john deere rain simulator final report
TRANSCRIPT
John DeereDesign Specification Report for
Design & Fabrication of Prototype Rain Simulator
April 4, 2014
Ryan BimesJustin FrazierBill LoffredoSean Munck
Xin Wen
Yes – Intellectual Property Rights AgreementYes – Non-Disclosure
Executive SummaryJohn Deere faced the problem of testing compact tractor components under various rain conditions at their Augusta, Georgia location. Previous solutions involved testing individual components under shower heads, sprinklers, or dripping mesh screens with fans to simulate wind. A large scale solution was required for John Deere to test full sized compact tractors. The rain simulator is required to be accurate and versatile with varying wind speeds, wind angles, and rates of rainfall. Also, due to increasing environmental concern, the device is required to filter and recycle runoff water from the test.
In order to accurately meet John Deere’s requirements, customer needs were established, existing patents and products were researched, and the rain simulator device was broken down into several subsystems. An external search provided insight on techniques for droplet formation and structure support. John Deere specified that the rain simulator requires adjustable rain fall from 0 to 6 inches per hour, wind speeds from 0 to 30 mph at 0 to 45 degree angles, and accommodate 1000 to 4000 series tractors. Several concept designs were generated which included fans, sprinklers, perforated tubes, locking pins, aluminum extrusions, etc. We identified three main subsystems which were the base, structure and water sprinkling device. Interchangeability of subsystem components allowed us to select wind simulation, droplet formation, water delivery, and structure for concept selection. The result of concept selection indicated that the final design would include fans for wind simulation, aluminum tubes with locking pins for structure, perforated tubes for water delivery, and some form of water droplet formation.
Detailed design of the rain simulator started with a simple and inexpensive base design utilizing a waterproof sheet with cinder blocks and boards to support the tractor. Analyzing prices on aluminum structural components and discovering heavy duty canopies showed it was more cost effective and convenient to use a pre-fabricated structure. Testing showed that a soaker hose effectively formed water droplets. Calculations were conducted to prove the design would meet specifications. Materials and components were finalized and ordered, and a manufacturing process was generated. A testing procedure was generated to ensure satisfaction of specifications. A complete CAD model was constructed showing all major components of assembly.
The alpha prototype was transported to August, Georgia for initial testing. It was discovered that the fans did not significantly change the speed or angle of rainfall, that the single-line soaker hose configuration restricted water flow, creating uneven distribution. Additionally, the cinderblock base was not needed as rubber tracks were provided. Based on these findings, our requirements were changed to simulate rate-adjustable standing rainfall only. We eliminated the fan system, and reworked the soaker hose configuration to a parallel hose design, utilizing PVC pipes as central lines, upon which soaker hose lines would branch. This allowed for even water distribution. We successfully tested this design, measuring adjustable rainfall rate as a function of pump flow rate. We created a poster summarizing the design for the engineering showcase. Our project was within our budget of $1000, and is ready to present to John Deere.
Table of Contents
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1.0 Introduction...........................................................................................................................4
1.1 Initial Problem Statement.......................................................................................................4
1.2 Objective................................................................................................................................5
2.0 Customer Needs Assessment.....................................................................................................6
2.1 Gathering Customer Input......................................................................................................6
2.2 Weighting of Customer Needs...............................................................................................6
3.0 External Search..........................................................................................................................7
3.1 Patents....................................................................................................................................7
3.2 Existing Products...................................................................................................................8
4.0 Engineering Specifications........................................................................................................9
4.1 Establishing Target Specifications.........................................................................................9
4.2 Relating specifications to Customer Needs...........................................................................9
5.0 Concept Generation and Selection...........................................................................................11
5.1 Problem Clarification...........................................................................................................11
Figure 1: Water flow model of rain simulator...........................................................................11
5.2 Concept Generation..............................................................................................................12
5.3 Concept Selection................................................................................................................16
6.0 System Level Design...............................................................................................................17
7.0 Special Topics..........................................................................................................................19
7.1 Preliminary Economic Analysis...........................................................................................19
7.2 Project Management............................................................................................................19
7.3 Risk Plan and Safety............................................................................................................19
7.4 Ethics Statement...................................................................................................................20
7.5 Environmental Statement.....................................................................................................20
7.6 Communication and Coordination with Sponsor.................................................................20
8.0 Detailed Design.......................................................................................................................21
8.0.1 Modifications to Statement of Work Sections..................................................................21
8.0.1.1. Introduction - no change...........................................................................................21
8.0.1.2. Customer Needs – no change...................................................................................21
8.0.1.3. External Search – no change.....................................................................................21
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8.0.1.4. Engineering Specifications – no change...................................................................21
8.0.1.5. Concept Generation and Selection – no change.......................................................21
8.0.1.6. System Level Design................................................................................................21
8.0.1.7. Special Topics...........................................................................................................21
8.1 Manufacturing Process Plan.................................................................................................21
8.2 Analysis................................................................................................................................23
8.3 Material and Material Selection Process..............................................................................25
8.4 Component and Component Selection Process...................................................................26
8.5 CAD Drawings.....................................................................................................................27
8.6 Testing Procedure................................................................................................................30
8.6.1 Procedure for Testing the Maximum Wind Speed.......................................................30
8.6.2 Procedure for Testing Rainfall Volume........................................................................30
8.6.3 Base Testing Procedure................................................................................................30
8.6.4 Procedure of test on the accuracy of voltage adjuster to vary the wind speed.............30
8.6.5 Procedure of test on the accuracy of valve to vary the rainfall rate.............................31
8.7 Economic Analyses - Budget and Vendor Purchase Information........................................31
9.0 Final Discussion.......................................................................................................................34
9.0.1 Introduction...................................................................................................................34
9.0.2 Customer Needs............................................................................................................34
9.0.3 External Search.............................................................................................................34
9.0.4 Engineering Specifications...........................................................................................34
9.0.5 Concept Generation and Selection................................................................................34
9.0.6 System Level Design....................................................................................................34
9.0.7 Special Topics...............................................................................................................34
9.0.8 Detailed Design............................................................................................................34
9.1 Construction Process............................................................................................................34
9.2 Test Results and Discussion.................................................................................................34
10.0 Conclusions and Recommendations......................................................................................34
11.0 Self-Assessment (Design Criteria Satisfaction).....................................................................34
11.1 Customer Needs Assessment.............................................................................................34
11.2 Global and Societal Needs Assessment.............................................................................34
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Appendix A – Patents....................................................................................................................34
Appendix B – Concepts.................................................................................................................35
Appendix C – Gantt Chart.............................................................................................................41
Appendix D – Initial Budget..........................................................................................................43
Appendix E – Bill of Materials......................................................................................................43
Appendix F – Detailed CAD Drawings.........................................................................................44
Appendix G – Team Resumes.......................................................................................................56
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1.0 IntroductionFor John Deere, reliability is key. The company’s core values are integrity, quality, commitment, and innovation. (Deere) These values extend to every product sold, and without proper weather testing, they could not be guaranteed. John Deere implements exhaustive tests on their equipment to make sure that degradation can be avoided, but as the products evolve, so too must the tests for reliability. John Deere performs system level testing on tractor components, but currently has no apparatus for entire tractor level rain testing. Our team is tasked with creating a rain simulator which is durable, easy to use and assemble, accurate, compact and portable, and within budget.
