Adirondack Chair : Center For Comprehensives Services Saluki Engineering Company, Team 58

Transcription

Adirondack Chair
For: Center For Comprehensives Services
Garrett Cook
By Saluki Engineering Company, Team 58
SEC Reference Number: # F07-58-ADRNDKCH
April 23, 2008
Saluki Engineering Company
Design Report for: Adirondack Chair
Client: Center For Comprehensive Services.
ACKNOWLEDGEMENTS
We would like to express our gratitude to those who made this project possible.
First during the initial design phase the Department of Mechanical Engineering at
Southern Illinois University at Carbondale (SIUC) allowed us the use of several powerful
software packages. We must express how grateful we are to the Department of Civil
Engineering again at SIUC for the use of the three point bending machine during the
testing phase. More specifically we must thank Dr. Lizete R Chevalier for the use of the
machine, Andy Bennett for the training necessary to use the machine, and Dr Gary
Butson for his advice and guidance.
Most importantly we must show our appreciation to our Client Mr. Garrett Cook
for his continued support answering all of our many questions. Additionally, we must
thank Mr. Ronnie Reams who was most accommodating to all of our requests for more
supplies and all of this was completed during our short timetable.
LETTER OF TRANSMITTAL
William Fogerson
301 W. Elm St
Apt #3
Carbondale, Il 62901
[email protected]
(217)-521-0498
Mr. Garrett Cook
Center for Comprehensive Services
306 W. Mill St
Adirondack Chair
Dear Mr. Cook:
The Saluki Engineering Company, team 58, is attaching a design report on the
redesign and packaging of the Adirondack chair. The design report covers all our work
and materials as described in the Request for Proposal.
I would like to thank Center for Comprehensive Services for allowing us to design this
project. We value you highly as a client and hope that we will have an opportunity to
work with you in the future.
I would be happy to answer any question on the contents of this document. Please
contact me at (217) 521-0498 or [email protected].
Sincerely,
…………………….
William Fogerson
Project Manager
Table of Contents
Author
Page
Section A
1.0 Executive Summary
WF
A-1
2.0 Introduction
WF
A-2
3.0 Overview
WF
A-2
4.0 Capital Cost Estimate
WF
A-4
WF
A-4
Table # A-4.0.1 Build Cost
5.0 Implementation Schedule
Table # A-5.0.1 Implementation Schedule
Section B Finite Elemental Analysis
1.0 Modeling Approach
CC
B-1
2.0 Force Position
CC
B-1
CC
B-2
3.0 Results and Analysis
CC
B-2
4.0 Corrective Measures
CC
B-3
5.0 Design Comparison
CC
B-3
1.0 Background on Four Point Bending
JH
C-1
2.0 Test Setup
JH
C-1
3.0 Results
JH
C-2
4.0 Redesign
JH
C-3
Figure B-2.0.1
Section C Arm Testing and Redesign
Figure C-2.0.1 Test Setup
Figure C-4.0.1 Revised Arm Design
5.0 Conclusion
JH
C-3
1.0 Minimization and Packaging
MM
D-1
2.0 Overview
MM
D-1
3.0 Packaging Directions
MM
D-1
4.0 Packaging Cost
MM
D-2
MM
D-2
JM
E-1
1.1 Option A
JM
E-1
1.2 Option B
JM
E-1
JM
E-1
2.0 Test Shipment
JM
E-2
3.0 Results
JM
E-2
4.0 Revisions and Conclusions
JM
E-3
WF
F-1
Section D Minimization and Packaging
Table 4.0.1 Summary of Cost to Package Chair
Section E Shipping
1.0 Cost Analysis
Table E-1.2.1 Carrier Options
Section F
Conclusions and Recommendations
Appendix
AA.
Bibliography
BB.
Recommended Vendors List
CC.
FEA Results
DD.
Physical Testing Results
EE.
Drawings and Assembly
FF.
Packaging Directions
GG.
