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

2. 2 Preliminary Design Review Agenda Project Background Project Objectives Benchmark Potential Users Customer Requirements Engineering Specifications Project Schedule Work Breakdown Concept Screening and Selection System Function Risk Mitigation Design Feasibility Studies Preliminary Project Budget Next Steps

3. 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 Image Courtesy directindustry.com

4. 4 Project Objectives Senior Design 1Senior Design 2 TasksConcept Generation and Selection Complete Pressure Vessel Construction Detailed Design, Ready for Construction Test Pressure Vessel Spec Stock PartsFinal Assembly Test Autoclave DeliverablesComplete Autoclave DesignComplete, Operable Autoclave Partially Built Pressure VesselManual for Operation Some Parts Obtained

5. 5 Benchmark: ASC Process Systems Econoclave 22” Dia x 48” Long Working Volume 200psig Max Pressure 500 o F Max Temperature 5 o F Temp Uniformity PC User Interface Electric Heat Extensive Safety Systems Fast-Closing Door Priced from $85k-$120k plus delivery and setup

6. 6 Potential Users of an Autoclave at RIT MET Department--Student Projects Proposed location: Composites Lab Student Teams: Baja, Formula, Aero ME Department for Research CIMS Future Senior Design Groups Anyone Needing a super lightweight structure Possible Outside Users Future, Unforeseen Uses

7. 7 Why Have an Autoclave at RIT? Strong lightweight components are becoming increasingly important Rented Autoclave Time is Rare and Expensive Production-Scale Utility Bills can reach $750/run On-Site Option Offers Convenience Could be Customized for Other Future Uses Learning Tool Enables Ongoing, Long-Term Research Renting Time Could Generate Funding

8. 8 Customer Requirements Customer Need # ImportanceDescriptionComments/Status CN11The pressure vessel can safely hold 150 psi @ 400F Pressure vessel will by hydrostatically tested to 300 psi CN21 Heating system can reach and maintain a temperature of 400F CN31The autoclave operates on 440 VAC or 220 VAC CN41 The autoclave is protected from over pressurization and over heating CN51The autoclave is accompanied by an operations manual CN61The pressure vessel has fittings for an external vacuum pump CN71The autoclave has safety signage CN82 The pressure vessel has a door sized the entire cross sectional area of the chamber CN92 The user interface directly controls pressure, temperature (ramp rates, cooling) CN102 The user interface displays pressure and temperature in real time CN112The pressure vessel is capable of holding a vacuum CN122The pressure vessel is thermally insulated CN132The autoclave has a uniform internal temperatureThis will be done with a blower CN143The pressure vessel interior is 3' in diameter and 4' deepThis is very budget depending CN153The autoclave is portable Pressure vessels are usually very heavy so portability is not feasible CN163The autoclave has plumbing for integrated cooling system

9. 9 Engineering Specifications MetricNeedSpecification or MetricImp.UnitsMarginal ValueIdeal Value 11,6Emergency Pressure Relief1psiMAOP +60MAOP +30 22Max Operating Temperature1Deg F250400 36Emergency Shut off Temperature1Deg FMAOT +100MAOT +50 416Delta Chamber Cut off Temperature1Deg F+/- 75+/- 50 5ASME,1Certification Pressure1psi1.5 * MAOP2 * MAOP 61Max Operating Pressure2psi35120 77Temperature Ramp Rates2Deg F/min510 82Temperature Resolution2Deg F101 91Pressure Resolution2psi101 3Interior Diameter3ft13 113Interior Length3ft14 124Supply Voltage3VAC440220 1311Autoclave Weight3lbs60001000 14 Max External Operating Temp3Deg F300100

10. 10 Project Schedule and Gantt Chart

11. Summarized MSD 1 Timeline Week 1 Background and research autoclave functionality. Team Organization Week 2 Interview potential customers Develop engineering specifications Week 3 Concept generation and selection Risk management Future Scheduling Week 4 Determine design feasibility Prepare for Preliminary Design Review Week 5 Prepare preliminary design review Weeks 6-8  Detail design generation  Spec stock components  Finalize Budget Week 8  Begin Pressure vessel construction Week 9  Generate Bill of Materials  Begin preparation for Final Design Review Week 10  Prepare for Final Design Review