1.1 Initial Problem StatementDeere & Co., commonly known as John Deere, is a major manufacturer of agricultural machinery, based in Moline, Illinois. Because the company’s equipment is regularly exposed to the elements, John Deere is in need of a rain simulator system for its testing facility in Augusta, Georgia. The system must be designed to test rain effects on commercial series tractors. The simulator must have the ability to control rate, direction and speed of rain, and should recycle water. The design needs to filter contaminates, such as oil, grease and dirt from the rainwater, and must be easy to set-up and tear down for shipment to the testing facility.
1.2 ObjectiveThe primary objective is to design a rain simulator for John Deere which, in descending order of importance to the customer is reliable, easy to use, easily assembled and disassembled, accurate, reasonably light and compact, and within the cost requirements of the project.
The most important design objectives are durability and reliability. The simulator needs to be run repeatedly without fail. Because it may be used on many different vehicles per day, the system should not have an operating limit which causes it to fail under expected use. The materials used will be constructed of aluminum, PVC, and rubber, so rust will not be a concern.
The sponsor would like a system which can be employed very quickly after the delivery date, with little to no learning curve for operation. The operating parameters and controls of our simulator will be very straightforward. The system will be easy to assemble and disassemble. Because John Deere may need to move the simulator between facilities, or even factory locations, easy setup and tear-down is crucial to the design. The structure will screw together and use locking pins so that setup is fast and easy.
The design will accommodate accurate control of water flow rate, wind intensity and rain direction. The direction will change up to 45 degrees in any direction from vertical. By electrically attenuating the speed of the pumps, rainfall will be adjustable between one and six inches per hour, to an accuracy of +/- one inch per hour. The wind speed will be continually
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variable up to 30 miles per hour. Additionally, the simulator must successfully filter and recycle used water. The system will employ a density separator for removing automotive oil, diesel fuel and grease, as well as a sediment filter and particulate trap for soil, grass, and other organic material which may be on the tested vehicle.
The design must be light and compact. John Deere has set a limit of 1000 lbs and a disassembled size of 66”wide x 44” deep x 50” tall. When assembled, the system will use a collapsible aluminum pole structure to expand to over 150” long x 80” wide x 100” tall, so that it may accommodate all of the commercial tractors to be tested. Although the weight and disassembled size is important, the working size is much more crucial in our design. John Deere has stated that our team has more flexibility on the disassembled size and weight.
The project budget of $1000 is the final major requirement of our project. We have been given tentative permission by John Deere to add to the budget if necessary, but only after justification to the company.
2.0 Customer Needs Assessment
2.1 Gathering Customer InputJohn Deere currently has a need for a rain-bay that can create rain to a pre-determined and selectable rate. The rain simulator needs to possess the ability to select the rate, direction and force of the water that has to hit the tractor. In order to develop a relationship with the sponsor and get customer input, a teleconference was scheduled and a list of preliminary questions that were going to be discussed in the teleconference was sent to Tom Aho. He answered the questions, providing a list of importance to John Deere. In order to further clarify the details of the customer needs, we held a teleconference with Tom Aho and Mark Beltowski from John Deere. The final order of decreasing importance of the given customer needs is as follows: reliability, ease of use, ease of set-up/disassembly, precision/accuracy, storage size, ability to recycle water, cost.
2.2 Weighting of Customer NeedsTo produce a rain simulator that best suites the needs provided by John Deere, the customer needs were weighed against each other. In this manner, we will determine which needs carry more weight than others, and to what degree. Using the weighted customer needs, we will then be able to accurately assess different concepts and select the concept that will best accommodate John Deere’s needs. Provided John Deere’s ranking of their needs, the team knew the ranking of each need and only had to determine how important they were to each other. In order to do so, an AHP matrix was used. Below, each need is weighted against another, if the need on the left holds more weight over the need on the right, a number will the assigned between 1 and 5. If the
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need on the left does not hold as much weight as the need on the right, a number between 0 and 1 will be assigned. Each corresponding cell across the diagonal hold the reciprocal of its counterpart.
Durability/Reliability Ease of Use Accuracy Ease of Assembly Weight/Size Cost Total WeightDurability/Reliability 1.00 1.11 1.25 1.43 2.50 3.33 10.62 0.25
Ease of Use 0.90 1.00 1.11 1.11 2.00 2.50 8.62 0.20Accuracy 0.80 0.90 1.00 1.25 1.43 1.67 7.05 0.17
Ease of Assembly 0.70 0.90 0.80 1.00 2.00 2.50 7.90 0.19Weight/Size 0.40 0.50 0.70 0.50 1.00 1.43 4.53 0.11
Cost 0.30 0.40 0.60 0.40 0.70 1.00 3.40 0.08
Table 1: AHP Matrix to Determine Weighting of Customer Needs
From the AHP matrix seen in table 1, durability/reliability account for about 25% of the total design. Ease of use, ease of assembly, and accuracy account for between 20-16%. Lastly, weight/size and cost only account for 10-8% of the total design. These weighted values will carry into the assessment of generated concepts.
3.0 External Search
An external search was conducted to find existing patents and products that relate to rain simulators. A few patents were found that involve rain simulation devices for various purposes, and these will be discussed below in section 3.1. There are no traditional rain simulation devices for sale right now that can be bought as a single unit, but there a few papers published online that document various other rain simulation devices. These will be discussed in section 3.2.
3.1 PatentsA thorough patent search was performed to find existing technologies that would help in the design of the final concept, as well as prevent any possible patent infringement. The patent search is summarized below with the use of an Art-Function Matrix. The functions of a rain simulator were broken into three main subsystems - a water sprinkling device, a main structure, and a base. The base envisioned would be a combination of devices to support the tractor, collect water, filter water, and pump water. Because the individual components of the base will be purchased and not designed, the main focus of the patent search was on the water sprinkling device and structural support. Most patents discovered related to different methods of creating rainfall. The water sprinkling devices fell into three categories – a standard sprinkler, a pipe with holes throughout, and either of the two in combination with a collection sheet or plate. The
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discovery of the collection sheet was significant in revealing another method of creating realistic raindrops, as opposed to John Deere’s solution of using a mesh screen. The patents found for rain simulators were designed for various purposes such as irrigation, testing on buildings, as well as for visual purposes. None of the patents found dealt specifically with vehicle testing. The exact configuration of components in the final design will differ from all patents discovered, and patent infringement will not be an issue. A summary of each patent in the table is provided in Appendix A.