Shipping Instructions
Additional Design Report Items:
Cover Page
WF
Table of Contents
WF
Transmittal Letter
WF
Section A
Project Background
Adirondack Chair
SEC Reference Number: F07-58-ADRNDKCH
TABLE OF CONTENTS – SECTION A
Initials
Page
1.0 Executive Summary
WF
A-1
2.0 Introduction
WF
A-2
3.0 Overview
WF
A-2
4.0 Capital Cost Estimate
WF
A-4
WF
A-4
5.0 Implementation Schedule
1.0 EXECUTIVE SUMMARY
This document contains a complete report of the results for the redesign and the
packaging as well as shipping information for the Adirondack chair. The
recommendations for redesign are based on the results from finite elemental analysis and
also from physical testing. While some concessions were made on the degree of the
loading case the results clearly show the overall stress in the arm has been significantly
reduced. Packaging instructions were created to allow the Center for Comprehensive
Services (CCS) work force to disassemble the chair as well as appropriately package the
chair. This packaging includes the placement of two kinds of bubble wrap in addition to
a list of all the required items that must be included in the shipment. A set of assembly
directions was created so that the end user can reassemble the chair upon receipt of the
shipment. With the fully packaged chair a test shipment was performed wherein the
package was sent from Carbondale, IL to Chicago, IL. Based on the information gained
from this test revisions were made to optimize this packaging and shipping process.
There were several other designs considered of which many were removed based on
testing and aesthetics. The redesigned arm contains two new parts as shown in Appendix
EE Drawings #EE-1.0 through EE-1.2. The addition parts add a very minimal cost to
the chair in terms of material costs coming in at less than a dollar per arm. However the
greater cost in during the manufacturing process were a greater amount of time must be
spent to manufacture the new parts. This isn’t a concern because of the nature of CCS’s
workforce.
A-1
2.0 INTRODUCTION
This proposal has been created to help solve several problems. First, a stronger arm is
required to allow for greater loads before failure. This entails testing of the current
design as well as the creation and testing of several alternative designs. Second, the
current design comes as one completely assembled unit, which due to its size prohibits
shipping. The Adirondack chair needs to be disassembled so that it can be shipped. The
final component, packaging, needs to undergo testing to ensure that all pieces arrive in a
safe and timely fashion. Packaging and wrapping options will be explored to ensure this
occurs. Lastly, directions for assembly upon arrival are required so that the end user can
adequately and safely assemble the chair.
3.0 OVERALL FUNCTIONAL DESCRIPTION
Included in this report is test data for 5 of the best designs of the arm. Included in the
testing phase many other designs were considered. Several of these were ruled out on the
basis of just one test or based on the results of the finite elemental analysis. Adding a
metal bracket for support instead of the wood bracket that is shown in Appendix EE was
considered but was rejected on the basis that it was difficult to achieve a great deal of
strength while remaining ascetically pleasing. From the data shown in Appendix DD it
was shown that the strength of the arm was improved from an average of 333 lbf to 565
lbf. While at the same time the standard deviation in the test data was reduced from 54
lbf to 12 lbf. The range also improved from 149 lbf to 17 lbf. All of this data is
confirmed by the results from the FEA and it shows that the strength of the arm was
greatly improved while at the same time the consistency was greatly increased. This
A-2
revised arm added two additional wood parts, glue, and 5 brads as shown in Appendix
EE Drawing # EE-1.0 through EE-1.2
With the revised arm a set of packaging instructions was created so that the CCS
workforce could package the chair in fashion that would insure safe arrival when shipped.
These packaging directions are shown in Appendix FF. The additional packaging
material adds just over $24 dollars to the cost. This package was then shipped at a cost of
$55 dollars to Chicago from Carbondale to test the durability of this system. This cost
can be reduced to $41 dollars by using a different shipping vendor. Based on the results
of this shipment modifications were made so that durability and ease of production could
both be increased. To complete the project, directions for the end-user are shown in
Appendix GG which were created and revised on the basis of the test shipment.
A second shipping option was considered wherein the cost of shipping could be
reduced to just under $20 dollars by shipping a completely disassembled chair. Based on
the cost analysis of what competing companies are selling similar products for the
additional cost doesn’t seem unreasonable. Also due the nature of the workforce where
the chair in manufactured it was decided that shipping a partially disassembled chair
would offer the most benefit to CCS.
While some concessions were made during the testing phase it is clear that the arm
strength has been improved to a reasonable level. Also more packaging material could be
used but it is the recommendation of this team that this wouldn’t cause a noticeable
improvement for the amount of cost added.
