P10229: Composites Autoclave

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P10229: Composites Autoclave. Brian Cario: ME Matt Brady: ME Matt DiFrancesco: ME Brandon Allen: EE John Mink: EE. 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 - PowerPoint PPT Presentation

Text of P10229: Composites Autoclave

  • P10229: Composites AutoclaveBrian Cario: MEMatt Brady: MEMatt DiFrancesco: MEBrandon Allen: EEJohn Mink: EE

  • *Background: Purpose of an AutoclaveDevice for Curing Components Made of Composite Materials Under Heat and PressureHigh-Strength, Low MassVery Low Void Ratio10x Wet Layup

    Image Courtesy directindustry.com

  • *Project Objectives

  • *Benchmark: ASC Process Systems Econoclave22 Dia x 48 Long Working Volume200psig Max Pressure500oF Max Temperature5oF Temp UniformityPC User InterfaceElectric HeatExtensive Safety SystemsFast-Closing DoorPriced from $85k-$120k plus delivery and setup

  • *Potential Users of an Autoclave at RITMET Department--Student ProjectsProposed location: Composites LabStudent Teams: Baja, Formula, AeroME Department for ResearchCIMSFuture Senior Design GroupsAnyone Needing a super lightweight structurePossible Outside UsersFuture, Unforeseen Uses

  • *Why Have an Autoclave at RIT?Strong lightweight components are becoming increasingly importantRented Autoclave Time is Rare and ExpensiveProduction-Scale Utility Bills can reach $750/runOn-Site Option Offers ConvenienceCould be Customized for Other Future UsesLearning ToolEnables Ongoing, Long-Term ResearchRenting Time Could Generate Funding

  • Feature-Cost Comparison to ASC Econoclave; Closest Competitor

    P10229EconoclaveWorking Diameter20"22"Working Length48"48"Max Temp400F500FMax Pressure150psig200psigDoorFlangeFast-CloseInterfacePC-BasedPC-BasedHeating240V480VPressurizationNitrogenOptionalCertificationRGE-TestedASMESafety SystemsDesignedStandardTotal Cost$9K$85K ++

  • Bill Of Materials Part I

    ElectricalDescriptionPart NumberSourceQuantityUnit PriceTotal PriceHigh Temperature WireTBDGoodman's50' roll$27.50/50ft$27.50Back Panel (22x22)N/APlastics Lab9FreeFreeDC RelaysN/APlastics Lab3FreeFreeDin-rail/TerminalsN/APlastics Lab9FreeFreeHigh Current Bulkhead Connector1575Pave Technology Co1$90.00$90.009 #22AWG Bulkhead Connector1588Pave Technology Co2$115.00$230.00Thermistor502JH1kUS Sensor5$10.00$50.003-Phase 45A RelayGA312D45ZCrouzet1$132.29$132.2922 AWG Red Wire22awgRedChrome Glow50ft$0.25/ft$12.5022 AWG Black Wire22awgBlackChrome Glow50ft$0.25/ft$12.503-Phase 240V Safety Switch7524K22McMaster1$83.89$83.89Subsystem Total$638.68

    Pressure Vessel and StandDescriptionPart NumberSourceQuantityUnit PriceTotal Price2" x 2" x 1/4" (48" length) A36 HR Angle SteelN/ARochester Steel and Surplus13$9.00/ Section$117.0024" x 48" (3/16 thick) A36 HR Sheet SteelN/ARochester Steel and Surplus1$45.00$45.00Titan 6" Casters with full brake5500398Tractor Supply4$29.99$119.961.25" x 1' A36 HR Steel BarR12Metals Depot1$12.01$12.01Rust-Oleum Hammer Black Paint170995Lowes2$14.98 /qt$29.965/16 - 18 x 1" Hex Bolts48872Lowes1$3.18 /25$3.185/16 - 18 Hex Nuts40958Lowes1$4.51 /25$4.512' x 2' x 1/2" A36 Steel PlateP112Metals Depot1$125.76$125.762' x 8' x 3/64" 3003 Aluminum SheetS3040Metals Depot3$40.96$122.881/8" x 1/8" Aluminum Rivet45309Lowes1$4.94 /100$4.94Tested RG&E Vessel Parts and Labor-RG&E1$3,700.00$3,700.00 Includes ~$2500 in partsGas Cylinder Clamp2283T12McMaster1$40.12$40.12Mesh for Part Rack9243T381McMaster1$59.02$59.02Door Hinge Bushing2938T62McMaster2$4.65$9.30Door O-Ring9396K418McMaster2$22.91$45.82Subsystem Total$4,439.46

