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Senior Design Proposal
Welding Station
Michael CorreiaZach LamarRyan FisherMatt Leigh
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Table of Contents1.1 – Background of need............................................................................................................................4
1.2 – Customer Needs.................................................................................................................................4
1.3 – Literature review................................................................................................................................4
1.3.1 – Prior Work.........................................................................................................................4
1.3.2 - Patents...............................................................................................................................4
1.3.3 – Codes and Standards.........................................................................................................5
2. Problem Definition..................................................................................................................................5
2.1 – Customer requirements.......................................................................................................5
2.5 – Test and Evaluation plan......................................................................................................7
3. Concept Development.............................................................................................................................7
3.1. Overview................................................................................................................................7
3.1.1. Creative Strategies..............................................................................................................7
3.1.2. Governing Principles............................................................................................................7
3.2. Synthesis and Analysis of Overall Concept.............................................................................7
3.2.1. Station Configurations.........................................................................................................7
3.2.1a. Industrial Hood..................................................................................................................8
3.2.1b. Downdraft Table................................................................................................................8
3.2.1c. Pipe with “Arms”...............................................................................................................9
3.2.2. Fan and Filter Configurations............................................................................................10
3.2.2a. Standalone......................................................................................................................10
3.2.2b. Dust Collector..................................................................................................................10
3.2.3a. Table design.....................................................................................................................11
3.3. Evaluation.............................................................................................................................11
3.4. Refinements.........................................................................................................................12
3.5. Selection...............................................................................................................................13
4. Design Specifications.............................................................................................................................13
4.1. Design Overview...................................................................................................................13
4.1.1. Description........................................................................................................................13
4.1.2. Design Schematics.............................................................................................................13
4.3. Physical Specifications..........................................................................................................16
4.4. Product QFD.........................................................................................................................17
4.5. Subsystems...........................................................................................................................17
4.6 Design Deliverables...............................................................................................................18
5. Project Plan............................................................................................................................................19
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5.1. Research...............................................................................................................................19
5.2. Critical Function Prototypes.................................................................................................19
5.3. Design...................................................................................................................................19
5.4. Construction.........................................................................................................................19
5.5. Testing..................................................................................................................................20
5.6. Project Deliverables..............................................................................................................20
5.7 Schedule................................................................................................................................20
5.8 Budget...................................................................................................................................21
5.9 Personnel..............................................................................................................................22
6. References:............................................................................................................................................22
7. Appendices............................................................................................................................................22
7.1. Loss Calculations..................................................................................................................22
7.2. Team Member Resumes.......................................................................................................23
7.4. Component Specification Sheets..........................................................................................28
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1.1 – Background of need
The University of San Diego’s engineering department currently has a welding area that is insufficient to the needs of the students. It only allows one student to work at a time, has minimal storage, and does not have an adequate fume extractor. The customers requiring an improved welding station include: the University of San Diego, USD Engineering Faculty and staff, USD Environmental Health and Safety, the San Diego Fire Marshall, and current and future USD student engineers. All of these people will be either end-users of the new welding station or validating that it works safely. The current welding station is inadequate and needs to be redesigned. The University of San Diego is the most direct customer, as the welding station is built for the school to keep. The USD Engineering Faculty and staff will be using the welding station to teach students how to weld as well as using it for their own projects. USD Environmental Health and Safety as well as the San Diego Fire Marshall need to make sure that the welding station is safe for use and will not start fires. Current and future USD Student Engineers will be using the station to learn to weld, practice welding and building their own senior design projects with it.
1.2 – Customer Needs
The Mechanical engineering program at the University of San Diego has an increasing need for a well functioning welding table and clean air in the engineering workshop. A good welding table is strong enough to support sufficient weight, rigid and sturdy so that it will not shake if slightly bumped. It is also
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durable enough to withstand the abuse of welding and efficient in regards to balancing storage space availability and space consumed in the basement. The next need is clean air; currently only one person can weld at a time using the current fume extractor. Also the fume extractor needs to be positioned close to be effective. A new fume extractor setup would allow for two simultaneous welders work and provide cleaner air in the workshop. With the addition of a new, redesigned welding station, each student will have more time to practice welding and their welding experience will be greatly enhanced.
1.3 – Literature review
1.3.1 – Prior Work
A welding table typically has a sturdy structure with an aluminum table top as the surface. A good welding area has plenty of storage so there is no clutter for the welder, as well as organization so the welder can work efficiently. Some type of a fume extractor is always used; most commonly an overhead extractor is used with a flexible arm so the welder has the freedom to move it where he/she feels would be best. When the welding is being done outside, no fume extractor is needed due to the openness of the welding site.
