Integrated System Build & Test
Table of Contents
|MSD I & II||MSD I||MSD II|
Phase 4: Integrated System Build & Test
Complete Design Documentation
Drawing PackageAll drawings for the hospitality room cabinet can be found here.
All drawings for the dining room cabinet can be found here.
All drawings for the storage carts (both large and small) can be found here.
Bill of MaterialsThe final bills of materials for the cabinets and carts are shown below. The live document can be found here (Microsoft Excel .xlsx format).
Assembly ManualThe assembly manual for the hospitality room cabinet, dining room cabinet, small storage cart, and large storage cart can be found here. As of May 1, 2017, only the cart assembly manuals have been completed. The assembly manuals for the cabinets will follow soon.
Brinkman lab - Preparing and Cutting Carts PartsOnce the parts for the carts arrived, the team went down to the Brinkman lab in order to cut the parts to the correct dimensions and prepare each part. The metal "L" bars were first sanded down to remove any residue. Then it was wiped down to get rid of the dust from sanding. Later, the "L" bars were cut to fit the width and length of the cart using a bandsaw. (Shown in Figure 1.)
Then holes were drilled into the bottom surface for the screws to go through. (Shown in Figures 2 and 3)
For the plywood, the panel saw in the wood shop was used to cut the wood to be 15.5" x 21". (Shown in Figure 4). Later, the parts for the double cart were also prepared and cut in the exact same manner.
MSD Area - First Prototype Cart AssemblyAfter the plywood and the metal "L" bars were cut to the correct dimensions, the "L" bars were attached to the plywood with screws using a drill. (Shown in Figure 5)
Then the plywood was flipped over and the casters were attached with screws using a drill and #6 X 5/8" wood screws. (Shown in Figure 6)
The completed cart is shown in Figure 7.
St. Joseph's - Double Cart AssemblyFirst the steel "L" bars were added to the cart. The dimensions the bars were placed were exactly the same as the small cart. A spacing in between the two areas was added in order to accommodate the slanting of the totes. (Shown in Figure 8)
Then the casters were added. Two swivels are on one side of the board and two rigid are on the other side. The rigid casters were attached using a screw and nut which the swivels were just screwed directly on. (shown in figure 9)
The completed double-stack cart is shown in Figure 10.
Home Depot - Purchasing partsOn April 4, 2017, the team went to Home Depot to purchase the plywood and lumber for the cabinet. The total purchase (including online orders) was about $1300.00 with a total weight of about 1000 lbs. Figures 11 and 12 show the lumber and plywood that was purchased.
The plywood and some of the lumber were too large to fit in our cars, so the bulk of the order remained at Home Depot. On Thursday, April 6, we returned for the plywood and the long two-by-fours with a rented U-Haul pickup truck. It was a rainy day, but a tarp purchased from U-Haul kept the wood largely dry until we were able to unload it into the RIT machine shop.
RIT Machine Shop - Building Piece PartsOn Tuesday, April 11, we began the task of cutting the plywood and lumber to the desired sizes. We began by marking the complex-shaped plywood pieces, as shown in Figure 13.
Throughout the following week, we met regularly to cut out plywood parts using the panel saw in the RIT wood shop, as shown in Figure 14. Figure 15 shows a panorama of the sometimes-crowded nature of working in the wood shop.
Figure 15: Finding room for four people to navigate around the stack of plywood was frequently a challenge.
In addition to cutting the plywood panels, we also met to cut two-by-fours to the design lengths using the miter saw. The miter saw enabled us to easily cut the angles needed for the hospitality room cabinet.
Shifting Base of Operations from RIT to St. Joseph'sOn Tuesday, April 18, we shifted our base of operations from the RIT senior design space to the hospitality room at St. Joseph's. Sam Huselstein assisted with the move, driving one of St. Joseph's vans to RIT. There, we loaded the plywood, lumber, and hardware into the van. We met Sam at St. Joseph's and immediately began unloading the supplies. Since St. Joseph's was closed for the week of April 17-21, we were able to spread our supplied out in the hospitality room.
