVER
PART SYMMETRIC ABOUT
PATTERN NOTE
SPACING: 1.00
TYPE: FILL
HOLE: .25
SCALE 0.350

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SCALE
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1 decimal lin: 0.1
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B
0.333
sheet
20.952.50
NO WOLFETP1@GCC.EDU TIMOTHY WOLFE 2414 518-774-5349
15-208-G04-P206 Dec-06-14
INSIDE ASSEMBLY BASE
ALUMINUM 1 of 1
CDS TPW CDS
.13 THICK
SCALE 0.200

A
A
D
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A
A
B
C
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GROVE CITY COLLEGE
SCALE
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TOL
1 decimal lin: 0.1
2 decimal lin: 0.01
1 decimal ang: 0.5
B
1.500
sheet
2.050
3.50
+.01
-.00
3.25
+.01
-.00
.125
.125
15-208-G04-P401 Dec-05-14
ICE TUBE
STEEL 1 of 1
CDS CDS DSD
1.500SECTION A-A
SCALE 1.000

D
C
A
A
B
C
D
4 2 13
3 2 14
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GROVE CITY COLLEGE
SCALE
SI
TOL
1 decimal lin: 0.1
2 decimal lin: 0.01
1 decimal ang: 0.5
B
1.500
sheet
.13
3.25
3.24
1.88
.13
15-208-G04-P402 Dec-05-14
ICE DOOR
POLYPROPYLENE 1 of 1
CDS CDS TPW
SCALE 1.000

A
A
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A
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SCALE
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1 decimal lin: 0.1
2 decimal lin: 0.01
1 decimal ang: 0.5
B
0.150
sheet
32.13
22.95
3.50
+.01
-.00
2.38
X 2.80
+.01
-.00
1.01
X 3.26
+.01
-.00
.50
112.5°
135.0°
FALSE DONATELLIDS1@GCC.EDU DOUG DONATELLI #2183
15-208-G04-P301
INSULATION
POLYURETHANE 1 of 1
DSD DSD CDS
15-208-G04-P301 Dec-02-14
INSULATION
POLYURETHANE 1 of 1
DSD DSD
0.150SECTION A-A
SEE DETAIL A
SCALE 0.500
DETAIL A
1.00 O_THICK
SCALE 0.075

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A
B
C
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3 2 14
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SCALE
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1 decimal lin: 0.1
2 decimal lin: 0.01
1 decimal ang: 0.5
B
2.000
sheet
1.50
2.13
.13
.80
15-208-G04-P305 Dec-8-14
NOZZLE FLANGE
STEEL 1 of 1
DSD DSD TPW
0.630 - 16.000 UNF - 2B INTERNAL
1.50 R10.35
SCALE 1.000

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A
B
C
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SCALE
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1 decimal lin: 0.1
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B
0.150
sheet
23.45
.25 O_THICK
3.50
+.01
-.00
2.63
X 3.80
+.01
-.00
1.26
2.50
X 3.26
+.01
-.00
1.50
32.38
.50
112.5°
135.0°
R.38
X 18
R.50
R.55 TYP
1.50 TYP
FALSE DONATELLIDS1@GCC.EDUDOUG DONATELLI #2183
15-208-G04-P302 Dec-8-14
OUTER SHELL
DSD DSD CDS
SEE DETAIL B
SECTION A-A
SEE DETAIL A
SCALE 0.750
DETAIL A
SCALE 0.300
DETAIL B
SCALE 0.100

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A
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A
B
C
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2.75
25.45
23.95
+.010
-.000
3X 60.0 EQ SP
3X R1.50
R.50 TYP
2.25
3.00
50.0°
+.5°
-.0°
.30
+.005
-.000
FALSE WOLFETP1@GCC.EDU TIMOTHY WOLFE 2414 518-774-5349
15-208-G04-P104 Dec-06-14
THREADED CAP
TPW TPW KMD
CUSTOM INTERNAL THREAD
PITCH .45
MAJOR DIA: 23.95
MINOR DIA: 23.81
SECTION A-A
SEE DETAIL A
.50 THICK
SCALE 2.000
DETAIL A
R.05 TYP
SCALE 0.167

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A
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1.50
20.20
23.93
1.25
1.38
.75
112.5° 112.5°
X 3.26
+.01
-.00
X 3.50
+.01
-.00
.03
+.00
-.01.28
+.00
+.01
15-208-G04-P101 Nov-19-14
THREADED RIM
TPW CDS DSD
THREAD NOTE:
MINOR DIAMETER: 23.93
MAJOR DIAMETER: 24.07
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SECTION B-B
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SEE DETAIL C
SECTION A-A
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SCALE 0.500
DETAIL A
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R.05 TYP
SCALE 1.000
DETAIL C

D
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A
B
C
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3 2 14
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SCALE
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1 decimal lin: 0.1
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1.000
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.20.38
2.50
+.00
-.01
4.00
1.17
15-208-G04-P304 Dec-8-14
DRAIN FLANGE
STEEL 1 of 1
DSD DSD TPW
1.290 - 12.000 UNF - 2B INTERNAL
SCALE 0.500