12. 12 Concept Screening Matrix: Pressure Vessel ABCDEF (Reference) Selection Criteria Fabricated Non-Certified Vessel Cast Iron Pipe and Flanges High- Pressure Water Tank ASME Certified (Econoclave) Used Certified Vessel Square Vessel Instead of Cylindrical Cost+++0++ Ease of Manufacture---00- Ease of Integration of I/O Ports---00- Ease of Adding Door---00- Pressure Capability-0000- Safety+-+00- Certification Needs0--00- Weight+--000 Portability+0-000 Ease of Heating0--000 Sum + 's412011 Sum 0's2211093 Sum -'s477006 Net Score0.00-6.00-5.000.001.00-5.00 RankT26T4T21T4 Continue?YesNo YesNo

13. 13 Weighted Concept Selection Matrix ABC D EE (Reference) Fabricated Non-Certified Vessel Cast Iron Pipe and Flanges High Pressure Water Tank ASME Certified (Econoclave) Used Certified Vessel Square Instead of Cylindrical Selection CriteriaWeightRatingWtdRatingWtdRatingWtdRatingWtdRatingWtdRatingWtd Cost20%51515130.640.851 Ease of Manufacture10%20.230.320.230.33 20.2 Ease of Integration of I/O Ports 7%20.1410.0720.1430.213 20.14 Ease of Adding Door10%20.230.310.130.33 10.1 Pressure Capability8%10.0830.243 3 3 10.08 Safety15%40.610.1520.330.453 10.15 Certification Needs15%30.4510.151 30.453 10.15 Weight3%40.1220.062 30.093 40.12 Portability2%50.130.0610.0230.0620.0430.06 Ease of Heating10%3 0.3030.31 0.1030.33 3 Total Score3.192.63 2.3133.182.3 Rank145326 Continue? YesNo YesNo

14. 14 System Function

15. 15 System-Level Risk Mitigation

16. 16 Pressure Vessel Feasibility Based on a 24” Diameter, 5-foot long Pressure Vessel Constructed of 0.250” Wall Grade-B Pipe, Caps, and Flanges Yield Pressure is Limited by Hoop Stress in the Cylindrical Portion of the Vessel to 729.17psi This is 3.86 times out maximum operating pressure of 150psi

17. 17 Insulation Feasibility 0.4m Outer Radius Corresponds to a 3.5” Thick Layer of Insulation Using Common R13 Fiberglass this gives an Outer Surface Temp of 80F

18. 18 Heating System Feasibility Total power to maintain max. temp: ~470W Total power to heat up air at 15F/min (total 27 min): ~1.5kW Allowing for thermal mass of parts/molds/pipe, ~4-5 kW needed Can easily be run on available 240V power Elements of this size commonly available Blower inside vessel will help maintain uniform temp.

19. 19 Pressurization Feasibility Assumes Use of Standard AL-size (9”x53” nom.) Gas Cylinder Filled with Gaseous Nitrogen One Bottle good for one full pressure run of 124psi or several runs at reduced pressure. Run NumberInitial Cyl Pressure (psi)Run Pressure (psi)Final Cyl Pressure (psi) 12000MAX124.34 Run NumberInitial Cyl Pressure (psi)Run Pressure (psi)Final Cyl Pressure (psi) 12000601094.915254 2 60189.8305085 Run NumberInitial Cyl Pressure (psi)Run Pressure (psi)Final Cyl Pressure (psi) 12000151773.728814 2 151547.457627 3 151321.186441 4 151094.915254 5 15868.6440678 6 15642.3728814 7 15416.1016949 8 15189.8305085

