l3 communications reverse engineering anish and jacobo
Post on 26-Jun-2015
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Constraints
Certain rules we must abide by
1. Alter the original testing rack, but without changing size and
overall design.
2. The timer inputs must not be altered.
3. The structure must support itself.
4. Materials that have a low melting or freezing point cannot be
used.
Problem and Design Statement
To Develop a new testing racks to hold timers. This rack must go
through any environment the timers would go through. L3 Avionics
would put this rack into a testing chamber to see if the structure and
timers and withstand the environmental forces.
Target Consumer and Client Co. would be L3 Communications.
Design Statement: To design, model and build a testing rack which
holds timers through contrasting temperatures and physical
movements.
Problems found
Main Problems
Solutions
Ideas
Material
Hardness
Sturdiness Weight Longevity Safety
Totals
Idea
#1
4 2 2 2 3 13
Idea
#2
1 3 2 1 3 10
Idea
#3
3 3 3 3 3 15
Idea
#4
2 2 1 4 2 11
1 2 3 4
Material
Hardness
The material will chip and
break easily.
The material has many
spots that can fracture, but
still retains some of the
structure after force has
been applied.
The material can withstand
much outside force, but can
chip or break in small spots.
The material of the structure
can experience much force
and not break.
Sturdiness The structure will fall
multiple times with
consistent outside forces.
The structure cannot stand
too long with consistent
outside forces.
The structure can withstand
much of outside forces, but
will fall if too much force is
applied.
The structure can withstand
much movement without
falling.
Weight The structure would be too
heavy for a person to carry
for more than 2 minutes.
The structure is somewhat
heavy and cannot be held
for too long.
The structure is somewhat
light weight and bearable to
carry.
The structure is light weight
and easy to carry.
Longevity The structure will need
many fixes and will not last
for a long period of time.
The overall product will
need replacing multiple
times.
The structure will last a
moderate amount of time
and will need many fixes.
The structure will last a long
period of time, but will
require a few fixes over
time.
The structure will last a long
period of time before the
need of a replacement.
safety The product has wires
sticking out that are used to
channel power. If there
wires were touched by
someone, the person
operating could receive
serious injuries.
The product has wires and
edges that are not covered
that may harm the user.
The product has certain
edges that may harm the
user.
The structure is all-around
safe for the users and
cannot harm the user if any
way, shape or form.
Chosen Idea
The proposed structure would contain a handle on the top and everything will acquire a new material scheme of Titanium.
The steel base of the structure would be removed.
There will be a plastic sheet covering the wiring in the back of the structure that can slide in and out of place for easy access.
The thickness of the Railings will be reduced.
The Titanium is known for its excellent resistance to corrosion.
Final prototype of Chosen Idea
New Back
Assembly Chart Group Members:
Anish Tailor and Jacob
Wilson
16-May-11
Pa
rt # Part Name
Qua
ntity Dimensions Function
Mat
erial
Textu
re/Fini
sh
Interaction with other
parts
General
notes
1
back board
1
16.75" X 14.5" X .1" thick
protects wires
phe
nol
smoot
h
connected to main part
necessary,
could be
lighter
2 plastic plugs 99
.725" outer diameter X 1.126" inner diameter X
1.640" length x .127" thick inner diameter indicator plugs inputed in
here
plast
ic dull
held in place by screws
and panels
cannot
remove
3
back hex
screws (small) 4
5.26 cm X inner diameter 1.5cm, 2.64 cm outer
diameter
holds back board steel dull
connects back to main
part
necessary,
could be
altered
4 handle 1
1.5" length X .25 thick X 6" width
carrying device
met
al
shiny/
smoot
h
part of the top, carries the
device
add another,
change
location
5
horizontal
bars 9
.25" length X 17" depth X 1" width plastic plug outlets are on
here
Gar
olite
shiny/
smoot
h
outlits are on them
change
shape and
material
6 top screws 2
.2" diameter X .5" length X .1" diameter
connects the top steel
shiny/
smoot
h
connects the top to the
TN-2588necessary
7
connection
cord 1
70" length X 1.75" diameter
allows it to be plugged in
plast
ic
dull/ro
ugh
provides power to the TN-
2588
stays the
same
8 plug 1
N/A
allow electricity in
plast
ic rigid
main source of powerstays the
same
9
horizontal
panel wires 2
13" length X .03 diameter
connect indicator outlets
cop
per shiny
allows electricity to flow
horizontally
stays the
same
10
vertical panel
wires
16
2" length X .075" diameter
connect panels and outlits
cop
per shiny
allows electricity to flow
vertically
stays the
same
11 Plug screws 198
inner diameter .055" X length .25" X .21" outer
diameter X .073" widthhold outlets in steel shiny
holds outlit onto panels Phillips
12 handle screws 2
.286" inner diameter X .33" outer diameter X .115"
length (top) X .626" widthconnects handle to the top steel rusty
secures the handle to the
top
change
location
13
Metal sqaures
with inslits 4
1" length X 1" width X .5" thick
holds the small metal bars
to the back plate
Gar
olite
shiny/
smoot
h
leaves a space between
the small metal bars and
the back plate
stays the
same
14 front screws 14
.235" inner diameter X .56" length X .451" outer
diameter X .166" width holds the small metal bars
to the big metal bars steel rusty
holds the small metal bars
to the big metal bars
stays the
same
15
small metal
bar 9
.25"length X 17" depth X 1" width, 0.618" diameter
holes (11 each) in them, .9" diameter holes (22
each .91 from larger holes)
holds the plugs
alu
min
um
shiny/
smoot
h
it is attached to the big
metal bars on the ends
stays the
same
16 vertical bars 2
.5" length X 15.5" depth X 1" width
holds up the small metal
bars
Gar
olite
shiny/
smoot
h
provides a space between
the small metal bars and
the back plate
stays the
same
17 hex screws 4
inner diameter .242" x inner length 1" .37 outer
diameter x .25" outer length holds in the bottom and top
small metal bars to the big
metal bars steel rusty
secures the metal bars to
the big metal bars
stays the
same
18
green back
screws 2
.187" inner diameter X 1" length X .35" outer
diameter X .19" widthholds the structure up
alu
min
um dull
screws on to the base N/A
19
green back
washer 2
inner diameter .215" X outer diameter .57" X thick
.056" secures the screw better
alu
min
um dull
underneath the screws N/A
20 handle plate 1
.25"length X 17" depth X 1" width, 0.618"
holds the structure together
alu
min
um
smoot
h
handles are screwed on to
it N/A
Materials used in proposal
Steel Green structure surrounding the product and the nuts
and bolts.
Aluminum Bars that create the rows and columns.
Epoxy Resin Slots for the timers to be placed in.
Phenolic Laminates Brown back sheet of structure.
Plastics
Ferrous Metals
Nonferrous Metals
http://www.lenntech.com/periodic/elements
/ti.htm
http://www.roymech.co.uk/Useful_Tables/
Matter/Titanium.html
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