Table 2: Art-Function Matrix
3.2 Existing ProductsThe device being designed for John Deere is very specific in its function as a rain simulator with adjustable rainfall rate, wind speed, and wind angle that recycles water and can accommodate compact tractors. Not surprisingly, there are no existing products on the market that satisfy these needs. There are also no products that could be found that were marketed as any type of rain simulator.
Although no existing products were found, some academic research articles were found online documenting rain simulators built for research purposes. These rain simulators used similar technology as discovered in the patent search, mainly relying on the use of sprinkler to deliver rain water. One such article revealed a structural technique found to be very convenient for ease of assembly. The structural support was built using aluminum pipes connected to fitting with holes for locking pins. This concept would be perfect for John Deere’s needs of easy assembly. A benchmarking table of the rain simulators found from research papers is shown below.
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Title Author(s)Important Aspects to
Project"The Use of a Rainfall Simulator for
Brush Control Research on the Edwards Plateau Region of Texas"
Shane Courtney PorterSprinkler heads,
Flow meter, Inline filter
"The Walnut Gulch Rainfall Simulator: A Computer-Controlled
Variable Intesity Rainfall Simulator"
G. B. Paige, J. J. Stone, J. R. Smith, J. R. Kennedy
Aluminum pipe structure, Telescoping legs,
Recycles water
"A Portable Rainfall Simulator for Plot-Scale Runoff Studies"
J. B. Humphry, T. C. Daniel, D. R. Edwards, A. N. Sharpley
Aluminum pipe structure, Locking pins,
Sprinkler nozzle Table 3: Benchmarking of Rain Simulators for Research
4.0 Engineering Specifications
4.1 Establishing Target SpecificationsJohn Deere provided us with target specifications. The dimensions were chosen to accommodate a compact tractor. The collapsible dimensions were chosen so the rain simulator’s container could be placed in a pickup truck with relative ease. The rate of rainfall was chosen to simulate foreseeable conditions.
Initial target specifications:Length: 150”Width: 80”Height: 100”Weight: <1000lbsRate of rainfall: 1” to 6” per hour, with accuracy of 1” per hourCollapsible into a 66”wide x 44” deep x 50” tall containerFilters oil and particulateProvides rain from 0 to 45 degreesSimulates wind speed up to 30 mphCost: <$1000
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4.2 Relating specifications to Customer Needs
Met
ric
# of
conn
ectio
n po
ints
Colla
psed
Size
Diam
eter
of s
mal
lest
filte
red
parti
cles
Pum
p He
ad
spac
ing
betw
een
hole
s
Wei
ght
Diam
eter
of h
ose
attac
hmen
t
Thick
ness
of s
uppo
rts
Degr
ee o
f sw
ivel
Fan/
Duct
SCF
M
Gallo
ns p
er m
inut
e
Supp
ort A
lloy
# of
cont
rol s
urfa
ces
Tens
ile S
tren
gth
of ro
of m
ater
ial
Tens
ile st
reng
th o
f bas
in m
ater
ial
Diam
eter
of r
ainf
all a
ttac
hmen
t poi
nt
Needeasily collapsible and buildable X X Xeasily transportable X XFilters out oil and particulate XRecycles Water X XProduces an even distribution of rain Xrelatively lightweight X X X XAttaches to standard water inlet XSupports any John Deere Compact tractor X XCan change the direction of rain XVariable Wind Speed X XVariable rainfall X X XDoesn’t rust Xeasy to use Xdurable X X Xreliable Xevolvable X X
Table 4: Needs-Metrics Matrix
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List of Metrics
# of connection Points 8Collapsed Size 66” x 44” x 50”Diameter of smallest filtered particles 1 µmPump Head 12ftSpacing between holes 3inWeight 1000lbsDiameter of hose attachment 1 inSupport thickness .25inDegree of swivel 45Fan SCFM 1500Gallons per minute 5.2Support alloy A-36 Steel# of control surfaces 1Tensile Strength of roof material 29007psiTensile Strength of basing material 4351psiDiameter of rainfall attachment point 1.5in
5.0 Concept Generation and Selection
5.1 Problem Clarification5.1 Problem ClarificationA water flow box model shows the parts involved in our Rain Simulator System, the output will be simulated rainwater. We want the raindrop in a specific angle and wind speed that is set by an operator. The wind speed and angle should be accurate. Also, the whole system can be disassembled so that John Deere could move it easily.
Figure 1: Water flow model of rain simulator
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Figure 2: Black box model of rain simulator
5.2 Concept Generation5.2 Concept GenerationConcept generation began with brainstorming. Numerous designs were discussed by all team members. All of the concepts were broken down into separate categories to simplify design considerations. Figures 3, 4 and 5 shown below are our three main subsystems.
Figure 3: Design Tree for Water Sprinkling Device.
Figure 4: Design Tree for Structure
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Figure 5: Design Tree for Base
Figure 6 to 11 are subsystem concept generations in response to the subsystem chart.
Larger versions of the sketches are available in Appendix B.
Figure 6: Overhead Sprinkler bars Figure 7: Single Overhead Fan, Fixed
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Figure 8: Single Overhead Fan, Fixed Screen Figure 9: Multiple Overhead Fans, Individual Screens
Figure 10: Fans with multiple rotating axis
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Figure 11: Fan attachment to sides of structure
5.3 Concept SelectionConcept selection was done for most important elements of the rain simulator where there are clear alternative concepts to choose from. The base subsection is not included in the selection because of its complicity. The overall function of the base will remain the same regardless of choices made from the base concept tree shown in section 5.2. Although different base designs will affect weight and ease of assembly, these designs rely highly on available materials and products which has not been determined at this point.