1.3.2 - Patents
Patent number 5511764 describes a self contained welding station with the fume extractor located beneath the table itself. This downdraft fume extraction setup is not ideal for the Loma workshop because it has a few shortcomings. The first one is that with a downdraft table, the fume extractor becomes less efficient as the sheet metal gets bigger, because then the vacuum is blocked and fumes will rise. This setup is only helpful for small welding jobs. The design is also not very space-efficient; there is minimal storage space available underneath the table.
Patent number 3886344 describes a fume extractor that is attached directly to the nozzle of the welding torch. This makes the torch heavier and more bulky to manage. This is a good idea for experienced welders that know how to handle a welding torch, but not as good for beginners that are still learning.
1.3.3 – Codes and Standards
Welding is a very dangerous activity in that it creates harmful fumes as well as extreme temperatures on metals. There are many codes and standards that apply to welding in general. The Occupational Safety and Health Administration (OSHA) has many standards that will be followed for a safe working welding environment. The standards that will be followed are:
Nothing flammable will be used in the construction of the area All of the air will be filtered as to remove the harmful fumes proper safety equipment will be provided
All of the codes for fire safety set by the National Fire Protection Association will be followed because of the possibility of a fire due to the hot sparks created while welding.
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One fire code in particular that may cause a substantial problem in the design process is NFPA Code 8.2.2.1.2. This code states that no operation that generates sparks can be attached to a dust collector.
2. Problem Definition
A redesigned welding workstation is needed in Loma 6 for more efficient welding and other related actions. The workstation needs to be ergonomically friendly and space efficient, able to withstand wear and tear form welding related actions, and easy to maintain. For safe welding, an improved fume extractor is needed for the removal of toxic waste/air.
2.1 – Customer requirementsHere are the customer requirements that will need to be followed in order to deliver a product the
customer will be happy with:
2.1.1 – FormThe welding station is expected to have the following attributes:
1. Appearance aesthetically pleasing and similar to standard welding workstations2. Table surface of aluminum3. Table flat to within 0.010 in. over 6 ft.
2.1.2 – FitDue to limited space in Loma 6 these requirements must be met:
1. Overall height ergonomically designed for comfortable usability2. Storage capacity for all welding workstation accessories3. Workspace provides room for one, average sized user4. Space within Loma 6 utilized efficiently 5. Machinery in Loma 6 will not interfere with station
2.1.3 – FunctionThe following are required functions of the welding station:
1. Weld various metals together in a safe and efficient environment2. Achieve noise level less than 75dB operating at 100% flow3. Functional for 25+ years 4. Maintenance costs less than $1000 over 10 years5. Easily serviceable and workstation components easily replaced
2.2 – AssumptionsThe assumptions that will be taken into account will be:
1. Customer Requirements will not be significantly altered midstream2. Loma 6 will be easily accessible3. Welding Workstation will be used safely and appropriately4. Welding Workstation will be used by students, faculty, or staff, trained in safe use
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2.3 – ConstraintsThe constraints that will have to be met for the welding station are:
1. Must be completed within 9 months2. Complexity must be within the capabilities of the design team3. Must meet all applicable codes, standards, and government regulations4. Must be stable5. Must be easily serviceable6. HVAC/Fume Extractor must operate at a minimum of 1200cfm for increased ventilation
2.4 – Customer Requirement Schematic (Figure 1)
Figure 1: CR Schematic
2.5 – Test and Evaluation plan
When the project is complete, testing will be performed on the area and the equipment to make sure everything is in working order. The most important test will be an air quality test which will be performed by welding in the area with the extraction running and then taking air samples and having them tested for harmful fumes. If the tests come back negative, then we will know that the fume extractor is working up to the desired standards.
The table will be tested for its strength and durability by adding a specific amount of weight to the top of the table to make sure it can withstand that load. We will be testing the table with roughly four hundred pounds. This goes with the assumption that nothing over four hundred pounds will be placed on the table.
3. Concept Development
3.1. Overview
3.1.1. Creative Strategies
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Welding Workstation
Noise (<80dB)
Heat
220V Power
Raw Materials (metals)
Finished Product (satisfaction)
Toxic Fumes/Smoke
Clean Air
Welding Source
Welder/spectator
Welder/spectator (safe, happy)
Research and analysis on industrial welding stations played a large role in the development of new concepts. The ideas were advanced through the processes of brainstorming, sketching, visualization, and role playing.