20. 20 Preliminary Electrical Design 240VAC Supply Stepped down to 120VAC and 12VDC as needed Electrical Pressure Control for Good Precision, Added Safety Electrical (PID) Heating Control including control of Ramp Rates External Electrical Layout

21. Bulkhead Connector Pressure tested to 2000psi Available with multiple wire combinations 9-wire, 22awg connector will work for our application Image © www.pavetechnologyco.com

22. Electrical Load Heater ~ 5kW @ 220V, approximately 23A Blower ~ ½ hp = 372.85W @ 220V, approximately 1.7A Computer ~ 300W @ 110V, approximately 3A DC Power supply ~ 1kW about 10A Pressure Regulator ~ 50mA at 12V 220V – 110V Transformer ~ 1kW, approximately 5A

23. 23 Control System Feasibility

24. 24 Preliminary Safety System Plan MSDS for potential resin systems External Signage Extensive Operations Manual Door Proximity Switch Over-pressure Blow-Off Valve Exhaust Routed into existing Fume Hood Thermal Fuse All Relays and Solenoid Valves Default to Safe Software Able to Detect Unsafe Conditions Emergency Stop Button

25. 25 Estimated Initial Budget Pressure Vessel 2' Diameter x 5' Long Pipe1N/ADonated 24" Outer Diameter Tank End Cap2445.28890.56 32" Outer Diameter 1.88" Thick Flange2650.081300.16 2" x 2" x.25 " Angle Steel40'9.00 per 4'90 24" x 48" x 3/16 Sheet Steel145 5" Diameter Swivel Caster414.9959.96 1"-14 x 5" Grade 5 Bolts2017.18 for 568.72 1"-14 Grade 5 Nuts206.25 for 1012.5 2' x 2' x 3/4" Steel Plate for Hinge Fabrication1203.76 Miscellaneous Other Tank HardwareN/A 20 Labor for Tank Machining and Welding10 Hours100/hr1000 Subsystem Total3690.66 Pressurization Nitrogen Regulator1150 Input Solenoid Valve175 Dump Solenoid Valve185 Pipe/Hose/Fittingsmisc.75 Subsystem Total385 Heating, Insulation, Circulation R13 Insulation63 ft^220 5kW Incoloy Heating Element1250 Sheetmetal Shell1125 Blower Motor1100 Squirrel Cage Blower115 Hi Temp Hi Pressure Shaft Seal23060 Subsystem Total570 Electrical 250C Rated Wire100ft30/50ft60 Standard THHN Wire100ft15/50ft30 1/2" Sealtite Conduit50ft50/100ft50 PaveTechnologies Bulkhead Connector2135 270 Subsystem Total410 Controls Thermocouple5525 Pressure Transducer190 Control Board1250 Subsystem Total365 Total$5420.70

26. 26 Commitments to Date $2000 from KGCOE Multidisciplinary Senior Design Pipe and Potential Labor Donated by Rochester Gas and Electric – estimated value = $1500+ 15hr/week x 5 team members x 22 weeks = 1650 hours x $85/hr = $140k+ in Free Design Time from the P10229 Team

27. 27 Next Steps Procure Funding – by 1-29-10 Complete Detailed Design Failure Mode Analysis FEA on Pressure Vessel, Stand Begin Pressure Vessel Fabrication Spec Stock Parts Simulate Controls and Software Solidify exact heating requirements

29. Heating Concept Screening Matrix ABCD (Reference) Selection Criteria Static Incoloy Heating Elements (no circulation) Nichrome Wire External Gas Burner/Heat Exchanger Convection Incoloy Tubular Heating Elements Manufacturing Cost++-0 Ease of Manufacture+0-0 Response Time--00 Ease of Control-0-0 Pressure Capability00-0 Safety-0-0 Infastructure Needs00-0 Operating Cost00+0 Portability00-0 Temperature Uniformity--00 Sum + 's2110 Sum 0's47210 Sum -'s4270 Net Score-2.00-6.000.00 Rank3241 Continue?NoYesNoYes