Selection Criteria Weight Rating Weighted Score Rating Weighted ScoreDurability/Reliability 0.25 3 0.75 2 0.5Ease of Use 0.2 3 0.6 3 0.6Accuracy 0.17 3 0.51 2 0.34Ease of Assembly 0.19 3 0.57 3 0.57Weight/Size 0.11 3 0.33 4 0.44Cost 0.08 3 0.24 4 0.32
Total Score 3 2.77Rank 1 2
Fan (ref) Angle/PressureWind simulation
Table 5: Pugh Chart for Wind Simulation
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Selection Criteria Weight Rating Weighted Score Rating Weighted Score Rating Weighted Score Rating Weighted ScoreDurability/Reliability 0.25 3 0.75 3 0.75 3 0.75 3 0.75Ease of Use 0.2 3 0.6 3 0.6 3 0.6 3 0.6Accuracy 0.17 3 0.51 5 0.85 5 0.85 5 0.85Ease of Assembly 0.19 3 0.57 2 0.38 2 0.38 2 0.38Weight/Size 0.11 3 0.33 3 0.33 3 0.33 3 0.33Cost 0.08 3 0.24 3 0.24 3 0.24 3 0.24
Total Score 3 3.15 3.15 3.15Rank 2 1 1 1
Droplet formationNone (ref) Screen/mesh Collection Sheet Rope
Table 6: Pugh Chart for Droplet Formation
Selection Criteria Weight Rating Weighted Score Rating Weighted ScoreDurability/Reliability 0.25 3 0.75 4 1Ease of Use 0.2 3 0.6 3 0.6Accuracy 0.17 3 0.51 3 0.51Ease of Assembly 0.19 3 0.57 3 0.57Weight/Size 0.11 3 0.33 3 0.33Cost 0.08 3 0.24 4 0.32
Total Score 3 3.33Rank 2 1
Water DeliverySprinkler (ref) Perforated Tube
Table 7: Pugh Chart for Water Delivery
Selection Criteria Weight Rating Weighted Score Rating Weighted Score Rating Weighted ScoreDurability/Reliability 0.25 3 0.75 1 0.25 3 0.75Ease of Use 0.2 3 0.6 3 0.6 3 0.6Accuracy 0.17 3 0.51 3 0.51 3 0.51Ease of Assembly 0.19 3 0.57 4 0.76 2 0.38Weight/Size 0.11 3 0.33 4 0.44 3 0.33Cost 0.08 3 0.24 4 0.32 2 0.16
Total Score 3 2.88 2.73Rank 1 2 3
StructurePipes/Locking pins Collapsible tent Aluminum extrusions
Table 8: Pugh Chart for Structure
The results of the concept selection show that the final concept will use some configuration of fans, a perforated tube, and pipes with locking pins. Some sort of droplet formation will be used, but further testing will have to be done to determine which method is most suitable.
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6.0 System Level DesignThe rain simulator consists of several elements but has one main process flow. First, water is dispensed into the basin via standard, 60 psi connection. When the pump is turned on, the water is adverted through the in-line filter. It then passes through the pump and is carried to the water delivery system. The water delivery system will be a perforated tube and the water will flow through the perforations and into some type of droplet creation device. The rain dispenser will consist of either a screen/mesh, a droplet sheet, or ropes. The water flows into the rain dispenser and turns into droplets. The droplets then hit the test subject and fall into the basin, where they are recycled again. The structure holding the enclosure consists of pipes with locking pins.
Figure 12: CAD drawing of rain simulator concept
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Figure 12 shows one possible configuration of the rain simulator. The structure is composed of aluminum pipe that will be connected using locking pins. The base uses a grating that is mounted on supports to suspend the tractor above the water. The base will be made of waterproof lining to collect water. Water will be pumped through a filter to the top of the structure though a hose to perforated pipe (not shown). Fans will be mounted in some configuration to simulate wind.
7.0 Special Topics
7.1 Preliminary Economic AnalysisThe preliminary economic analysis consists of the initial budget and the Bill of Materials (BOM). These can both be seen in Appendices D and E respectively. The budget of $1000 set by Penn State University is not firm due to the magnitude of this project and does not include travel expenses. Team Rain Simulator will aim to meet the $1000 budget by using available resources to buy materials at reduced cost. Additionally, the team will optimize the design to use the lease amount of material safely possible.
7.2 Project ManagementTeam rain simulator consists of five mechanical engineers. Together, we possess a powerful variety of technical skill, leadership, and ability to work as a team. This project involves different engineering principles. Fluid mechanics is needed to produce rain the right way. Structural mechanics is needed to make sure the frame supports the weight of the assembly and the water. Some team members specialize in fluid mechanics while others specialize in structural mechanics. Additionally, we have all taken design courses and have used the Product Development Process. With our combined skills used in school and on the job, we possess all the skills necessary to deliver all the customer needs and to meet all due dates. Due dates can be found in Appendix C.
7.3 Risk Plan and SafetyThis project involves different types of risks. Most of them are associated with technical problems, but other risks include safety issues and scheduling issues. To minimize these risks we are designing the rain simulator early to allow for one major failure. We are also designing the system with flexibility and redundancy. During the build, we will keep safety in mind to prevent injury. Keeping these risks in mind will ensure success, even if failure does occur at some point.
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Table 9: Risk Plan
7.4 Ethics StatementDuring the entirety of this project, we will abide by the ASME Code of Ethics. It States:“Engineers uphold and advance the integrity, honor, and dignity of the engineering profession by: I. Using their knowledge and skill for the enhancement of human welfare
II. Being honest and impartial, and serving with fidelity their clients (including their employers) and the public
III. Striving to increase the competence and prestige of the engineering profession
7.5 Environmental StatementTeam Rain Simulator strives to exceed all environmental standards set within this project’s field of expertise. We aim to abide by these standards by minimizing waste and choosing products from companies that abide by environmental standards. More specifically, we will guarantee no harmful runoff from the rain simulator and 100% containment of environmentally harmful substances.
7.6 Communication and Coordination with SponsorMeetings with John Deere will happen via progress report and teleconference unless specified otherwise. Team Rain Simulator’s point of contact (POC) is Mr. Thomas Aho of Augusta, Georgia. Progress reports include action items that need to be discussed, things that have been
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Risk Level Actions to Minimize Fall-back strategy
Rain Simulation Inaccurate
Medium Build Alpha prototype early enough to re-do if needed
Re-work initial design
Frame doesn’t support weight
Low Incorporate factor of safety Slowly load supporting members until max weight
Personal injury during manufacture
Low Don’t stand under overhead loads
Wear personal protection equipment
Basin springs a leak High Test before installation Use repair materials
Pump is too small Low Check fluid equations for correctness
Return pump and buy a bigger one
Something doesn’t fit Medium Design for flexibility Re-work
Filter doesn’t separate oil from water
Low Make system redundant Employ natural separation
done in the past week, and things that will be done in the upcoming week. They will be emailed to our POC weekly. Typical teleconferences will happen on an as-needed basis, whenever is most convenient for the POC. We will use the teleconferences for guidance and answers to specific questions.
8.0 Detailed Design
8.0.1 Modifications to Statement of Work Sections
8.0.1.1. Introduction - no change
8.0.1.2. Customer Needs – no change
8.0.1.3. External Search – no change
8.0.1.4. Engineering Specifications – no change
8.0.1.5. Concept Generation and Selection – no change
8.0.1.6. System Level Design Rather than fabricating our own aluminum structure, we have chosen to buy a pre-
fabricated canopy to tie into the base. During testing we found that adding cinder blocks to our design was pointless. We were able to wrap the tarp around the tractor and tie it to the base without any leaks. This rendered the cinder-block base unnecessary.
8.0.1.7. Special Topics Updated the Gantt Chart, Budget, and BOM to include new materials and updated
designs.