3.1.2. Governing Principles
Key principles that govern the welding station are:
Statics Mechanics of Materials (material strengths, structure design, component stresses) Ergonomics Heat Transfer (heat due to welding, exhaust gases) Fluid Dynamics (air flow, ducting) Acoustics (noise control) Electronics (control panel)
3.2. Synthesis and Analysis of Overall Concept
Each of these ideas came from concepts already in use in industry. These designs each have their fine points, especially since many are open to customization and modification for future upgrades. Ultimately, the ideal concept will be one that requires the least amount of construction, is the least expensive, and provides the greatest ease of use and benefits.
3.2.1. Station Configurations
There are three main ideas for the way in which the welding station could be configured. These are: an industrial hood, a downdraft table, and a pipe with one or multiple “arms”. In addition to these air entry configurations, there are a couple of different ways that the fan and filter system can be configured as well. One idea is to build a standalone fan and filter unit. The other idea is to modify the dust collection system that already exists in Loma 7 and extend the ducting to the welding station in Loma 6. Both of these ideas is suitable for proper fume extraction and can be connected to any of the station configurations.
3.2.1a. Industrial Hood
Industrial hoods are most often found in kitchen stove units as heat and fume extractors. A similar design would be incorporated into the welding station with the hood acting as a fume extractor (Figure 2). The hood would be constructed of sheet metal, attached to the wall above the table, and provide a vacuum over the entire surface of the table. This design will only work with the hood positioned at the correct distance from the table surface to provide adequate vacuum in pulling the fumes from the source and into the filtering unit located above the hood. One advantage to this design is a greater quantity of air moved away from the table which improves fume extraction. Another advantage is the extra storage space available around the table. Additionally, this design allows for the easy installation of a spark arrestor and sound damping material. Also, sparks are unlikely to be pulled from the table through the hood.
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Figure 2: Fume Hood
3.2.1b. Downdraft Table
Downdraft extraction is a concept discovered through research of current welding stations. The downdraft concept consists of a fume extractor built into the underside of the welding table (Figure 3). The table top has evenly spaced holes over the entire surface which are large enough to provide sufficient airflow, but small enough to prevent work items from falling through. The fume extractor creates a vacuum through the surface of the table, and then pulls the fumes through a filtering unit mounted under the table. One advantage to this design is that the table and extractor can be built as one unit. On the other hand, it would limit storage space for equipment and materials. With this design, there are noise concerns as the fume extractors are very loud and this is all one contained unit. This design is also more suitable for a factory setting than for a small workshop.
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Figure 3: Downdraft Table
3.2.1c. Pipe with “Arms”
Lincoln Electric installs custom fume extraction solutions. An illustration in their catalog shows a single duct with multiple flexible hoses (arms) extending to individual welding stations (Figure 4). The arms are adjustable such that the welder could move them into the desired position to concentrate vacuum where it is needed. A similar design would be incorporated into the welding workstation. One advantage to this design is that the user could turn off one arm when not in use by means of a blast gate built into the ducting. This setup is also very space efficient leaving the over head space virtually open for storage. Negatives to this design are that it is more difficult to install a spark arrestor and due to the number of bends in the pipe, airflow will be decreased.
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Figure 4: Pipe with Arms
3.2.2. Fan and Filter Configurations
3.2.2a. Standalone
Any of the air entry configurations could be connected to a standalone fume extraction unit. This unit would include a fan and a filter to provide sufficient suction and pull the toxic fumes away from the workstation filtering them into breathable air. One downfall of this idea is that it would be more expensive than the alternative. It would also take away from the already limited space in Loma 6 and 7. On the other hand, building a standalone unit would provide an easier way to obtain the required air flow and eliminate the hazard of sparks mixing with wood dust from the wood shop. To reduce excess noise from this system the fan and filter would be encased in an insulated box.
3.2.2b. Dust Collector
The current dust collector in Loma 7 is a ducting system that produces suction to multiple wood-working stations. A blower pulls the wood dust through filters to provide a healthier environment. The existing fan and filters are safe to use for welding although the addition of a spark arrestor is necessary to prevent rogue sparks from traveling through the ducting and igniting the wood dust. A three way connection would replace the existing two way connection and an additional pipe would cross Loma 6 into the welding area. From there, the pipe could be routed and set up to extract fumes. The main advantage for this setup is that building another fume extractor would be unnecessary. However,
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obtaining the required air flow may prove difficult. Additionally, this idea may not meet certain fire codes as welding is a spark producing operation. With regard to noise considerations, the majority of the noise emitted in this setup would be the air traveling through the ducts. This can easily be reduced with sound damping materials wrapped around the ducts.
