Preliminary Detailed Design
Table of Contents
Our team's plan for this phase was to is to begin the preliminary design of our vacuum former. Using the subsystems that we determined in the previous phase, we created designs for each subsystems, as well as bills of materials and cost projections. Due to the uncertainty of our choice of heating system, we created designs for both electric and propane systems. Our team visited a vacuum forming company Farro Industries and were able to learn from their industry experience. At the end of this phase, the majority of our design is finalized and components are ready to be purchased, with only a few detail design questions remaining to answer in the next phase.
Team Vision for Preliminary Detailed Design PhaseDuring this phase, our team's plan was to:
- Further analyze our concept design, and finalize other evaluations for our design to be efficient and logical.
- Create a preliminary Bill of Materials and review them against budget.
- Continue our preliminary CAD models and drawings.
- Test plans for the parts of the system.
- Investigate requirements to ensure on track to meet important ones.
- Investigate mitigation of risks defined in previous phases.
- Visit Faro Company to further understand the process and gather all important information related to our concept design.
We have successfully accomplished all the plans listed above and uploaded them on EDGE.
Feasibility: Prototyping, Analysis, Simulation
This picture is a side cut-out of how the walls of the superstructure are and how the heating element will be placed on it. The first layer will be thermal flocking to protect operators from burns the next will be the metal structure, insulation, and then a metal plate to mount the heating element to.
SuperstructureThe superstructure of the vacuum former was designed in Fusion 360 primarily using downloaded components from 80/20 Inc and McMaster Carr.
Bill of Material (BOM)
Electric Heating System
Propane Heating System
This is the bill of materials for the propane heating element design I showed. This bill of materials shows different heating element configurations and what that will do to the price. The design is based of 1 propane tank for 1 propane heater because we do not know if will be able to do have 2 or 4 heaters on 1 propane tank. So the 4 heaters is the worst case scenario.
Propane Heating Element Testing: machine shop welding area
- Distance/Temperature Testing – taking infrared thermometer readings at different distances to find the optimal distance to hold the plastic from the heater
- Time to Heat – determining how long it will take to heat the plastic to the correct forming temperature
- Diffusion – using screens to attempt to diffuse the heat to achieve even heating and ensuring that there is only a need to use one heater
Vacuum Pump Testing: Construct or MSD Design Center
- Power – determine if there is enough power to fully pump down the tanks
- Time to Pump Down – determine how long it takes to remove air from the tanks
- Time to Form – determine how long it takes to draw all the air from the mold