8.1 Manufacturing Process PlanOur manufacturing process plan placed emphasis on Design For Assembly. Design For Manufacturing was not as important as the rain simulator will not be mass-produced. Nevertheless, the rain simulator must accommodate for evolution in design and be easily adaptable to make way for bigger tractors.
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Table 10: Manufacturing Process Plan
Assembly Name Material Type Raw Stock Size OperationsStructure Pre-fabricated canopy 10'x15'x8' Set up canopy
Drill 16x.12” holes into horizontal members below roof
Eye Hooks Install into horizontal members
Fans Fans, PVC pipe 1.25 inch pipe Install 2 fans per 5’ PVC section, make 3 of these
PVC 1.5 inch T’s Connect 2 1.5 inch t’s per the design. Make 6 of theseMount fan sections onto T-sections.
PVC Pipe 5’ 1.25 inch sections Mount horizontal PVC sections on the roof with T’s and 4-waysMount fan assemblies onto horizontal PVC roof sections per the design
Base Pressure Treated Wood
4"x6"x10' Cut to 8x2.5' sections
Drill 2x .5” holes on top and 1x .5” hole on bottom of 4 on each side, staggeredDrill 2x .5” holes on top and 1x .5” hole on bottom of 4, 1 side only
1.5"x6"x5' Drill respective holes into these boards
Threaded Rod 3/8” Cut with band saw into 54x6” sections, 8x8” sections.Bevel each section on both sidesAssemble wooden base per drawing. Use threaded rod with nuts and washers to
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hold wood together3” wood screws Lift assembled
canopy onto wooden base, drill wood screws into canopy holes and base wood
Collecting Basin Waterproof tarp 12'x20' Install rivets 3' apart on every cornerPlace rivets into respective bolts on the base.
Water delivery system
Pump, hose, filter Hose 15" long Connect sediment filter to pump and hose to filter. Tie to structure
Soaker hose 125’x3/8” Hang soaker hose with eye hooks and tie into water line
Electrical Fan plugs Attach 2 fan plugs to 1 surge protector, attach surge protector to voltage adjuster. Carry out 3 times
Surge protector Attach 3 voltage adjusters to main surge protector
Electronics box Contain electronics in electronics box, attach to canopy
8.2 Analysis During the design development process, our team knew that we had several important parameters within which we had to work, namely the required variability and accuracy of water flow volume and speed, and known weight and size specifications.
Our design calls for six fans which accelerate the water droplets from above. When deciding on a fan to purchase, we needed one which would achieve 30 mph wind speeds while being of reasonable weight, cost and size. Because fans are measured on their volumetric flow rate, we needed to convert to wind speed ourselves. The calculations used for our chosen fan are below.
Windspeed=Vol . Flow RateArea
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Windspeed=6725 ft3
min400 ¿2 [ 1 ft2
144 ¿2 ] [ 1mile5280 ft ][ 60 min
1 hour ]Windspeed=27.51 mph
Our next calculation was an estimate of the total water-mass running through the soaker hoses during operation. We were able to use this data, in combination with the weight of the fans and frame, to make sure our chosen canopy could safely support the system.
Mass of water=(density of water )(inside volume of hose )
Mass of water=(998 kgm3 ) (0.009525m )2( 1
4π )(37 m)
Mass of water=2.63 kg
Another calculation we had to make involved the horizontal loading of the wind from the fans. Assuming a wind speed of 30mph, we calculated the thrust and in turn, the loading on the structure.
Thrust=Velocity x Mass Flow Rate
Mass Flo w Rate per fan=ρVA=(1.165 kgm3 ) (27.51 mph )[ .44704 m
s1 mph ]( 400 ¿2 )[ 0.00064516 m2
1¿2 ]Mass Flow Rate per fan=3.70 kg
s
Mass Flow Rate total=22.2 kgs
Thrust=(22.2 kgs )27.51mph [ .44704 m
s1mph ]
Thrust=273 N [ 0.22481lbf1 N ]=61.4 lbf
Although experimentation is necessary to verify the stability of our structure, we could still form an educated estimate for factor of safety. Because our canopy is not an engineered rigid structure, it has no official snow or wind load ratings, but based on an engineered structure of similar size (built by the same company), we found that that the roof supported 43 pounds per square ft. Because our structure is not as heavy duty, we estimated a load rating of about 10
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lbs/sq. ft. As long as the weight of our system is distributed evenly over the upper frame of the canopy, this should be a reasonable estimate.
Supported weight=(10 lbsft 2 )(15 ft)(8 ft )
Supported weight=1200 lbs
FOS= 1200lbs(weights of (water+rainfall system+fans))
FOS= 1200lbs(5.8 lbs+4.5 lbs+50 lbs+6(5.5 lbs)+40 lbs)
FOS=9.00
We were given a range of rainfall rates for the simulator (0 to 6 in/hr). As a result, we needed to convert rate of rainfall to required volumetric flow rate, based on the dimensions of our simulator.
Water Flow rate=( Rateof rainfall )(area of basin)
Water Flow rate=(6 ¿hr ) (15 ft ) ( 8 ft ) ¿
Water Flow rate=449 galhr
Each of these calculations was very beneficial in deciding upon which products to use, but experimentation was necessary to verify the max wind speed and flow rates. These procedures are detailed in the Test Procedure section.
8.3 Material and Material Selection ProcessIn order to assemble a rain simulator, we utilized many prefabricated and existing
components in order to reduce construction time and cost. Weight, cost, and strength were the three most important aspects of material selection for the few remaining components that could not utilize pre-existing products. Depending on the function of the structural component, different factors carried more weight. For example, when deciding upon a material to support the weight of the tractor, compressive strength was most important. With several strong materials available, our second factor was cost. With a very low cost to strength ratio, the final
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material selected to support the tractor’s weight was cinderblocks. Materials for other aspects of the rain simulator were accessed as seen in Table 11 below.
Table 11: Material Selection Process
Part Selected Material Positives NegativesFan Support Structure Aluminum Piping Lightweight, Strong High Cost
Tractor Support Cinderblocks Strong, Low Cost Heavy
Water Containment Sheet
TarpStrong, Low Cost,
Replacable
Potential Low
Availability
Canopy Support/Raisers
Wood Strong, Low CostPotential
Low Durability
Grating Steel Grating Strong, Availability Heavy
8.4 Component and Component Selection ProcessThe goal of our component selection was to find the components that, for the price, were most cost-effective, easiest to work with, and either most durable or easiest to replace.
The frame for the rain simulator is a pre-fabricated, 10x15 ShelterLogic canopy. Our original frame would have been fabricated out of aluminum piping and locking pins. After market research, we determined that a pre-fabricated canopy would not only be easier to assemble and cheaper, but it would also hold the piping and fans just as well.