A
A
D
C
A
A
B
C
D
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3 2 14
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SCALE
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1 decimal lin: 0.1
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4.000
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.58
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R.49
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STOPPER
STEEL 1 of 1
DSD DSD CDS
1.250 - 12.000 UNF - 2A EXTERNAL
SECTION A-A
SCALE 2.000

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0.100
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15-208-G04-A201 Dec-06-14
INTERIOR
SEE PARTS 1 of 1
CDS TPW CDS
INTERIOR BOM
INDEX COMPONENT DRAWING NUMBER QTY MATERIAL DESIGNER DRAFTSMAN SP
1 INNER SHELL 15-208-G04-P201 1 ALUMINUM CDS CDS YES
2 DIVIDER ROD 15-208-G04-P202 1 ALUMINUM CDS CDS YES
3 INTERNAL DIVIDER 15-208-G04-P203 3 ALUMINUM CDS CDS YES
4 ICE SECTION BOTTOM 15-208-G04-P205 1 ALUMINUM CDS CDS YES
5 DRINK SECTION BOTTOM 15-208-G04-P204 2 ALUMINUM CDS CDS YES
6 INSIDE ASSEMBLY BASE 15-208-G04-P206 1 ALUMINUM CDS CDS YES
1
2
3
4
5
6

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A
B
C
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3 2 14
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SCALE
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2 decimal lin: 0.01
1 decimal ang: 0.5
2 decimal ang: 0.50
B
0.150
sheet
NO DONATELLIDS1@GCC.EDU DOUG DONATELLI #2183
15-208-G04-A303 Dec-07-14
EXTERIOR
SEE PART 1 of 1
DSD DSD CDS
EXTERIOR BOM
1 OUTER SHELL 15-208-G04-P302 1 POLYPROPYLENE DSD DSD YES
2 INSULATION 15-208-G04-P301 1 POLYURETHANE DSD DSD YES
1
2

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A
A
B
C
D
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3 2 14
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GROVE CITY COLLEGE
SCALE
SI
TOL
2 decimal lin: 0.01
1 decimal ang: 0.5
2 decimal ang: 0.50
B
2.000
sheet
NO DONATELLIDS1@GCC.EDU DOUG DONATELLI #2183
15-208-G04-A301 Dec-07-14
DRAIN
SEE PART 1 of 1
DSD DSD CDS
DRAIN BOM
1 DRAIN FLANGE 15-208-G04-P304 1 STEEL DSD DSD YES
2 STOPPER 15-208-G04-P303 1 STEEL DSD DSD YES
1
2

D
C
A
A
B
C
D
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3 2 14
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GROVE CITY COLLEGE
SCALE
SI
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2 decimal lin: 0.01
1 decimal ang: 0.5
2 decimal ang: 0.50
B
0.333
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15-208-G04-A101 Dec-06-14
SCREW TOP
SEE PARTS 1 of 1
TPW TPW CDS
SCREW TOP BOM
1 THREADED RIM 15-208-G04-P101 1 POLYPROPYLENE TPW CDS YES
2 THREADED CAP 15-208-G04-P104 1 POLYPROPYLENE TPW TPW YES
3 RIM NUT 15-208-G04-P103 3 STEEL LIBRARY N/A NO
4 RIM SCREW 15-208-G04-P102 3 STEEL LIBRARY N/A NO
1
2
3
4

D
C
A
A
B
C
D
4 2 13
3 2 14
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GROVE CITY COLLEGE
SCALE
SI
TOL
2 decimal lin: 0.01
1 decimal ang: 0.5
2 decimal ang: 0.50
B
1.000
sheet
NO SUNDHOLMCD1@GCC.EDU CALEB SUNDHOLM 2374 717-398-8197
15-208-G04-A401 Dec-06-14
ICE RELEASE
SEE PARTS 1 of 1
CDS CDS DSD
ICE RELEASE BOM
1 ICE TUBE 15-208-G04-P401 1 STEEL CDS CDS YES
2 ICE DOOR 15-208-G04-P402 1 POLYPROPYLENE CDS CDS YES
1
2

D
C
A
A
B
C
D
4 2 13
3 2 14
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GROVE CITY COLLEGE
SCALE
SI
TOL
2 decimal lin: 0.01
1 decimal ang: 0.5
2 decimal ang: 0.50
B
0.125
sheet
15-208-G04-A500 Dec-07-14
SPORTS DRINK COOLER
SEE PARTS 1 of 1
CDS TPW DSD
SPORTS DRINK COOLER BOM
1 EXTERIOR 15-208-G04-A303 1 SEE PART DSD DSD YES
2 INTERIOR 15-208-G04-A201 1 SEE PARTS CDS TPW YES
3 SCREW TOP 15-208-G04-A101 1 SEE PARTS TPW TPW YES
4 ICE RELEASE 15-208-G04-A401 1 SEE PARTS CDS CDS YES
5 DRAIN 15-208-G04-A301 1 SEE PART DSD DSD YES
6 NOZZLE FLANGE 15-208-G04-P305 2 STEEL DSD DSD YES
1
2
3
4
5
6

grp04_208_f15_final

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