Once all the supplies had been unloaded, then first order of business was to varnish the cabinet panels, since nearly all the assembly required the panels to be finished and dried. We borrowed two tarps from St. Joseph's to use as drop cloths, as well as a brush, roller, and roller pan. We laid out several panels, and got right to work. We were instantly impressed with the results, as the polyurethane brought out the grain of the red oak plywood. Figure 16 shows the varnished panels arranged on the floor of the hospitality room. Figure 17 shows how the varnish brought the beauty of the red oak to life.
Figure 16: Cabinet panels arranged on the floor of the hospitality room, in varying stages of the finishing process.
St. Joseph's - Dining Room CabinetAssembly of the dining room cabinet began the same day as varnishing the panels. We first assembled the rectangular frame that makes up the base of the dining room cabinet, as shown in Figure 18.
Figure 18: The first step of assembling the dining room cabinet: constructing the base of the frame.
On Thursday, April 20, we followed by assembling the top of the dining room cabinet frame. The next step was to attach the floor of the cabinet to the base frame, as shown in Figure 19. Aligning the base frame to all four sides of the floor helped to square the base frame.
Then we turned the cabinet on its side, to simplify the assembly of the upright beams of the frame. This allowed us to place the upright beam flat on the floor, align it with the base, and secure it with screws. We repeated this for the adjacent beam, then attached both of those beams to the top frame, as shown in Figure 20.
After these two beams had been secured, we rotated the assembly by 180 degrees, so that its opposite side rested on the ground. Then we repeated the previous steps to attach the other two upright beams. Having completed the assembly of the frame, we stood the cabinet up and moved it onto the window ledge. We attached the back panel of the cabinet in the upright position, as shown in Figure 21.
We began to install one of the side panels when we realized that the process would be much simpler if the cabinet were again laying on its side. We laid the cabinet back down, and attached the side panel. We found that laying the cabinet down made it easier to press the side panels against the frame, enabling us to get a tight fit between the panel and the frame. We also discovered that it was easier to square the frame when the cabinet was on its side. This process required one team member to climb inside the cabinet while another team member drilled the screws from the outside, as shown in Figure 22.
Once the side panels of the dining room cabinet had again been attached, we stood it back up (a much harder task to accomplish this time) and moved it back to the window ledge of the dining room. Then the door for the Kitchen Room cabinet was made. This was completed by laying the beams for the frames on the floor and screwing the parts together, as shown in Figure 23 below.
The plywood for the Kitchen Room cabinet was then placed on top of the frame and was screwed down onto the frame as shown in Figure 24.
Then the door was attached to the side of the plywood of the side panel and the frame beam of the door by using three hinges with 6 screws each as shown in Figures 25 and 26.
In the inside of the cabinet, there were 6 hooks attached onto the beam frame for the bungee support using 4 screws each for both vertical cabinets. This is shown in Figure 27.
Hospitality CabinetAssembly of the hospitality room cabinet followed assembly of the dining room cabinet, beginning on the 21st of April. We quickly realized that some modifications of the cabinet were in order. First, we discovered that our measurements of the hospitality room were slightly off, and that the "cut-out", designed to fit around a protrusion from south wall of the hospitality room. We elected to removed the cut-out entirely, by cutting a few inches off the end of the cabinet. This required modification of the top and bottom panels of the cabinet, as well as the fabrication of a new end panel for the cabinet. It also made three small panels in the "cut-out" obsolete.
We first assembled the top frame of the tall portion of the cabinet, shown in Figure 28.
This was followed by attaching the vertical beams of tall section of the cabinet (see Figure 29).
After we had assembled the tall frame of the cabinet, we placed it in its designated position. This caused us to discover a second small issue: an electrical outlet on the wall that we had failed to account for. The frame, placed (as designed) in the extreme corner next to the door, prevented use of the outlet. However, the removal of the cut-out was in our favor. The cabinet was now a few inches shorter, allowing us to reposition the entire cabinet, shifting it away from the outlet. Figure 30 shows the test alignment of the tall frame.