A-3
4.0 CAPITAL COST ESTIMATE
Build Cost
Item Decription
1x6 Cedar Lumber
2x6 Cedar Lumber
Three Point Bending Machine
Autodesk Inventor
Cordless Drill
Brad Nailer
Large Bubble Wrap
Small Bubble Wrap
Packing Tape
Box
Brads
Adhesive
Digital Camera
Shipping Insurance
Misc. Software
Shipping Costs
5.0
Cost Per unit
$1.16
$1.31
$7,000.00
$5,295.00
$29.97
$59.97
$0.65
$0.40
$0.02
$11.95
$0.00
$8.00
$95.00
$2.05
$399.00
$55.19
Quantity
Purchased or
Borrowed
45
8
1
1
1
1
50
50
330
2
2000
1
1
1
1
1
Quantity
Used
8
8
1
1
1
1
16
3
25
1
20
1
1
1
1
1
Build Cost
$52.03
$10.50
$7,000.00
$5,295.00
$29.97
$59.97
$32.50
$20.00
$5.95
$23.90
7.84
8.00
95.00
$2.05
399.00
55.19
Total cost
$9.25
$10.50
$7,000.00
$5,295.00
$29.97
$59.97
$10.40
$1.20
$0.45
$11.95
0.08
8.00
95.00
$2.05
399.00
55.19
Total
$13,096.90
$12,988.01
Source
6
6
3
1
6
6
11
11
11
11
6
6
14
13
9
13
IMPLEMENTATION SCHEDULE
Implementation Schedule
Task #
A
B
C
D
E
F
G
Action
Cut Rear Armbracket as Shown in Drawing EE-1.0
Cut Support Rodas Shown in Drawing EE-1.1
Assemble Both parts as Shown in Drawing EE-1.2
Finish assembly as previously done
Follow packing instructions as shown in Appendix FF
Include Assembly directions with shipment as Shown in Appendix GG
Take Package to Shipping Vendor
Day #
1
1
1
2
2
2
2
A-4
Section B
Finite Elemental Analysis
Adirondack Chair
TABLE OF CONTENTS – SECTION B
Initials
Page
1.0 Modeling Approach
CC
B-1
2.0 Force Position
CC
B-1
CC
B-2
3.0 Results and Analysis
CC
B-2
4.0 Corrective Measures
CC
B-3
5.0 Design Comparison
CC
B-3
Figure B-2.0.1
1.0 MODELING APPROACH
The modeling approach at the start of this project was straightforward. Take the
initial design, test it, and revise based on the data. Using Autodesk Inventor(1), the
left arm of the chair along with the supporting structures was created. The chair was
created as several parts and then assembled in the program. This enabled the physical
properties of the arm to be viewed and edited easily.
After inspecting the chair and using basic engineering principle it became evident
where the maximum stress should be when subjected to the loading condition. The
cross-sectional area at the back of the arm where the arm meets the back of the chair
was comparatively very small. This area when exposed to the load appeared to be the
weakest part of the arm.
Since a new design was completely out of the question, restraints needed to be
employed when it comes to cost and manufacturing. The facility that manufacturers
these chairs have processes and tooling installed that are going to continue to be used
for the chairs they produce in the future. The uniqueness of their workforce also
plays a large role in what can be done to improve the strength and life of their product
without impacting the main goal of the facility which is rehabilitation.
2.0 LOADING POSITION
The main goal of this project was to improve the strength and durability of the
Adirondack chairs produced by CCS. During our tours of the facility the major
problems that needed to be alleviated had to do with the arm. Too many chairs have
failed because the current arm design could not support the loads that were applied.
B-1
To recreate the loading conditions, two independent forces were employed. The
first load that was applied to the model was a 100 psi force positioned in the center on
top of the arm roughly one third of the distance from the rear of the arm. This load
resembled the weight or load applied by the user as he/she lifts him/herself out of the
chair.
The next load applied to the arm of the chair consisted of a 100 lb couple. This
couple replicates motion of the arm as the person lifts him/herself out of the chair.
The arm will tend to rotate creating a couple while the user is applying the pressure
force directly on top of the arm. The forces applied can be viewed in Figure B-2.0.1.
Figure B-2.0.1 Force and Couple Applied
These forces were applied using the ANSYS software supplied with Autodesk
Inventor.
3.0 RESULTS AND ANALYSIS
Analysis of the results confirmed what we expected based on the existing failures.
Figure CC-1.0 Original Design in Appendix CC shows the results. The thin
B-2
segment on the back of the arm indeed has the maximum stress of the part at 1.19x
105 psi. These results that will be confirmed through physical testing prove two
things. First, to significantly improve the strength of the arm: 1. the cross-sectional
area of the arm must be larger, or 2. additional supports must be added.
4.0 CORRECTIVE MEASURES
Two options were discussed and agreed upon. The first option was to increase the
cross-sectional area of the arm. A simple plan was employed to do so. The previous
design was constructed entirely with 1” x 6”dimensional cedar lumber. By using a 2”
x 6” piece for the arm, the cross-sectional area will double, which will increase the
strength of the chair halving the stress.
The second design option was to design a support rod and rear arm bracket. The
support rod was a 29” x 9/16” x ¾” rod as shown in Appendix EE DWG # EE-1.1..