3.2.3a. Table design
The table design (Figure 5) will provide a sturdy structure for welding operations to occur. It will incorporate a large surface allowing two welders to work simultaneously, ample storage space, and convenient tool holders.
Figure 5: Welding Table
3.3. Evaluation
Based on the decision matrix below (), modifying the existing dust collector was shown to be the best design concept due to ease of installation, noise control properties, space efficiency, cost, and aesthetics. However after a simple analysis (See appendices) of the losses through the ducting, adding an additional thirty feet from Loma 7 to Loma 6 would make it difficult to obtain the required air flow. The blower in the dust collector currently pulls about 4000cfm through two different paths. If a third is added and it is assumed that the resistance through those paths is equal then it would leave approximately 1330cfm through each. In reality, the resistance in the third path is almost double the current resistance through the existing two paths. Therefore meeting the customer requirement of at least 1200cfm would be unattainable. The theoretical air flow at the welding station was not calculated because the solution would be so non-linear that it would be beyond the scope of this proposal.
In addition to not being able to obtain the required air flow, the NFPA fire code stated in section 1.3.3 presents a major problem with using the dust collector. This code does not allow a spark producing operation, such as welding, to be connected to a dust collection system.
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All of the air entry configurations described in section 3.2 could be combined or interchanged to create more effective designs. For example, the industrial hood could be used with the upright portion of the downdraft table to provide more air flow. The downdraft design contained the most disadvantages in regard to adequate ventilation, sufficient storage, and floor space. All design concepts were created with the belief that “less is more,” while taking into account the need for durability, ease of installation, necessary potential modifications, and space maximization.
Table 1: Decision Matrix for Fume Extractor
Decision Matrix for Fume Extractor
Serviceability Cost Construction
Weight Factor: Go / No 10 10 8 6 7 8 5 10Downdraft (stand alone) Go 8 5 5 8 3 4 8 7
No 4 4 6 6 5 5 7 8
Go 6 8 8 8 4 8 3 7
No 3 5 9 6 7 9 8 8
Features / Selection Criteria:
Meet Codes?
High Velocity airflow near
welder
Total Air Flow
Efficient use of Space
Visual Appeal
Welder Safety
Downdraft (Dust Collector)Industrial hood ( Stand alone)Industrial Hood (Dust Collector)
3.4. Refinements
The best overall concept would be comprised of an industrial hood connected to a standalone fume extraction unit. One alternative would be to incorporate the industrial hood in conjunction with the upright portion of the downdraft table. An industrial hood would act as an overhead barrier to harmful fumes, and the combination of a piping/arm system could concentrate the fume extraction more precisely. The controls system could also be refined as needed. It would be ideal for the extractors to automatically turn on when needed and turn off when not needed, and this could be done by incorporating a light sensor panel behind the welding helmets. An example of this idea is the solar panel in the welding helmet. When it detects the welding light the shield dims to protect the eyes from the harmful light. If this could be applied to the extractors, such that the hood or arms start to pull in air when the intense light from welding is detected, that could reduce power consumption and noise when the extractors are not in use
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3.5. Selection
After reviewing all the concepts and analyzing both their advantages and disadvantages, the decision to build a standalone fume extraction unit is the most feasible solution. It will eliminate the danger of mixing sparks with wood dust, creating a fire hazard. It will also provide the necessary air flow to efficiently pull the fumes away from the work station. To reduce the excess noise, this unit and the pipes will be insulated. Moreover, the use of an industrial hood will provide the necessary airflow to effectively pull the rising hot air and other ambient toxins through the filter.
4. Design Specifications
4.1. Design Overview
4.1.1. Description
The standalone unit will include a blower, filter(s), a sound insulated casing, and a spark arrestor. The hood will be made of aluminum sheet metal, and the table will be an aluminum tabletop on a steel frame. There will be shelving underneath the tabletop for additional storage and support. The welding table will have a number of features designed to assist the welder, including multiple holsters for the welding torch and other tools, two spare pipes underneath the table used to bend metal into a and a section of the tabletop that extends beyond the support frame to make clamping parts to the table easier. The performance target that the table will support is at least 400 pounds.