The next step was to attach the rear and side panels to the tall frame, as shown in Figure 31.
Once we had completed this step, we pushed the tall cabinet into the corner, aligning it with the edge of the base panels. We attached it to the base panel by drilling screws through the front and rear two-by fours on the base of the cabinet. Our next step was to attach the top of the cabinet. As we began this step, we realized that it should have preceded the attachment of the cabinet to the base. Since the corner of the cabinet was in the corner of the room, and the assembly too heavy to move, it was difficult to reach some of the screw locations which held the top to the tall cabinet. However, with some difficulty, we were able to attach the top of the tall cabinet, as shown in Figure 32.
We then turned our attention to the bench portion of the hospitality room cabinet. We first assembled the top frame of the bench, using the long beams and the cross beams. Then, with the top frame resting on an array of chairs, we attached the legs of the bench. When attaching the legs of the bench, we omitted the three legs which were adjacent to the tall portion of the cabinet. We decided that it would be easiest to install those three legs after the bench frame had been positioned next to the tall portion of the cabinet. We then attached the rear panels to the bench, which left the frame assembly in the state shown in Figure 33. As with the dining room cabinet, attaching panels to the frame enabled us to square the frame.
Once the new end panel for the bench had been cut, we attached it to end of the bench portion of the cabinet. Once this step was complete, we placed the bench frame in position on the base panels, since we no longer needed to access the rear and side of the bench. We then attached the bench frame to the tall portion of the cabinet, including the three legs omitted earlier. Once that attachment was complete, we attached the rest of the legs to the base panels, and began filling all joints in the cabinet with caulk, as shown in Figure 34.
Once the frame was completed, the front door was attached. A dremel was used to cut into the plywood to fit the hinge underneath the plywood so that there would be no gap between the door. The hinges were then screwed onto the plywood door and the beam frame. As shown in Figures 35 and 36 for the horizontal mattress storage and the additional storage area doors.
Once the doors were attached, door handles were attached using the dremel and drill to create a whol for the door knob to enter. A piece of wood was attached to the other side to hold the door knob in place, as shown in Figure 37 and 38.
Then the dremel was used to create a hole for the door plate to sit on and was screwed in place, as shown in Figure 39.
Then weatherstrip was added to the door for all the cabinet openings, as shown in Figure 40.
Then caulk was added to the top of the frame so that it can seal the cracks once the top plywood was placed. (Shown in Figure 41)
Then the top plywood boards were placed on top and screwed in place. The completed horizontal cabinet is shown in Figure 42.
TestingThe following tests have been completed:
- TR0010 - Verification of weight of guest belongings that the system can support - the storage carts were tested by loading them with gym weights. The weight used in the test was determined by visting St. Joseph's during the shelter season to weigh loaded totes from the storage closet. We found that the heaviest tote weighed 30 pounds. With six totes on the small cart, this is a total weight of 180 pounds. With 12 totes on the large cart, this is a total weight of 360 pounds. We included a factor of safety of 1.5, so the small carts were tested with a weight of 270 pounds, and the large carts were tested with a weight of 540 pounds. All carts survived testing satisfactorily, showing no signs of failure and rolling readily. The full test report can be found here.
- TR0013 - Verification of Volume of Belongings that Can Be Stored - the storage totes at St. Joseph's were measured and found to each contain a volume of 2.04 cubic feet. Each guest will be allowed two totes, so the total volume of storage available to each guest is 4.08 cubic feet. Engineering Requirement #6 requires that at least 3 cubic feet of storage space be available to each guest, so the system meets this requirement. The full test report can be found here.