The bracket was decorative design which also supports the rod as shown in Appendix
EE DWG # EE-1.0. This support rod was first glued and fastened with screws to the
arm. While the bracket was butted up against it and screwed in.
These models were created in Autodesk Inventor and finite elemental analysis
was completed on them. The design with the larger cross-sectional area had a
maximum stress of roughly 57000 psi. The additional support rod and bracket
decreased the maximum stress to almost 9000 psi. These two results can be viewed
in Appendix CC as CC-2.0 2x6 Design and CC-3.0 Original Design with Bracing
and Adhesive.
B-3
5.0 DESIGN COMPARISON
The two design changes that were tested dramatically reduced the maximum
stress with respect to the FEA models. While increasing the cross-sectional area did
reduce the maximum stress by a large portion, the addition of the support rod and rear
back bracket is clearly the superior design.
B-4
Section C
Arm Testing and Redesign
Adirondack Chair
TABLE OF CONTENTS – SECTION C
Initials
Page
1.0 Background on Four Point Bending
JH
C-1
2.0 Test Setup
JH
C-1
3.0 Results
JH
C-2
4.0 Redesign
JH
C-3
JH
C-3
5.0 Conclusion
1.0 BACKGROUND ON FOUR POINT BENDING
To simulate someone applying force to the arm, a four point load was used for
testing. This four point testing method provides an excellent simulation of the actual
forces that would be placed on an arm of a chair. A testing setup was made to
simulate as if the arm was actually on the chair and to fit under the testing machine.
This force that is being applied by someone’s hand could not be perfectly replicated
but an increase in strength on a four point bending machine will represent a better
performance when someone’s hand is applied.
2.0 TEST SETUP
A test setup of the arm on the Adirondack chair was made to allow for testing. A
stand was created to fix the arm similarly to the original design. The stand was made
out of 2” by 4” pine boards. The stand had to be able to hold the arm without twisting
when a load was applied. Figure C-2.0.1 Test Setup shows what the stand looks
like.
C-1
Force was applied until the fracture point occurs. Once this happens the loading is
released and the maximum load and the deflection were recorded. This process was
repeated for all the revised designs. A picture of the three point bending machine is
shown in Figure C-2.0.1 Test Setup.
3.0 RESULTS
The test data, shown in Table DD-3.0.3 in Appendix DD, for each of the designs
shows the average, standard deviation, range and percent range. From this table,
Figure DD-3.0.1 Force Testing Results and Figure DD-3.0.2 Testing Results as a
Range were created.
Figure DD-3.0.1 Force Testing Results in Appendix DD shows the average and
the range for each of the five designs. As can be shown, the original design labeled #1
had an average maximum load of 333.66 lbf but a range from the maximum load to
the minimum load of 149.80 lbf. In this design there was a significant difference in
this range. This shows how susceptible the current design is to the differences in
cedar. In the final design, the average max loading was 565.11 lbf and the range was
17.67 lbf. This design had the best results of the five designs and had the highest
possible loading with the lowest range.
For Figure DD-3.0.2 Testing Results as a Range in Appendix DD shows the
range percentage of each of the different designs. This figure shows the range divided
by the average loads. The original design had the highest range percentage showing
that there were significant differences in each trial. The final design had the lowest
range expressed as a percent when testing. This design was the best out of all of the
designs and better than the original design as you can see.
C-2
4.0 REDESIGN
The revised design was to take the original arm shape and add a support rod and a
bracket underneath the arm to strengthen it. The support rod is shown in DWG # EE1.0 and the rear arm bracket is shown in DWG # EE 1.1. This new design added only
six more screws to the assembly and sticks with the original arm shape which will
help with the manufacturability of these additional parts. A picture of the revised arm
is shown below in Figure C-4.0.1 Revised Arm Design.
5.0 CONCLUSION
To conclude, the testing showed that when a support rod and bracket were added
to the original arm design the average maximum load increased from 333.66 lbf to
565.11 lbf. This shows an improvement of almost 70 percent. A lower range means
C-3
the arm strength is much more consistent. The new design not only supports larger
loads but also has a significantly lower range, which will provide the consistency.
C-4
Section D
Minimization and Packaging
Adirondack Chair
TSaluki Engineering Company
TABLE OF CONTENTS – SECTION D
Initials
Page
1.0 Minimization and Packaging
MM
D-1
2.0 Overview
MM
D-1
3.0 Packaging Directions
MM
D-1
4.0 Packaging Cost
MM
D-2
MM
D-2
Table D-4.0.1 Summary of Cost to Package Chair
1.0 MINIMIZATION AND PACKAGING
The packaging developed as shown in Appendix FF will reduce the volume of
the chair as shipped to approximately 11 cubic feet with the following dimensions 21” x
24” x 38”.