4.1.2. Design Schematics
The following is a schematic that shows the different features of the welding station.
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Figure 6: Feature Schematic for Welding Station
The function schematic shows the separate functions of the stations itself. The table can support a large amount of weight on top. The harmful fumes are extracted through the hood and flow to the filters.
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Figure 7: Function Schematic for Welding Station
Functional specifications include FS1: To achieve flow greater than 1200cfm, a 3hp, backward inclined blower will be used FS2: To ensure the table will hold over 400lb, a steel frame will be used for support FS3: To ensure that two welders can work comfortably and simultaneously, there will be a large
industrial hood FS4: To ensure noise is kept to a minimum, sound damping material will be wrapped around the
pipes and the blower housing, and mufflers will be incorporated into the piping FS5: To make changing tanks and maintenance easier, the table will be mobile via lockable
wheels FS6: To provide more storage, shelving and drawers will be added
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4.3. Physical Specifications
Figure 8: Package Drawing for Welding Station
PS1: Fit into Loma 6 without taking up unnecessary floor space
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4.4. Product QFD
Product Design
Reqmts
FS3:
Ove
rhea
d Fu
me
Extr
acto
r
FS1:
St
anda
lone
Fan
FS7:
Cab
inet
s an
d dr
awer
s/O
rgan
izatio
n
PS1:
Fit
in
Lom
a 6
FS4:
Noi
se
Leve
l
FS5:
Rel
iabi
lity
and
Mai
nten
ance
FS2:
Str
engt
h an
d Du
rabi
lity
Budg
et
Customer Reqmts
5 ● □ □ □ □5 ● □5 ● □ □ □4 ∆ □ ● ●4 □ □ ● ●4 ∆ ● ● □
2 □ □ □3 ∆ ● □4 ∆ □ ∆ ●2 □ □
1200 cfm 1200 cfm 10 Ft3 6'x9'x12' ≤ 75dB 10+ yrs 400lb ≤ $2000
4 3 2 3 5 4 3 2
176 74 76 106 52 97 86 121
□Moderate Relationship 5
∆ Weak/Negative Relationship 1
RELATIONSHIPS:
● Strong Relationship 9
Importance Rating
Technical Difficulty
Target Value
User FriendlyCostNoise ReductionTwo Welders Simult.
Storage SpaceDurableRigid and SturdyMeet Codes
Not Applicable
Clean Air
Competitive Evaluation
Airflow
Priority
Figure 9: QFD
4.5. Subsystems
The project can be split into subsystems; air collection and welding table.
Air collectiono Blower selectiono Filter selection o Noise reductiono Hoodo Ducting and blast gates
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o Control system
Welding tableo Tabletopo Frameo Tool holders and bending pipeso Storage space
The air collection system has many different parts; it begins with the hood that is optimally positioned. The air system will have a controller so the welder can start up the air flow without having to walk into the other room. The ducting will have to be done in a way that will reduce the loss of air flow by having minimal bending in the pipes. There will be at least one spark arrester along the ducting as well as one in the arm or hood to make sure that no sparks come in contact with the saw dust. A blast gate will also be used so the air flow can be shut off to an individual arm or so that the dust collector can be used independently of the welding station.
The table will be made of a frame that can support the weight of the aluminum table top as well as 600 lb. Currently steel is the most commonly welded material, so the tabletop will be aluminum. It will have vice grips and clamps nearby and the edge of the table will be a convenient spot to use those on. It will have two pipes welded to the bottom of the table for a quick and easy way to bend metal. Also, there will be tool holsters on the side to keep the welding torch and other tools close and handy. There will also be underneath storage.
4.6 Design Deliverables
By the end of the first semester the customer will receive: Preliminary design report with associated modeling and analyses
o This proposalo Analysis of table design and ability to support weighto Analysis of extractor volume flow rate
Both arms on Individual arm
Full set of engineering drawingso Schematics already in this proposalo Package drawing
Bill of materialso Aluminum table top already suppliedo (4) 2”x2”x40” rectangular steel tubing; table heighto (2) 2”x2”x30” rectangular steel tubing; horizontal short side supporto (2) 2”x2”x70” rectangular steel tubing; horizontal long side supporto 12” diameter x 50’ aluminum ducting
Corner pieces required to attach ducting Cost estimates
o Bill of materials
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o Any machining needed that is not possible to do at USD
5. Project Plan
5.1. ResearchAdditional required research includes:
The relationship between pressure and flow through the piping needs to be investigated to ensure the fan will have the necessary volumetric flow rate. Also research needs to be done on acoustics and how to most effectively dampen noise being emitted from the air in the pipes, the hood, and from the fan.