- TR0015 - Verification of Cart Safety with Respect to Tipping - a dynamic analysis of the storage cart was performed to determine the force required to tip the cart. In this analysis, it was assumed that the wheels would not roll, which is surely a worst-case scenario. In the test, the cart was loaded with gym weights, and pulled with a luggage scale. The weight of the load on the cart and the force required to cause the cart to roll were recorded. For all loads up to 270 pounds (1.5 times the maximum expected load in service), the force required to cause the cart to roll was less than the force required to tip the cart. Therefore, we expect that the cart will roll rather than tip. For applied loads less than or equal to the maximum expected load in service, the factor of safety against tipping was at least 1.3. The full test report can be found here
- TR0001 - Time to Set Up Shelter - This test was designed to verify the performance of the mattress storage cabinets with respect to Engineering Requirement #2: time to move sleeping materials from storage to sleeping configuration. The team conducted a benchmark test and found the existing system to have a setup time of 3:13. The same test was conducted on the new cabinet system and the total setup time was 1:29. This showed an over 50% reduction in setup time and required significantly less effort to complete. The proposed method should also increase the lifespan of the mattresses as there is minimal wear and tear under the proposed system. The full test report can be found here.
- TR0002 - Time to Clean up Shelter - This test was conducted to verify the performance of the mattress storage cabinets with respect to Engineering Requirement #3: time to move sleeping materials from sleeping configuration to storage. The benchmark test of the existing system yielded a duration of 3:28. The system test of the cabinet system yielded a duration of 2:07. This was an improvement in total duration but the biggest difference between the tests was the effort required to complete the tasks. The cabinet system does not require mattresses to be lifted above 6" as compared to the 9' of the benchmark system. Combined quicker times plus reduced total effort should increase guest participation in cleaning the shelter each day. The full test report can be found here.
- TR0006 - Maximum Distance Sleeping Materials must be Carried - This test was conducted to verify the performance of the sleeping materials storage system with respect to engineering requirement #9: distance sleeping materials must be moved from sleeping configuration to storage. The benchmark test concluded that the maximum distance a mattresses would need to be moved was 53'. The cabinet system test concluded that the maximum distance a mattresses would need to be moved was 24'. Due to the location of the cabinets being stored in each of the two rooms at St. Joe's, Mattresses only need to travel less than half the distance of the prior system. The full test report can be found here.
- TR0007 - Maximum Height to Which Sleeping Materials must be Lifted - This test was conducted to verify the performance of the sleeping materials storage system with respect to engineering requirement #10: maximum height to which sleeping materials must be lifted. The benchmark test of the existing system concluded a maximum lifting height of 8.5'. The cabinet system test concluded a maximum lifting height of 0.5'. This test displays the greatest advantage of the cabinet system to the existing loft storage system. Minimizing lifting height reduces the amount of effort required to set up and clean up the sleeping materials. The full test report can be found here.
- TR0011 - Floor Space Occupied by Storage System - This test was conducted to verify the performance of the sleeping materials storage system with respect to engineering requirement #5: floor space occupied by the mattress storage system. The goal of this requirement was to minimize the amount of floor space that would be lost when a new system was established. The existing loft system does not take any floor space within the hospitality or kitchen rooms. The test concluded that the floor space area the cabinets occupied is 71.01 sq. ft. One exception to this result is that the hospitality room horizontal cabinet can be used during the day as a bench and at night as a bed. If this space is not deemed "lost" due to the cabinet system, the total area occupied by the cabinets drops to 30.7 sq. ft. The full test report can be found here.
- TR0014 - Weight of Mattresses that the Cabinet can Support - This test was conducted to verify the performance of the sleeping material storage system with respect to engineering requirement #17: total weight of mattresses that the storage cabinets can support. The total weight of the mattresses loaded into the cabinets was 340 lbs. The cabinets were inspected for any signs of damage such as cracking or fatigue in the wood. No indications of damage were found when the system was under max storage capacity weight. The team is confident that the system is able to support both the weight of the mattresses and the weight of individuals sitting on the bench section of the hospitality room cabinet. The full test report can be found here.
Performance vs. Engineering RequirementsThe table below summarizes the results of tests as of 5/4/2017, showing performance relative to engineering requirements.
Summary of system performance with respect to engineering requirements, for tests conducted to date.