The base is comprised of a wooden shell, waterproof tarp, and cinderblock track. A wooden shell was chosen to accommodate for discrepancies between the advertised frame height and the actual frame height during testing and to provide a sturdy support for the frame. A waterproof tarp was chosen for ease of assembly and to ensure cheap water-holding capacity. Cinderblocks were chosen to support the track because they are both economical and strong.
The water delivery system is comprised of a sump pump, in-line sediment filter, hoses, box fans, and soaker hose. The sump pump and in-line filter were chosen for ease of assembly. Hoses were chosen as a cheap alternative to pipes. Box fans were chosen for their low cost and ease of replacement. Soaker hoses were chosen for their cheap droplet formation.
The main tradeoffs involved cost vs performance. Many of the ideal components for the rain simulator cost much more than our entire budget. For example, the best pumps that can be found online eclipsed $300. Through our research we were able to find a pump that performed almost as well for 1/6 the price of the ideal pump. Another example was the oil collection system. Rather than spend $500+ on expensive oil-water separator technology, we opted for cheap oil-
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collection sheets. Using research, outside-the-box thinking, and common sense, we are able to slash our costs significantly.
Table 12: Component Selection Process
Part Selected Component Positives NegativesFrame Pre-fabricated Canopy Easy to modify Lack of stiffnessBase Wooden Structure Easy to modify BulkyWater Delivery Utility Pump Low cost, versatile None
Sediment Filter Low cost Doesn’t filter oilHoses Flexible Minor LossesSoaker Hose Even Distribution Lacks powerOil Sheets Cost effective Not 100% effective
8.5 CAD DrawingsFigure 13 shows the detailed CAD drawing of the John Deere Rain Simulator. Included in this drawing are the ShelterLogic canopy, base constructed of wood, tractor supports constructed of cinder blocks and wood, two service ramps, wind simulators constructed of PVC and box fans, and soaker hose winding across the canopy frame. Not included in this view is the pump, filters, connecting hose, wiring, voltage regulator, tarp, and canopy cover. These were excluded as they did not affect the major dimensions of the system. The canopy cover can fully enclose the canopy, and open in the front to allow tractor entrance. Holes may be needed in the top for wind circulation. The tarp will lie within the base using towels or other soft material as a cushion to prevent tears. The pump will be submersed in the water below the tractor.
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Figure 13: Detailed CAD Drawing
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Figure 14: Close up of wind simulators
Each individual wind simulator is constructed of two box fans mounted to the shelter frame using 1.5” PVC pipe. The grey connecting components are two 2” PVC tees cemented orthogonally. The oversized tees allow for lateral movement and rotation of each pair of fans. The fans will be rotated by winding rope around one end of the axle pipe, pulling from either direction, and securing the rope to a lower support.
The base will be constructed of 20” long 4”x4” pressure treated wood blocks and various lengths of 2”x4” wood. Figure 15 shows holes where dowels can be used to secure the base, allowing easy assembly and disassembly. After the canopy is secured on top of the base, it will be raised 20” to allow for maximum sized tractors to fit below.
Detailed drawings of each component can be found in Appendix F.
Figure 15: Close up of Base Construction
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8.6 Testing Procedure
In order to verify that the rain simulator is capable of meeting requirements, several tests will be conducted to verify the appropriate parameters.
8.6.1 Procedure for Testing the Maximum Wind Speed1. Assemble and wire the fan array on the top of the frame.2. Point all fans in the same direction.3. Using an anemometer, record average wind speed at various locations within the
rain simulator. Make sure all fans are set to their max wind speed setting.4. Record wind speed for at least four locations at three different distances from the
fans. (4 locations at 1 ft, 4 locations at 5 ft, 4 locations at frame base).5. Create a table of average wind speeds for each distance, and a final average
maximum wind speed. Compare to theoretical fan wind speed.
8.6.2 Procedure for Testing Rainfall Volume1. Use a single soaker hose and measure its length. Attach the hose to a utility
pump, and suspend the hose 10ft above the pump.2. Place the pump in a basin of water of which original volume of water is known,
and turn on the pump. At the same time, begin a stopwatch.3. Turn off the pump after five minutes has passed. Record the new volume of water
in the lower basin. Use this information to find the change in volume of water with time, and calculate the resulting inches per hour of rainfall in the full-scale simulator. Perform several tests and average the results.
4. Repeat Steps 1-3 with a segment of rope-lined PVC pipe.
8.6.3 Base Testing ProcedureIt is imperative that the rain simulator's base be tested to make sure that it can support the full range of tractors to be tested. Here is the procedure for testing the base:
1. Transport Rain Simulator base and several tractors of various size to a flat field2. Set up the ramps and base of the Rain Simulator in desired location3. Slowly drive the smallest tractor onto the base and see if base is stable.4. Drive tractor off the base and make sure the base's structural integrity is upheld5. Drive tractors onto the base one at a time in order from lightest to heaviest. 6. Drive each tractor off and make sure the base is not compromised. Stop if the
base’s integrity was compromised by the loading from the previous tractor.
8.6.4 Procedure of test on the accuracy of voltage adjuster to vary the wind speed One of our customer needs is being accurate. We are using fans to simulate wind from 0 to 30 mph. As a result, the accuracy of our wind speed is important in our project.
1. Attach the voltage adjuster to the fan 2. Measure the distance from fan to raindrop simulator device in the real model. For
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instance, X meter3. Set the wind speed meter X meter away from the fan 4. Twist the voltage adjuster several times in small increments, read the wind speed
meter, mark the actual speed if necessary5. Turn off the fan and wind speed meter6. Redo step 4 with speeds that marked to see if they are still the same
8.6.5 Procedure of test on the accuracy of valve to vary the rainfall rate Also important to test the tractors is the rainfall rate. This is adjusted using valves for the soaker hoses.
1. Attach flow meter to water line. 2. Completely open valve to guarantee correct full flow3. Close the valve 1/3 of the way and make note of the flow rate and the valve position4. Close the valve another 1/3 and again make note of the flow rate and valve position5. Tweak the valve positions to ensure 1/3 reductions of flow rate for each position
8.7 Economic Analyses - Budget and Vendor Purchase InformationIncluded in this section is our current bill of materials. It takes into account the initial budget in appendix 4 and the changes we have made from our initial budget.