5.2. Critical Function Prototypes
The two main critical functions with the new welding station are to support over 400lb on the welding table and achieve a flow rate of at least 1200cfm through the fume extractor. Analysis will be the most sufficient method in designing to achieve these requirements as well as validating them. The welding table will be able to hold more than 400lb and it will be physically tested to ensure this specification. As far as the fume extraction goes, an airflow meter will be used to ensure a minimum of 1200cfm.
5.3. Design
The first process in the design phase will be to come up with an original design of the system as a whole. This will be done first using the dimensions of the welding area and making sketches of the desired design. Once sketches have been done, analysis will be done on the welding table’s ability to support the required weight and on the fume extractor’s ability to achieve the desired flow. Different engineering tools such as Pro/Engineer and Solid Works will be used to draw up scale models of the specific parts. These parts will then be put together in an assembly so that the entire area will be a scale 3D drawing for verification.
5.4. Construction
The welding table will be constructed of a steel supportive frame with an aluminum tabletop. The steel frame will be welded together in the design selected after doing an analysis on its supportive capabilities. The tabletop on the current workstation will be used secured to the frame from the bottom, using multiple blind bolts along the perimeter.
The fume extractor unit will include a blower, a filter, and a housing made of sound dampening material. It will be mounted on the wall or to the ceiling on the west side of Loma 6. The piping will include a muffler as well insulation around the pipes to dampen the noise emitted from them as well, and will be mounted to the wall. The pipe will come out of the blower/filter housing and go to a hood attached to the ceiling. The hood will be positioned four to five feet above the table.
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5.5. Testing
The first and most important test for the welding table itself will be that it can support the amount of weight it was designed to support. In this case, that weight is 400 lb and can be tested with the use of a jackscrew. It will also be tested for its rigidity; how little it moves when bumped. For the fume extractor, an airflow meter will be used to ensure that there is a flow rate of at least 1200 cfm. The spark arrestor will be tested before installation, to ensure sparks will not ignite wood dust.
5.6. Project Deliverables
The tangible items delivered at the end of the spring 2008 semester include: New multifunctional welding table capable of supporting over 400lb Redesigned fume extraction system with two individual arms User instructions for operation of the blast gates and control systems.
5.7 Schedule
The following Gantt chart (Figure 10 and 2) shows the proposed schedule for this project.
ID Task Name Duration Start Finish
1 1st Semester-Part 1 78 days? Wed 9/3/08 Fri 12/19/08
2 Proposal Draft Sec 1-2 7 days? Mon 9/22/08 Tue 9/30/08
3 Proposal Draft Sec 3-4 5 days? Wed 10/1/08 Tue 10/7/08
4 Proposal Draft Sec 5-7 5 days? Wed 10/8/08 Tue 10/14/08
5 Complete Formal Proposal 3 days? Wed 10/15/08 Fri 10/17/08
6 Presentation Slides Draft 3 days? Fri 10/17/08 Tue 10/21/08
7 Proposal Presentations 0905-1205 1 day? Tue 10/21/08 Tue 10/21/08
8 Design Table 38 days? Tue 10/21/08 Thu 12/11/08
9 Ducting Design 38 days? Tue 10/21/08 Thu 12/11/08
10 Arm Design 38 days? Tue 10/21/08 Thu 12/11/08
11 Request Funding 15 days? Wed 10/8/08 Tue 10/28/08
12 Order Parts 15 days? Fri 12/12/08 Thu 1/1/09
13 Complete PDR Report 0 days Fri 12/12/08 Fri 12/12/08
14 PDR Presentations 1 day? Mon 12/15/08 Mon 12/15/08
15 Binder Due 1 day? Tue 12/16/08 Tue 12/16/08
10/21
12/12
12/15
9/21 9/28 10/5 10/12 10/19 10/26 11/2 11/9 11/16 11/23 11/30 12/7 12/14 12/21
Figure 10: 1st Semester Gantt Chart
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ID Task Name Duration Start Finish
16 2nd Semester- Part 2 88 days? Mon 1/26/09 Wed 5/27/09
17 Ensure Raw Materialreceived/available
4 days? Mon 1/26/09 Thu 1/29/09
18 Cut Steel 1 day? Fri 2/6/09 Fri 2/6/09
19 Assemble Table 13 days? Mon 2/9/09 Wed 2/25/09
20 Test Table 2 days? Thu 2/26/09 Fri 2/27/09
21 Test The Fan 3 days? Fri 2/6/09 Tue 2/10/09
22 Build Extractor Unit Casing 6 days? Wed 2/11/09 Wed 2/18/09
23 Assemble Extractor Unit 6 days Wed 2/11/09 Wed 2/18/09
24 Critical Design Review 0 days Tue 3/31/09 Tue 3/31/09
25 Build Arms 16 days? Fri 2/27/09 Fri 3/20/09
26 Test Fume Extraction System 3 days? Mon 3/23/09 Wed 3/25/09
27 Final Design Review 0 days Wed 5/27/09 Wed 5/27/09
3/31
5/27
1/25 2/1 2/8 2/15 2/22 3/1 3/8 3/15 3/22 3/29 4/5 4/12 4/19 4/26 5/3 5/10 5/17 5/24 5/31 6/7
Figure 11: 2nd Semester Gantt Chart
5.8 Budget
Below is the proposed budget (Table 2) for this project.