2.0 OVERVIEW
The reduction in the packaging size of the Adirondack chair lowers the cost of
shipping the chair as well as decreasing storage space required for completed chairs that
are not yet delivered. The packaging directions, as listed in Appendix FF, show how the
packaging of the Adirondack chair was minimized, while still allowing the customers to
easily and efficiently assemble the chair.
3.0 PACKAGING DIRECTIONS
The packaging directions as shown in Appendix FF, Figures 1-4, show that
proper packaging of the chair requires the chair to be disassembled into nine main
sections which are: the seat back, seat back support, chair base, two arms, two large
braces, and two small braces. The disassembly of the chair into these sections allows the
customer to quickly assemble the chair while greatly decreasing the shipping costs. The
disassembly of the chair for proper packaging requires the removal of 18 ea. 1 ¼” screws
and 26 ea. 1” screws using a #2 Phillips bit. The two different size screws are packaged
separately into plastic storage bags which are then labeled and taped as shown in
Appendix FF, Figures 5 and 6. Plastic storage bags are an easy way to package the
screws and since they can be resealed, they decrease the chances of lost screws during
assembly.
D-1
Next, the arms, large braces, and small braces are wrapped together with small
bubble wrap cut to a size of 2’ by 3’. The bubble wrap is then secured with tape as
shown in Appendix FF, Figures 7-10. Figures 11 and 12 of Appendix FF shows the
seat back and seat back support placed on the chair base. This is then wrapped twice with
large bubble wrap cut to 8’x 2’ and secured with tape as shown in Figures 13-18 of
Appendix FF. The bubble wrap not only protects the parts from damage during the
shipping process, but also keeps the parts together, thus decreasing the chances of lost
parts. Figure 19 shows how the arm is placed and tightly taped underneath the chair base
to decrease movement inside the box which decreases the chances of damage during
shipping.
Figures 21-22, in Appendix FF shows the preparation of the box for the
Adirondack chair. The two sides of the box that are uncut need to be cut down the
corners ten inches so that when folded over, the height of the box will be no longer than
38”. This is important since many shipping companies will not ship packages if the
circumference around the box plus the height is more than 130”.
Next, as shown in
Appendix FF, Figures 22-25, the seat back is placed into the box facing in the direction
of the cuts. The box flap is then placed over the back of the chair legs and taped. This
keeps the product from moving around inside the box, thus preventing potential damage.
Next, the assembly directions (placed in an envelope) and the two bags with screws are
taped to the box flap that was folded over. This helps prevent moving parts inside the
box and also guarantees the customer will immediately find the directions when opening
the package. The box flap that is on the other side of the one with the directions and
D-2
screws is then folded over. Next the other two flaps are placed over the box. The top and
bottom of the box are both securely taped and the box is ready to be shipped out.
4.0 PACKAGING COST
As shown in Table D-4.0.1 below, the total estimated cost of packing one
Adirondack chair in the manner described in Appendix FF is almost twelve dollars. The
total price includes the price of a 16 ft piece of large bubble wrap, a 3 ft piece of small
bubble wrap and 25 feet of packaging tape, two zip lock bags, and the cardboard box.
Each item, its unit price, amount used, and cost per amount used for the packaging of one
Adirondack chair are all listed in the Table D-4.0.1.
Summary Of Cost To Package One Chair
Amount
Item
Unit Price
Used
$Cost
Large bubble wrap (2'
wide)
$0.65/foot (3)
16 feet
10.40
Small bubble wrap (2' wide)
$0.40/foot (3)
3 feet
1.20
$5.95/double
Packaging Tape
roll@55 yard/roll
(3)
0.46
25 feet
3.44/box of 100
Ziplock bags
(6)
2
0.07
21"X24"X48" box
$11.95/box (2)
1
11.95
OVERALL PRICE TO WRAP
$24.08
Table D-4.0.4 Summary of Cost to Package One Chair
D-3
Section E
Shipping
Adirondack Chair
TABLE OF CONTENTS – SECTION E
Initials
1.0 Cost Analysis
Page
JM
E-1
1.1 Option A
JM
E-1
1.2 Option B
JM
E-1
JM
E-1
2.0 Test Shipment
JM
E-2
3.0 Results
JM
E-2
4.0 Revisions and Conclusions
JM
E-3
Table E-1.2.1 Carrier Options
1.0 COST ANALYSIS
Before shipping the packaged chair, a cost analysis was performed on the four major
shipping companies near the Center for Comprehensive Services; DHL, FedEx, UPS, and
USPS. Two methods of packaging were considered for CCS: One in which the chair was
completely disassembled (Option A) which decreased the price of shipping and in the
other method, the chair was broken down into its main components and shipped (Option
B).
