Corrosion Test StandCorrosion Test Stand

Concepts ReviewConcepts Review

October 14, 2008October 14, 2008

Vance Beatty

Rob Goodwin

Jacob Mattox

Scott Mayo

Alan Peters

Jackson Wilson

Agenda

• Introduction

• Project Requirements

• “Easel” Concept Proposal

– Questions– Questions

• “Bed Frame” Concept Proposal

– Questions

• “Tent” Concept Proposal

– Questions

• Evaluation of Concepts

• Conclusion & Recommendation

Requirements

• Lightweight (< 70 lbs.)

• Easy assembly & disassembly (< 1 hour with 2 people)

• Coupons insulated from rack

• Coupons held at 45° angle

• Corrosion resistant• Corrosion resistant

• Withstand specified environmental effects

• Low cost (< $3,000)

• Holds 50 coupons (3”x5”x1/8”)

Mission: “To build a portable, corrosion resistant rack to hold 50 metal coupons at a 45° angle.”

“Easel” ConceptPresented By:

Scott Mayo

Jackson Wilson

“Easel” Support Assembly

• Simple Design

• Easy to Assemble

• Low Weight

• Structure:• Structure:– Square Tubing

– Channel Bars

– Angle Bars

– Hinges

– Nuts and Bolts

“Easel” Coupon Retainer

• Coupons slide into edges of board

• Board placed into metal framemetal frame

• Metal frame attached to hinges

“Easel” Range of Motion

“Easel” Angle Lock

• Wing nuts can lock frame at different angles

“Easel” Grounding

• 4 holes per leg stand

• Can be • Can be bolted, tied, or staked to ground

“Easel” Cost EstimateItem

Steel Item

Cost Aluminum Item Cost # Steel Total Cost

Aluminum Total

Cost

Fiberglass Channel Coupon Inserts n/a n/a 10 $130.00 $130.00

Square Tubing (1.25 X 1.25 X 48 in.) $15.00 $18.00 1 $15.00 $18.00

U-Channel Tubing (1.25 X 1.25 X 48 in.) $27.00 $18.00 2 $54.00 $36.00

Angle Iron Tubing (1.25 X 1.25 X 48 in.) $9.00 $11.00 4 $36.00 $44.00

Angle Iron Tubing (2 X 2 X 48 in.) $11.00 $21.00 2 $22.00 $42.00

Plate Metal (angle lock) $26.00 $36.00 2 $52.00 $72.00

Sheet Metal (support coupon frame) $7.00 $8.00 1 $7.00 $8.00

Hinges $5.00 $5.00 3 $15.00 $15.00

Nuts and Bolts pack of 25 (0.25 in. - 20) $9.00 $9.00 1 $9.00 $9.00

Totals $340.00 $374.00

“Easel” Benefit Analysis

• Pros:

– Simple design

– Lightweight (30 lbs. w/out coupons)

• Cons:

– May collect standing water

– Difficult to remove & w/out coupons)

– Corrosion resistant

– Easy to assemble & manufacture frame

– Inexpensive

– Durable

– Difficult to remove & replace coupons

– Difficult to manufacture coupon board

Questions?

“Bed Frame” ConceptPresented By:

Rob Goodwin

Alan Peters

“Bed Frame” Support Assembly

• Aluminum 6061 frame

“Bed Frame” Coupon Rack

“Bed Frame” Coupon Retainer

“Bed Frame” Assembly

“Bed Frame” Cost EstimateItem # Part Description # Required Price Each Total Price

1 Polycarbonate Square Stock 1"x1" 50 $0.10 $5.00

2 Polycarbonate Sheet 48"x96"x.25" 2 $186.00 $372.00

31/4"-20 UNC x 3-1/2" LG.- Fully Threaded

Rod - 18-8 Stainless Steel50 $0.82 $41.20

4 1/4"-20 UNC - Hex Nut 18-8 Stainless Steel 66 $0.44 $28.93

5 1/4" - 18-8 Stainless Steel - Flat Washer 66 $0.18 $12.17

61/4"-20 UNC - Threaded Hole -

Polypropylene Knob50 $0.71 $35.50

71-1/2" x 1-1/2"x1/4" (4' LG.) - Aluminum

Angle 6061-T6 - Aluminum Structural Angle8 $20.24 $161.92

8 1/4"x1-1/2" (4' LG.) - 6061 Aluminum - Flat 4 $13.20 $52.80

91/4"-20 UNC (1" LG.) - Standard Hex Bolt -

18-8 Stainless Steel36 $0.26 $9.41

"1/4" - 18-8 Stainless Steel - Spring Lock

Washer - Heavy Duty16 $0.19 $3.09

Total Cost $722.03

“Bed Frame” Benefit Analysis

• Pros:– Simple design

– Lightweight

– Individual coupon

• Cons:

– Shadow effect

– Coupons fixed at 45°– Individual coupon

access

– No mechanical moving parts

– Easy to assemble & manufacture frame

– Shadow effect

45°

– Bulky

Questions?

“Tent” ConceptPresented By:

Vance Beatty

Jacob Mattox

“Tent” Coupon Retainer

“Tent” Coupon Positioning

• Venetian blinds style of movementmovement

• 180° of rotation

• Lever controlled

“Tent” Grounding

• 2 holes per leg stand

• Can be • Can be bolted, tied, or staked to ground

“Tent” Assembly/Disassembly

• Removable legs

“Tent” Assembly/Disassembly

• Foldable structure

“Tent” Cost Estimate

“Tent” Benefit Analysis

• Pros:

– Adjustable coupon angles

– Easy to assemble

• Cons:

– Use of special machinery required for manufacturing– Easy to assemble

– Portable

– Inexpensive

– Lightweight

– Wind / Weather resistant

for manufacturing

– Time intensive installation of coupons

Questions?

Decision Matrix

Concepts

Criteria Importance Tent Bed-Frame Easel

Light Weight 19 0.75 0.75 0.90

Easily Assembled 11 0.80 0.50 0.95

Coupons Insulated 19 0.95 0.90 0.50

Coupons at 45° Angle 15 0.99 0.90 0.95Coupons at 45° Angle 15 0.99 0.90 0.95

Hold 50 Coupons 16 0.99 0.99 0.99

Easy to Maintain 8 0.80 0.80 0.80

Cost Less than $3000 12 0.90 0.85 0.95

Satisfaction 88.99 82.79 84.94

Gantt Chart

Future Development

• Detailed CAD Drawings

• Engineering Calculations

– Structural Analysis

– FEA– FEA

• Manufacturability Assessment

• Material Selection

• Cost Analysis

Recommendation

• Incorporate key aspects of all concepts

– Frame of “Tent” concept

– Coupon retainer of “Bed Frame” concept

– Angle lock mechanism of “Easel” concept– Angle lock mechanism of “Easel” concept

Summary

• Introduction

• Project Requirements

• “Easel” Concept Proposal

– Questions– Questions

• “Bed Frame” Concept Proposal

– Questions

• “Tent” Concept Proposal

– Questions

• Concepts Evaluation

• Conclusion & Recommendation

Questions?