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Table 13: Bill of Materials
Component Dimension Unit Purchased Materials Total costFrame 0
Canopy (Shelterlogic Autoshelter 1015) 1 290.95 290.95Wind simulator 0
Fan 6 128 128Voltage adjust 0 0 0PVC pipe mounted fans 1-1/2inx80in 3 16.47 16.47PVC pipe mount to frame 1 1/2inx59.5in 6 22.08 22.082 in PVC Tee 2in 12 35.52 35.52The thing that fix the angle 0
Raindrop simulator 0Soaker hose 1 6.02 6.02Rope Cotton Cord 1 1.84 1.84
Base 0Cinder Block 8inx8inx16 12 17.52 17.52Pressure Treated Lumber 72.16 72.16Outer raiser 4inx4inx20in 8 0Inner raiser 4inx4inx20in 4 0Corner wall 2inx4inx57.5in 8 0End wall 2inx4inx51in 8 0Side wall 2inx4inx59.5in 4 0
Other 0Ramp 2 0 0Filter (Culligan House Water Filter HD-950A) 1 64.99 64.99Pump (Ace 1/6 HP Utility Pump) 1 66.99 66.99Other cost 100 100
0Total Cost 822.54 822.54
Refrencehttp://www.acehardware.com/home/index.jsphttp://www.ecanopy.com/http://www.mscdirect.com/http://www.lowes.com/
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Table 14: Budget 4/8/2014
Amount($) Location DateBeginning Budget 1000
1 17.49 ACE 2/25/20142 128 MSC Online3 290.95 ECanopy Online4 49.88 Home Depot 3/24/20145 12.69 Home Depot 3/24/20146 45.28 Home Depot 3/25/20147 49.07 Home Depot 3/25/20148 43.96 Home Depot 3/25/20149 40 Home Depot 3/25/201410 13.81 Home Depot 3/25/201411 45.2 ACE 3/26/201412 42.47 ACE 3/26/201413 37.48 Home Depot 3/27/20141415
Ending Budget 183.72
9.0 Final Discussion
9.0.1 Introduction – no change
9.0.2 Customer Needs – no change
9.0.3 External Search – no change
9.0.4 Engineering Specifications After testing in Augusta, Georgia demonstrated that the fan assembly was ineffective,
John Deere indicated that the 0-45° angle and 0-30mph wind speed requirements were no longer required. Simulation of vertical rainfall from 0-6 in/hr is the only rainfall specification.
9.0.5 Concept Generation and Selection – no change
9.0.6 System Level DesignBased on our observations at the John Deere testing facility in Augusta, Georgia, we
determined that fans were inadequate for directing rainfall. The fans used in the overhead configuration did not have an effect on the angle or speed of the rain. Further testing was done using a large industrial fan supplied by John Deere which failed to produce noticeable changes in
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angle or speed of the rainfall. Considering the inability of the fans to produce the rainfall requirements, it was decided that the wind simulation was no longer required and the current fan configuration would be excluded from the final design.
9.0.7 Special TopicsUpdated the Gantt Chart, Budget, and BOM to include new materials and updated
designs.
9.0.8 Detailed DesignTesting in Augusta, Georgia revealed that our current single continuous hose
configurations created kinks and a large pressure drop. This was evident because of a dramatic uneven distribution of rain fall. In order to create an even pressure through the length of the simulator, two parallel PVC pipes were used to create a uniform pressure down the length of the simulator. The soaker hose was cut into sections and was secured to the pipes in a parallel configuration. The hose sections were secured using barbs and hose ties, which were sealed with silicone to prevent leaks.
The cinderblock and wood plank track system was more complex and unwieldy than the rubber tracks supplied by John Deere. As a result, the rubber tracks will rest on top of the tarp for the final design.
9.1 Construction Process
9.2 Test Results and Discussion
10.0 Conclusions and Recommendations
11.0 Self-Assessment (Design Criteria Satisfaction)Based upon the requirements initially set by our sponsor, our team met many important
goals in our design. We created a working simulator which was easily transportable, simple to assemble, filtered and recycled water, was accurate, and was within budget. Although we could not complete a system for changing water speed and direction in our allotted time and budget, we build a successful piece of equipment upon which future designs can be added.
Our project is unique because it is not intended to be a mass produced product. Instead, John Deere will use the simulator to test new prototypes. Because of this, function over form has been key. Although John Deere may wish to alter our design in the future, we have made sure that the core functions of accuracy, portability, usability and self-containment are upheld.
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11.1 Customer Needs AssessmentOur final design meets the all of the revised customer needs. Initially, John Deere
wanted a rain simulator that could create wind speeds from 0-30 mph causing rain to fall from 0˚-45˚ from vertical. After alpha prototype testing in Augusta, it was concluded by John Deere engineers and the members of the Capstone team that the current fan set up would not be adequate for wind simulation. As a result, the customer needs were modified to focus on simulating natural vertical rainfall. The 0-6 in/hr requirement still applied, as well as the size requirements. With a flow meter attached downstream of the filter, our pump was pushing 5.3 gal/min. With our area of rainfall, a gallon per minutes equals roughly an inch per hour of simulated rainfall. This falls within 1 in/hr of the maximum of 6 in/hr required.
It was recommended to John Deere to add an additional pump to increase flow rate and even the pressure in the soaker hoses. Also, possible future plans at John Deere are to add high pressure cone nozzles that could be secured at different spots of the structure to simulate desired wind speed and angle.
11.2 Global and Societal Needs AssessmentGlobal and Societal needs are based on the environmental impact of building and running
a rain simulator along and the lessons learned during the project that can be used by other people in the world with the same needs.
Any design improvements or changes would strictly benefit John Deere. With that being said, there are many changes that can be done. The design could be scaled for their larger tractors and could also be made a permanent fixture if needed.
The global needs of the rain simulator involve environmental impact. The fabrication of the rain simulator proved environmentally friendly. Running the rain simulator has little environmental impact as long as any oil from the tractor is absorbed and the used water is disposed of down a proper drain.
Appendix A – Patents
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WO2005063001 A1 - Rain simulator for environmental studies
This invention relates to a rain simulator which is used to carry out environmental studies. The inventive simulator is based on a combined structure comprising a
fixed part and a mobile part. The mobile structure moves from side to side so as to be positioned sequentially over plots of land or surfaces of a determined width in order to wet. The tubes bearing sprinklers or nozzles are fixed to the cables forming the mobile structure, and nozzles are supplied by means of a general supply system.
CN101912832 A - Self-controllable wind-induced rain load simulation experimental device for buildings
A wind-induced rain load simulation experimental device for buildings comprising a water tank, water pump and separator, an array of spray heads attached to cross beams, and a frame. Each spray head is connected with a horizontal rotary motor for spray simulation.
CN202587987 U - Artificial rain-making simulating device
An artificial rain making device comprising a rain-making system, a circulating water supply system and a supporting frame. The rain-making system comprises a rain-making plate, reflection plate, and nozzle pipes.
US6945468 B1 – Rainfall simulation apparatus
A rainfall simulation apparatus and structure comprising an electric pump, riser pipe, V-shaped aperture-containing trough connected to roof, and elongated collection bin below the trough and connected to the pump. The rainfall simulation apparatus has particular utility in connection with providing the relaxing acoustic effect of rainfall on a structure while additionally providing the visual effect of rainfall through the windows of the structure.