Table 2: Initial Budget
Cost Quantity Shipping/Tax SubtotalSteel Tubing
STOCK 4 $0.00 $0.00STOCK 2 $0.00 $0.00STOCK 2 $0.00 $0.00$33.95 3 $17.00 $118.85
$700.00 1 $100.00 $800.00$20.53 8 $14.00 $178.24$46.16 1 $50.00 $96.16$2.99 1 $4.00 $6.99STOCK 4 $0.00 $0.00
TBD TBD TBD $100.00
TBD TBD TBD $100.00
TBD TBD TBD $100.00
Total $1,500.24
Part/Material
Wel
ding
Ta
ble
Sheet Metal - Stainless Steel (12"x24")Industrial Fan - BI 1200 cfm
Rectangular (2”x2”x40”)
Fum
e Ex
trac
tor
Screws, nuts, bolts
FiltersFiberglass Tape (2" x 10yd)
Machining
Rectangular (2”x2”x30”)Rectangular (2"x2"x70")
Misc
ella
neou
s
Miscellaneous
10" Diameter (50 ft)
Noise Insulation (Fiberglass 4"- 80 ft2)
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5.9 Personnel
The following flow chart (Figure 12: Organizational Chart for Welding Station shows the personnel responsibilities further organizing the project.
Figure 12: Organizational Chart for Welding Station
6. References:
Welding Table:Miller, Dan. "Build your own welding table." <http://progressivefarmer.com/tabid/579/default.aspx>.
Fume Extraction:Lincoln Electric Catalog. 2008.
Codes and standards:http://www.osha.gov/pls/oshaweb/owasrch.search_form?p_doc_type=STANDARDS&p_toc_level=0&p_keyvalue=
7. Appendices
7.1. Loss Calculations
hl=flV 2
D2 gMajor Losses
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hl=k lV 2
2 g Minor Losses
Modification to the current dust collector
Three paths for the air to travel:1. Short path to band saw/sander/chop saw2. Medium path to table saw3. Long extension to welding station
Assumption: V = 61 ft/s
Losses: hl, 1 = 7.85 fthl, 2 = 23.99 fthl, 3 = 43.41 ft
Hood versus Arms
Assumptions: V = 80 ft/s
Two arms in parallel connected to a “Y” junction:
hl, arms = 25.04 ft
Hood:
hl, hood = 2.29 ft
7.2. Team Member Resumes
See following pages for resumes.
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Michael Correia3435 Wisteria Dr.
San Diego, CA 92106(619) 993-1842
EducationSt. Augustine High School (San Diego)
Honors Pre-calculus, AP American HistoryUniversity of San Diego
USD 95.5 units completed toward a Bachelor of Science/Bachelor of Arts in Mechanical Engineering with a Math minor
Work ExperienceTaylor Guitars (May-August 2007) & (May-August 2006) Preventative maintenance and repairs on Fadal CNC machines, Multicams, Straight-line rip saw
and dust collection systems Assisted in building an ultra-violet oven to quickly dry the finish applied to the guitars
Engineering Courses CAD & Machine shop, Statics, Dynamics, Fluid mechanics, Engineering economics, Thermal
Science, Applied Thermodynamics, Engineering Materials, Machine Design, Manufacturing processes
Computer proficiency Solid Works, Pro/Engineer, Matlab, Auto CAD, CNC programming, Self taught: Solid Works, Maple, Microsoft Office (Word, Excel, PowerPoint, and Outlook),
Photoshop, HTML and iMovie. Awards and Honors
First honors(3.6-4.0) : 9th grade Third place in the regional ROV competition
Clubs and activities Robotics club 11th and 12th grade.