1.1 OPTION A
The price of shipping the chair completely disassembled was approximately
twenty dollars for each carrier for a basic shipment to the test area code in the Chicago
suburbs. This option was not pursued as the nature of the CCS facility is to provide
rehabilitation to its clients and assembly of the chair is a large part of this rehabilitation.
1.2 OPTION B
Table E-1.2.1 shows the cost analysis for shipping the chair disassembled into its
major components:
Table E-1.2.1
Price to
Carrier ship
DHL
$41 (4)
FedEx
$52.92 (5)
UPS
$61.88 (12)
USPS $55.19 (13)
Carrier Options
Time of
Nearest Location
arrival
Kopies and More
2 days (4)
Marion
same day (5)
Murdale Shopping Center
2 days (12)
University Mall Area
2 days (13)
Distance from CCS(mi)
1.7 (4)
16.6 (5)
1.1 (12)
2.6 (13)
As shown in Table E-1.2.1, the most economical shipping carrier is DHL in Carbondale.
Also, another important aspect in shipping is how close the carrier is to CCS and Table
E-1.2.1 shows that the closest carrier is UPS in the Murdale Shopping center. Overall,
E-1
from Table E-1.2.1, it appears that the cheapest and most efficient way to ship is to use
DHL at $41and 1.7 miles away. The addresses and phone numbers of the carriers listed in
Table E-1.2.1 are listed in Appendix BB in the Recommended Vendor List.
2.0 TEST SHIPMENT
For research, USPS was used to ship the chair. Upon Arrival at USPS, on March
24th, the box had dimensions of 21”X24”X48” and a weight of 28 lbs. 5 oz and included
a copy of the Assembly Instructions. USPS would not ship the chair because the box was
too large. The distance around the box plus the height of the box was 132” and USPS will
only ship a package if that value is less than 130” (13). This same methodology is applied
at the other major carriers. In order to solve this problem, the chair was modified by
removing the seat back support and repackaging everything. The seat back support was
included in the shipment but by removing it from the seat back, it was possible to take
four inches off of the height of the box reducing the total distance around the box plus its
height to 128”, which is two inches below the maximum allowable value of 130”. After
repackaging the chair, the Assembly Instructions were modified to fit the changes as
described above. The chair was then shipped via USPS on March 25th with final
dimensions of 21”X24”X38” at a weight of 28 lbs. 11oz. with insurance for $100 for a
total cost of $57.24 (10). The chair was shipped to Laura Mathews at area code 60490 in
South Chicago. Overall, the price to package and ship one chair to the Chicago area came
to be $81.32.
3.0 RESULTS
Although USPS advertised 2 day shipping for the packaged, it did not arrive at
Ms. Mathews’ house for 6 days. Ms. Mathews stated that the package arrived on May 31st
E-2
after leaving Carbondale on the 25th (9). Upon arrival, Ms. Mathews was able to assemble
the chair in 35 minutes, using the Assembly Instructions provided (9). Ms. Mathews
stated that assembly was easy although she had some recommendations for the Assembly
Instructions (9). Ms. Mathews stated that each consecutive picture should be labeled with
numbers in increasing order, instead of with letters, as the parts of the chairs are also
labeled with letters and she thought that lettered pictures were referring to lettered parts
(9). She also stated that in step E of the assembly instructions, there should be a note
telling the builder to make sure that the rounded side of the large arm brace faces
forward; Ms. Mathews could not tell which way the large arm brace was supposed to face
and during initial assembly, she accidently installed it backwards (9).
4.0 REVISIONS AND CONCLUSIONS
Ms. Mathews’ recommendations were included in a final revision of the assembly
instructions titled Assembly Instructions as can be seen in Appendix GG. A more cost
effective option for shipping was considered for CCS: If the chair was completely
disassembled before shipping, the box size could be reduced enough to ship at a much
lower price. The current price of shipping, $57.24, included an oversize package charge
of about forty dollars: This means, that if the chair was disassembled and shipped, it
could be done for twenty dollars. As previously stated, this concept was not pursued as
the nature of the CCS facility is to provide rehabilitation to its clients and assembly of the
chair is a large part of this rehabilitation. Also, the current chair price is $100 without
shipping and the price of the chair with shipping and packaging will become $181.32.