30. Heating Weighted Concept Selection A B C D Static Incoloy Heating Elements (no circulation)Nichrome Wire External Gas Burner/Heat Exchanger (Reference) Convection Incoloy Tubular Heating Elements Segment Selection CriteriaWeightRatingNotesWtdRatingNotesWtdRatingNotesWtdRatingNotesWtd Manufacturing Cost15%4 0.604 1 0.153 0.45 Ease of Manufacture15%40.6030.4510.1530.45 Response Time15%20.302 30.453 Ease of Control8%10.0830.2410.0830.24 Pressure Capability10%30.303 20.2030.30 Safety10%20.2030.3010.1030.30 Infastructure Needs10%30.303 10.1030.30 Operating Cost5%30.153 40.2030.15 Portability2%30.063 10.0230.06 Temperature Uniformity10%1 0.102 0.203 0.303 Total Score 2.69 2.90 1.75 3.00 Rank 3 2 4 1 Continue? No Yes

31. Pressurization Concept Screening Matrix ABCD (Reference) Selection Criteria Shop Air with AccumulatorShop Air Bottled Gaseous Nitrogen On-board Compressor Manufacturing Cost-++0 Ease of Manufacture-++0 Temperature Stability00+0 Operating Cost00-0 Pressure Capability--+0 Safety0000 Certification Needs-000 Weight-++0 Portability--00 Strain on Infastructure0-00 Pressurization Rate+0+0 Sum + 's1360 Sum 0's45411 Sum -'s6310 Net Score-5.000.005.000.00 Rank4T21 Continue?No YesNo

32. Pressurization Weighted Concept Selection A B C D Shop Air with AccumulatorShop Air Bottled Gaseous Nitrogen (Reference) On-board Compressor Segment Selection CriteriaWeightRatingNotesWtdRatingNotesWtdRatingNotesWtdRatingNotesWtd Manufacturing Cost9%2 0.185 0.455 3 0.27 Ease of Manufacture9%30.2740.364 30.27 Temperature Stability15%30.453 50.7530.45 Operating Cost9%40.364 30.273 Pressure Capability15%20.302 50.7530.45 Safety10%30.303 3 3 Certification Needs9%10.0930.273 3 Weight3%20.0650.1540.1230.09 Portability2%10.0220.0430.063 Strain on Infastructure10%30.3010.1030.303 Pressurization Rate9%4 0.362 0.185 0.453 0.27 Total Score 2.69 2.96 4.08 3.00 Rank 4 3 1 2 Continue? No Yes No

33. Controls Concept Selection Matrix ABCD (Reference) Selection Criteria On/Off (no adjustability)Knobs and DialsPID Control Computer Interfaced Manufacturing Cost+++0 Ease of Manufacture+++0 Ease of Operation+0-0 Temperature Control--00 Feedback--00 Programmability---0 Safety Controls--00 Weight+++0 Portability+++0 Sum + 's5440 Sum 0's0139 Sum -'s4420 Net Score1.000.002.000.00 Rank2T31 Continue?Yes

34. Controls Weighted Concept Selection A B C D On/Off (no adjustability)Knobs and DialsPID Control (Reference) Computer Interfaced Segment Selection CriteriaWeightRatingNotesWtdRatingNotesWtdRatingNotesWtdRatingNotesWtd Manufacturing Cost5%5 0.255 4 0.203 0.15 Ease of Manufacture10%50.5040.404 30.30 Ease of Operation18%40.7230.5420.3630.54 Temperature Control 18%10.1820.3630.543 Feedback15%10.151 30.453 Programmability15%10.151 20.3030.45 Safety Controls15%10.151 30.453 Weight2%50.105 5 30.06 Portability2%50.105 5 30.06 Total Score 2.30 2.20 2.90 3.00 Rank 3 4 2 1 Continue? No Yes

35. Resin System MSDS http://www.westsystem.com/ss/assets/MSDS/MSDS105.pdf http://www.westsystem.com/ss/assets/MSDS/MSDS205.pdf