1. FIRST Robotics Competition 2. Under water ROV competition
Eucharistic minister and Alter Server at St. Charles Borromeo Junior Racquet ball association (age 14 – present) Festa do Santo Amaro (Portuguese Religious Organization) Volunteer San Diego (SAVY) (2002 - present) S.E.S –Society of the Holy Spirit National Student Leadership Conference (Engineering)
Community Service Tutor 6th, 7th & 8th graders in math Cabrillo Festival (2003 to present) Red Cross fundraiser in Mexico ( 2002 and 2003) Helped set up the computer lab for student use at St. Charles Borromeo (2001) Volunteer worker Festa Do Santo Amaro (2005/2006) Volunteer worker SES ( Society of the Holy Spirit) ( 2004 to present)
Personal Background Interests: Certified diver, golf, racquetball, camping, biking, billiards, 3-D animation, driving,
playing the guitar, swimming, built own computer in high school and recently.
26Zachary Lamar
5998 Alcala Park Unit 6107 1050 Meisner Rd.
Matthew S. Leigh
5375 Napa Street #B202San Diego, CA 92110
816 - 377 - [email protected]
www.myspace.com/ccjazzwww.ccjazz.com
OBJECTIVE: Seeking an entry level position in music production and acoustics/acoustic engineering to utilize and strengthen my technical knowledge and gain hands on experience.
EDUCATION: University of San Diego B.S., B.A., with honors, Mechanical Engineering – Graduation Expected: December 2009 Business Administration, Minor GPA: 3.69 Plan on pursuing Graduate studies in related field
COURSEWORK & LAB EXPERIENCE:Classically trained musician, Synthesizer programming, MIDI programming, Digidesign Pro Tools, Physics: Sound Waves, Acoustic Theory, Electrical Signal Processing
EXPERIENCE:Recording Engineer Intern: 6/08 – Present: Boys & Girls Club Linda Vista, Teen Center Recording Studio, San Diego, CA Volunteer time to help develop skills of young musicians, singers, and songwriters Produce artists by creating beats and providing guidance with lyrics Act as chief engineer on various studio sessions
Producer: 6/06 – 8/06: Cruise Control: City Life ©2007, Kansas City, MO Composed all material for full-length album Acted as manager for band during recording and following summer (2007), by handling finances,
scheduling tour dates, rehearsals, web design, photo shoots, etc.
TECHNICAL EXPERIENCE & SPECIAL PROJECTS: USD Mechanical Engineering Welding Table Design Project (ongoing): Designed,
fabricated/selected components, assembled, tested, and selected final design of noise control system/acoustics within HVAC/fume extractor
TECHNICAL SKILLS: Instruments: Bass, Piano, Guitar, Trumpet, Latin percussion Operating Systems: Windows XP, Vista; Mac OSX Software and Plug-ins: Digidesign Pro Tools, Microsoft Office, IK Multimedia Reason, Antares Autotune,
Altiverb
HONOR’S & AWARDS: USD Alcala Senior Honor Society Chapter of Mortar Board – President – Senior Honor Society based
on the values of Scholarship, Leadership, and Community Service Tau Alpha Zeta Engineering Honors Society Charter Member Dean’s List, First Honors – Fall 2005, Spring 2006, Fall 2006, Fall 2007 Sigma Phi Epsilon Balanced Man Scholarship – September 2005- Given to a young man for
exemplifying the ideal of the balanced man and excellence in academics, athletics, community service and social activities
Order of Omega Greek Honor Society – Selection based on betterment for Greek community, concern for welfare and development of the university, and contributions in the furtherance of Interfraternal relations seeking the ideals of fraternal brotherhood
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7.3. Vendor Information
In order to gain further understanding in the overhead fume extracting arms, the Lincoln Electric catalog was used as a visual.
Figure 13: Lincoln Electric Overhead Fume Extractor Arms Concept
Figure 14: Lincoln Electric Overhead Fume Extractor Arm Concept (close-up)
7.4. Component Specification Sheets
We have not identified certain parts at this time, but a new fume extraction arm will be selectedPerhaps information about the steel used for the table and the volume of air the fan can pull in?
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