This price can be further reduced to $167.13 by using DHL which is our recommendation
based on price and location relative to CCS. These prices may seem high but from
E-3
previous research, it is not uncommon for a handmade Cedar Adirondack chair to sell for
over $200 dollars, so the cost is not unreasonable (2).
E-4
Section F
Conclusions and Recommendations
Adirondack Chair
CONCLUSIONS AND RECOMMENDATIONS
In short, it is the recommendation of this team to manufacture the parts shown in
Appendix EE Drawings # EE-1.0 through EE-1.1 and assembled according to drawing
EE-1.2. This recommendation is based on the ease of manufacturing in addition to the
testing performed as shown in Appendix DD. The packaging and shipping of the chair
does add significant cost however this cost is still within the norms of the industry.
Included in this report are directions for packaging and directions for assembly which
will provide CCS a safe and cost effective method of shipping an Adirondack chair.
F-1
APPENDIX AA
BIBLIOGRAPHY
Bibliography
1. Autodesk. (n.d.). Autodesk Inventor Suite 2009. Retrieved April 2, 2008, from http://store.autodesk.com/servlet/ControllerServlet?Action=DisplayPage&Env=BASE&L
ocale=en_US&SiteID=adsk&id=ProductDetailsPage&productID=103607600 2. Cedar Adirondak. (2007, November 14). Retrieved April 2, 2008, from http://www.cedaradirondack.com/chair.html 3. Cole Parmer. (n.d.). Retrieved April 2, 2008, from http://www.coleparmer.com/ 4. DHL Corporate. (n.d.). DHL. Retrieved April 2, 2008, from http://www.dhl‐
usa.com/home/home.asp 5. FedEx. (n.d.). FedEx . Retrieved April 2, 2008, from http://www.fedex.com/us/ 6. Lowes Corporate. (2008, April 2). www.lowes.com. Retrieved from www.lowes.com: http://www.lowes.com/lowes/lkn?action=home 7. Mathews, M. L. (2008, March 31). Shipping Revisions. (J. Mathews, Interviewer) 8. MBE. (n.d.). Mail Boxes Etc. Retrieved April 2, 2008, from http://www.mbe.com/ 9. Newegg. (n.d.). Newegg. Retrieved April 2, 2008, from http://www.newegg.com/Product/Product.aspx?Item=N82E16832116161 10. The Mentor Network. (n.d.). Center For Comprehensive Services. Retrieved April 2, 2008, from http://thementornetwork.com/standard/Location.aspx?guid=8b1eb36d‐be93‐
4e1f‐9f9b‐0cc74d9b4d91 11. U‐haul Corporate. (n.d.). www.uhaul.com. Retrieved April 2, 2008, from http://store.uhaul.com/product_detail.aspx?id=6560 12. UPS Corporate. (n.d.). Retrieved April 2, 2008, from http://www.ups.com/ 13. USPS Corporate. (2008, April 2). www.usps.com/. Retrieved from http://www.usps.com/ 14. Wal‐Mart Corporate. (n.d.). Retrieved April 2, 2008, from http://www.walmart.com/ APPENDIX BB
RECOMMENDED
VENDORS LIST
Recommended Vendor List
DHL (Shipping)
811 S. Illinois Ave.
Carbondale Il, 62901
Inside Kopies and More
Ph# (800) 225-5345
Fedex (Shipping)
507 N 5th Street
Marion Il, 62959
Ph#(800) 463‐3339 Lowes (Glue, Brads)
1170 E Rendleman Road
Ph#(618) 529-8400
Mail Boxes Etc. (Packaging, Shipping)
1809 West Main Street
Ph#(618) 529-6245
U-Haul (Packaging)
415 N Illinois Ave
Carbondale IL, 62901
Ph#(618) 529-2771
UPS (Shipping)
1809 West Main Street
Inside Mail Boxes Etc.
