Contruction

This project was conceived, analyzed, and designed at CWU. Working with the constraints of the university resources and the budget of the JCATI project, parts will be bought from different distributors and assembled using university resources. These bought parts will be made of a 20-gauge steel sheet for the enclosure, a 2 in mineral wool for insulation, and a heat-resistant vinyl sheet to cover the conveyor hole. To assemble and manufacture the parts it will undergo a decision matrix to show what the best option will be.

Methods

Figure 1: Drawing Tree of the JCATI project

Figure 2 shows a matrix for deciding how holes/steel sheets will be cut. The options included power tools, laser cutter, and CNC (plasma cutting). The main criteria are based on was its availability, knowledge of the equipment, and the accuracy of the device. With those factors in mind, they were weighted at different in order of risk. Knowledge of the equipment leads to the most risk, so it was weighted 3 times the usual. Availability is the next one with the most possible risk, so it was weighted 2 times the usual. Finally, the accuracy was also weighed 2 times the usual since not having accurate cutes can lead to misalignments in assembly which is a potential risk. Thus, the matrix showed that using a CNC was to be the best option and the laser cutter and power tools fell shortly after.

Appendix F-2 shows a matrix for deciding how to assemble the encloser together. The options included welding, power tools, and welding paste. Welding showed high points on accuracy, availability, and efficiency. What made this a less viable option compared to power tools is the knowledge of using the equipment since the project engineer has not taken the welding class at the university and is not verified to use the equipment. Even with this lack of knowledge welding showed to be the best assembly process over power tools and welding paste.

From Appendix F-3 and Analysis 1, a material selection- 2-inch mineral wool was selected on the requirement of keeping 500C inside and 45C surface temperature. From the matrix, it showed that the major factors that it was chosen were its heat resistance and the high R-value that it had. These two components were crucial to the analysis and are the main reason it became the number one contender for material selection. These two components were also weighted the most in the matrix because of their importance to the analysis and if either of the components then it would not be a suitable material for the application. The other component of the matrix was the thickness, the mineral wool was 2 in thick which was not the most suitable compared to the thermal blanket that was 1 inch thick. This component was weighted on a scale of one since the thickness was not a crucial part of the analysis and was only considered to keep the enclosure smaller and easier to handle. Since this component was not weighted as heavily it made mineral wool the best material to select compared to the thermal blanket and the polyisocyanurate insulation.

Figure 2: Matrix 1 cutting decision

Figure 3: Matrix 2 assembly decision

Figure 4: Matrix 3 material decision for insulation

Figure 1: 48" X 96" 20-gauge steel sheet

Raw material used to cut the U-shape sections that when assembled will create the outer enclosure.

Figure 2: Shear Cutter

This was the machine used to cut down the 48" X 96" sheet to the size of each enclosure.

Figure 7: Inner Enclosure bent peices

Both MR_20-001 and MR_20-002 where bent at the notches and layed side by side before assembly.

Figure 1: 48" X 96" 20-gauge steel sheet

Raw material used to cut the U-shape sections that when assembled will create the outer enclosure.

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Inner Enclosure

Comprises of two U-shaped sections of parts MR_20-001 and MR_20-002. MR_20-001 is the front, bottom, and back sections of the cube-shaped enclosure. While MR_20-002 comprises of the top and sides of the cube. The total size of the cube, when assembled, is 16.5" X 16.5" X 14.5".

Figure 1: 48" X 96" 20-gauge Steel Sheet

Raw material used to cut the U-shape sections that when assembled will create the outer enclosure.

Figure 2: Marked out outer enclosure on steel sheet

Since the outer encloser was too big for plasma cutter the design of the outer enclosure was marked on the steel sheet so that it can be hand plasma cutted.

Figure 4: Outer Enclosure

Both pieces of the outer enclosure where layed on top of each other to verify that all tolerances where met.

Figure 1: 48" X 96" 20-gauge Steel Sheet

Raw material used to cut the U-shape sections that when assembled will create the outer enclosure.

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Outer Enclosure

Comprises of two U-shaped sections of parts MR_20-003 and MR_20-004. MR_20-003 is the front, bottom, and back sections of the cube-shaped enclosure. While MR_20-004 comprises the top and sides of the cube. The total size of the enclosure, when assembled, is 21" X 21" X 19"

Figure 1: MR_20-009

Cut out flaps from heat resistant material.

Figure 1: MR_20-009

Cut out flaps from heat resistant material.

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Converyor Flaps

This covers the hole is both the front and back of the outer enclosure. This heat resistant pad will be able to block argon from escaping and try to keep and maintain the heat in the system. On the back of the flaps it has a magnet that will allow easy installation.

Figure 1:MR_20-006

Lays between the top section of of the inner and outer enclosure. The hole is for the argon tube to go through so that argon can be supplied to the oven.

Figure 2:MR_20-005

Located between both sides of the inner and outer enclosure. There is a total of two pieces that are 20.5" X 14.5".

Figure 4:MR_20-008

This lays in between the bottom section of the inner and outer enclosure. It measures to be 20.5" X 20.5"

Figure 1:MR_20-006

Lays between the top section of of the inner and outer enclosure. The hole is for the argon tube to go through so that argon can be supplied to the oven.

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Insulation

The mineral wool insulation has a total of 6 pieces and 4 drawings. The corresponding drawings are MR_20-003 to MR_20-006. The 48" x 24" piece of insulation was measured and cut with a serrated knife while having the appropriate PPE on (gloves and mask).