  • ControlsDescriptionPart NumberSourceQuantityUnit PriceTotal PricePressure TransducerPX91N0-10KSVOmega1$860.00$860.00Standard Power Supply iDRN-PS-1000Omega1$150.00$150.003-Phase Circuit BreakerQO340Schneider-Electric1$240.00$240.00Relay501-00010MPJA1$19.95$19.95ComputerEL1600-01eMachines1$229.99$229.99DAQNI USB-600National Instruments1$169.00$169.00Subsystem Total$1,668.94

    PressurizationDescriptionPart NumberSourceQuantityUnit PriceTotal PriceNitrogen Regulator7897A12McMaster1$137.88$137.88Inlet Solenoid Valve10M61Magnatrol2$153.00$306.00Blow-off Valve4673K71McMaster1$104.23$104.2336" Nitrogen Inlet Hose5676T846McMaster1$66.39$66.391.5"x3/8" Pipe Bushing4638K575McMaster1$5.13$5.136 feet 3/4" Copper Tube8967K8McMaster1$25.27$25.273/4" NPT Compression Fitting5272K294McMaster1$11.85$11.853/8" MxF Stainless Braided Hose5676T342McMaster1$41.26$41.263/4" x 3/8" Reducing Tee44605K468McMaster1$4.25$4.253/4" NPT Nipple7736K114McMaster1$13.47$13.472"x3/4" Pipe Bushing44605K295McMaster1$6.53$6.533/8" Pipe Nipple7727K162McMaster2$3.47$6.941-200psi hi-temp Pressure Gauge4010K116McMaster1$108.58$108.583/8" Pipe Tee44605K402McMaster2$6.09$12.181.5" Pipe Elbow MxF44605K138McMaster1$7.11$7.11Subsystem Total$857.07

    Heating, Circulation, and InsulationDescriptionPart NumberSourceQuantityUnit PriceTotal PriceMineral Wool Insulation, 2"x2'x4' qty. 6N/AATS Acoustics3$34.00$102.004kW Straight Incoloy tubular heating elementsTHE04061Tempco3$131.05$393.15bulkhead connectors for heating elements?Tempco3$34.95$104.855-blade fan, 1000CFM, CW rotation2UJU3Grainger1$19.71$19.711/50 HP 115VAC Motor for fan58459Drill Spot1$38.46$38.465/16" shaft seal13125K76McMaster1$20.13$20.133/8" flanged bearing for fan shaft9440T18McMaster1$1.56$1.561"OD, .5"ID steel tube for fan shaft supportT21250Metals Depot1ft$9.01$9.013/8" 1018 steel rodR238Metals Depot2ft$2.46$2.461/4" shaft coupler6412K11McMaster1$5.44$5.44Galvanized steel plug for blower shaft mount7739K188McMaster1$6.00$6.001x3x11ga. Steel Tube for motor mountT13111Metals Depot2ft$6.96$6.9611 gage steel sheet for heating element mountsS111Metals Depot1ftx2ft$21.40$21.40Subsystem Total$731.13

    Autoclave Total$8,335.28

  • Funding OptionsCurrent funds: $4000: Pressure Vessel, Incomplete Stand, Completely designed system$4500: Complete Pressure Vessel and Complete Stand$6000: Complete Pressure Vessel, Stand, Heating System, and Pressurization System$8500: Complete Autoclave as Designed

    Design will have all the basic functionality of commercial unit at 1/10 the cost