US5137214 A - Method and apparatus for creating artificial rain
An artificial rain creating apparatus using spray nozzles and a vertical planar collection sheet. A water tank supplies water under pressure to an overhead manifold which feeds water to a plurality of spray nozzles. The spray nozzles spray a horizontal fan of water onto a vertical collection sheet. The water then runs to the bottom of the collection sheet which contains pointed teeth, and water droplets are formed from each tooth.
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Appendix B – ConceptsConcept 1 –Fans blowing through mesh screen
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Concept 2: Fans mounted on rotating axis
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Concept 3: Multiple tractor entry points for different angled tests
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Concept 4: Rotatable perforated tube
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Concept 5: Fans with multiple rotating axis
Concept 6: Fan attachment to sides of structure
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Appendix C – Gantt Chart
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Appendix D – Initial BudgetOur initial budget is meant to reflect our first attempt at calculating the total cost of our rain simulator. It does not include travel expenses. A 30% contingency has been added in case modifications are needed.
Item CostFrame Material $400Basin Material $30Ramp $40Oil Collection $40Grating $150Piping $25Pump $100Hose attachment $10Fans $150Side Skirting $75Mesh $10Other Hardware $5030% Contingency $324
Total $1404
Appendix E – Bill of Materials
Part # Part Name Part Source Price Quantity Total CostM-CPVC57-30MIL 5' x 7' Clear Vinyl Tarp - 30 MIL tarpsplus.com 64.75 4 2592534T12 8' Steel Clamp-on framing fittings McMaster-Carr 11.65 16 186.444155K88 Oil Absorbing Pillows McMaster-Carr 35.67 1 35.674892K95 1.5" PVC pipe McMaster-Carr 10.79 2 21.584880K25 90° Elbows, Female Unthreaded Socket Ends McMaster-Carr 1.16 10 11.6T9FB430490 8' X 10'' Heavy Duty Black/Silver Tarp globalindustrial.com 16.75 2 33.5
Irrigation Pump ACE Hardware $50 1 50T9F258323 Floor Fan 12 Inch - Global Industrial globalindustrial.com $44 4 17685385T11 Corrosion-Resistant Type 304 Stainless Steel Wire Cloth McMaster-Carr $39.91 4 159.64
Other Hardware McMaster-Carr $50 1 50603635 2 in. x 4 in. x 16 ft. Douglas Fir Lumber Home Depot 7.86 20 157.2
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Appendix F – Detailed CAD Drawings
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Appendix G – Team Resumes
Justin R. Frazier [email protected] Steven Martin Drive, Fairfax, VA 22031 703-474-5939
EDUCATION: Bachelor of Science in Mechanical Engineering May, 2014 The Pennsylvania State University, University Park, PA 3.11 GPA
TECHNICAL SKILLS:
Engineering Design: Component design, Process Flows, AutoCAD, Solidworks, Open-Source 3D printing Computer Expertise: Excel, Statistics, basic Java, ACSPL+ Motion Control, Image Pro Plus, Matlab Testing Proficiency: wind and water tunnel testing, laser profilometry and velociometry, material testing Proven ability in technical writing, team leadership, and conflict resolution Professional knowledge in statics, dynamic systems, heat transfer, fluid mechanics, and material science
RELEVANT WORK EXPERIENCE
Project Engineer, MeadWestvaco Paperboard Division, Covington, VA Jan-May 2013 Supported engineers with the construction of a $300 million biomass power plant Engineered all Lock-out Tag-out procedures for a power boiler and turbine generator Created lubrication routes for boiler equipment Audited boiler equipment, worked with contractors to ensure safe working conditions
Paper Science Researcher, MeadWestvaco Paperboard Division, Richmond, VA May-Aug 2013 Automated a new piece of laboratory equipment capable of imitating high-speed automation Developed a method of calibration for paperboard creasing equipment Created experiments to study the effects of creasing on paperboard properties Quantified a measurement for the amount of cracking in a paper crease
Camp Counselor, Fairfax County Park Authority, Fairfax, VA Summers of 2010-2012 Supervised early teens and younger as part of the Fairfax County Summer Recreation program Planned daily camp activities and details involving safety, allergies, and costs. Maximized facility usage and regularly adapted to changes in plans
Math Tutor, Penn State, taught elementary math through Calculus I Oct 2010-Apr 2011
OTHER EXPERIENCE AND AWARDS:
Eagle Scout Project. Led 3 dozen Boy Scouts in a project to collect bicycles for charity. Planned the project and presented details to Troop and District authorities. Secured funding, moving van, and use of school facilities. Organized and led Scouts in implementing the project which collected 75 bicycles and monetary donations totaling $750.
Mechanical Engineering and Systems Engineering. Designed and built a working tabletop wind turbine. Solved problems regarding system efficiency, material selection, and industrial fabrication. Performed research by analyzing data to draw conclusions about real problems and events such as infrastructure corrosion and the September 11th attacks.
Mechanical Systems Maintenance and repair. Fixed an air compressor with no prior knowledge of the subject. Repaired bicycles, specifically drivetrains, brake systems, and chains. Performed preventative maintenance and tested for proper operation prior to returning each bicycle to owner.
AWARDS/LEADERSHIP
Eagle Scout, Boy Scouts of America, 2009 Dean’s List, Fall Semester, 2013 Order of the Arrow, Boy Scouts of America, 2007 John Philip Souza Band Award, Paul VI High School, 2009
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Sean W. Munck616 E. College Avenue, Apt. 506, State College, PA 16801Phone: 717 713 0815 Email: [email protected]
____________________________________________________________________________
Education: The Pennsylvania State University, University Park, PABachelor of Science in Mechanical EngineeringExpected Graduation: August 2014Current GPA: 3.40 / 4.00
Semester Exchange Program Fall 2013Monash University, Melbourne, Australia
Awards: Bricker James Memorial Engineering Scholarship 2010-2014Dean’s List 2011
Relevant Courses: Internal Combustion Engines, Heat Transfer (including Lab), ME Design Methodology, Senior Capstone Design Project
Work ACE Hardware May 2013-CurrentExperience: - Sales Associate
- Organized, constructed and sold ACE products- Assisted customers with household projects and repairs
TAG Trailers / Lion Launch Pad June 2012-Dec 2012- Intern- Used SolidWorks to design new components for an electric bicycle
trailer- Assisted with prototype trailer fabrication- Designed new business logo- Camp Counselor
Camp Pemigewassett (Sleep-away Camp) June 2011-Aug 2011- Managed a cabin of eight campers full-time- Worked and lived at camp for eight week session- Coached boys’ basketball and baseball teams- Taught woodshop classes, served camper meals
Computer Skills: MS Office, MATLAB, HTML, SolidWorks
Activities: OPPerations THON Committee, Four Diamonds Fund- Volunteer for student-run pediatric cancer charity- Blue Love Chairperson
Aeromodelers Association of Pennsylvania- Builder/Flyer of model airplanes
Penn State University Cycling Club- Member, competitor in cycling competitions
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