Design of an All-Terrain Intermediate Frame Transport and Storage System
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MDS Aero Test has tasked JML Consulting (Team 8) with designing an All-Terrain Intermediate Frame Transport and Storage System. MDS Aero Test tests engines for jet engine manufacturers: Pratt & Whitney and Rolls Royce. Each engine manufacturer has an intermediate frame (IF), which connects an engine undergoing testing to the thrust frame on the test stand. This report covers the project definition and concept generation through the final design. The team analyzed the project’s needs, target specifications, limitations, and constraints. The three main project requirements are: to transport the IF across the test sites, to accommodate year-round storage of the IF outdoors or in the company’s cold storage facility, and lastly, to position the IF to be hoisted at the test sites. Therefore, the team will design a Transport and Storage Cart (TSC) for the IF. The Transport and Storage cart (TSC) will provide a simplified and efficient means of transporting the IF alone - without an engine. It would also act as a storage unit for the IF, freeing up valuable space in the MDS Aero Test prep shop where it is currently stored. The team generated several concepts to meet the design requirements. Then, the various concepts were filtered to the top two using a weighted decision matrix, and the team discussed these concepts with the client. After performing a preliminary analysis of the top concepts, the team selected the final design using the SLST concept. The final design has three functional sub-assemblies: storage, lift, and transport subassembly. A detailed analysis of the final design included an FEA numerical analysis to analyze the stress, strain, and displacement. In addition, the team analyzed the torque and torsional force applied to the shafts and performed other minor calculations to validate the TSC. Finally, the team optimized the final design using the results from the analysis. Commercial and fabricated parts are used as much as possible in the design. However, due to the requirements of the lifting assembly, a custom-made scissor lift table is required. The team contacted various custom lift table manufacturers with the design specifications and confirmed the feasibility of the specified lift table. At this design stage, the manufacturers cannot provide a detailed quote. But all the information supplied and the initial quote is included in the report. The report includes all deliverables, including preliminary engineering drawings, with a BOM, supporting calculations, and estimated build costs. The compressed height of the TSC is 12.75 ft, so it can be stored in the cold storage facility. Its elevated height is approximately 21 ft and will allow the IF to be hoisted at site B. Still, it would depend on the specific scissor lift table selected. The TSC can be stored outdoors year-round, and the TSC will transport the IF across the test sites. The TSC satisfies all the project needs and is within the constraints provided by the client.