Ph#(618) 529-6245
USPS (Shipping)
1301 E. Main Street
Ph#(618) 351-5600
Wal-Mart (Packaging)
1450 E Main St
Carbondale IL, 62901
Ph#(618) 457-2033
APPENDIX CC
FEA RESULTS
Figure CC-1.0 Original Design
Note: 100psi pressure 100lbf couple
Figure CC-2.0 2x6 Design
Figure CC-3.0 Original Design with Bracing and Adhesive
APPENDIX DD
PHYSICAL TESTING
RESULTS
Figure DD-1.0 Force Testing Results
600.00
565.11
535.83
#1 Load
#1 Range
#5
#5 Range
#6
#6 Range
#7
#7 Range
#8
#8 Range
500.00
444.28
418.17
400.00
LBF
333.66
300.00
200.00
149.80
124.35
100.00
56.49
23.33
17.67
0.00
Figure DD-2.0 Testing Results as a Range
50.00
44.90
45.00
#1
#5
#7
#8
40.00
35.00
29.74
Percent
30.00
25.00
20.00
15.00
10.54
10.00
5.25
5.00
0.00
3.13
#6
Table DD-1.0 Data From Three Point Bending
Design # 1 Trial # 2 3 4 5 7 Load (LBF) 330.11 265.40 342.90 415.20 314.70 Deflection (in) 0.74 0.80 0.84 0.74 0.92 Average S. Deviation. Range Range Percent 2 6 3 8 9 11 333.66 54.23 149.80 44.90 336.10 336.10 487.29 335.65 450.38 0.81 0.08 0.18 0.80 0.80 0.89 0.62 1.11 Average S. Deviation. Range Range Percent 4 10 5 12 13 14 424.44 79.08 151.64 35.73 313.00 313.00 459.81 436.54 436.48 0.87 0.25 0.49 0.61 0.61 0.75 0.89 0.79 Average S. Deviation. Range Range Percent 6 15 16 17 18 19 444.28 13.45 23.33 5.25 358.47 482.82 400.58 426.99 422.00 0.81 0.07 0.14 0.75 0.62 0.70 0.77 0.67 Average S. Deviation. Range Range Percent 7 20 21 418.17 45.13 124.35 29.74 507.58 564.07 0.70 0.06 0.15 0.748 0.553 Average S. Deviation. Range Range Percent 8 22 23 535.83 39.94 56.49 10.54 556.27 573.94 0.65 0.14 0.20 0.59 0.63 Average S. Deviation. Range Range Percent 565.11 12.49 17.67 3.13 0.61 0.03 0.04 APPENDIX EE
DRAWINGS &
ASSEMBLY
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
2
1
1.00
.75
B
B
.35
.38
.28
.65
.68
1.80
1.15
R1.00
.75
Dimensions in inches
A DRAWN
Craig Craddock
Drill Holes: v0.375" Ø0.125"
3/29/2008
F07-58-ADRNDKCH
CHECKED
4/10/2008
Jason Hick
QA
TITLE
Rear Arm Bracket
MFG
APPROVED
SIZE
EE-1.0
A
SCALE
2
REV
DWG NO
1:1
2
Sheet 1 of 3
1
A
2
1
Note: To be manufactured by ripping
down standard 0.75" stock lumber.
Must be installed with grain running
lengthwise.
B
B
.75
.28
4.31
.56
.56
29.56
.75
.75
Right side view 1:1
Drill Holes: v0.375" n0.125"
Dimensions in inches
A DRAWN
Craig Craddock
3/29/2008
F07-58-ADRNDKCH
CHECKED
4/10/2008
Jason Hick
TITLE
QA
Support Rod
MFG
APPROVED
SIZE
EE-1.1
A
SCALE 0.125
2
REV
DWG NO
2
:1
Sheet 2 of 3
1
A
2
1
2
4
B
B
1
3
7
6
TYP. for right side
ITEM
1
2
3
4
5
6
7
A DRAWN
Craig Craddock
QTY
1
1
1
1
7
1
1
Parts List
PART NUMBER
Back Support Arm
Adirondack Left Arm
Front Support Arm
Front Left Brace
1.125" screw
Support Rod
Rear Arm Bracket
4/10/2008
DESCRIPTION
Current
Current
Current
Current
Current
DWG. EE-1.1
DWG. EE-1.0
Note:
Where top of support
rod meets bottom of left
arm apply standard
amount of Titebond III
Wood Glue or similiar
exterior glue. Secure
left arm to support rod
with five 1" x 18 gauge
brads evenly spaced
installed from top down.
A
F07-58-ADRNDKCH
CHECKED
Jason Hick
4/10/2008
TITLE
QA
Revised Arm Assembly
MFG
APPROVED
SIZE
EE-1.2
A
SCALE
2
REV
DWG NO
1:4
2
Sheet 3 of 3
1
APPENDIX FF
PACKAGING
DIRECTIONS
Figure F-1.0 Packaging Instructions
PACKING INSTRUCTIONS
PART1: Disassembly
Remove screws shown in boxes from both sides of chair (1)(2).
1
2
With this step complete, you should have the following in front of you (3)(4):
3
e
a
d
f
b
c
g
4
h
PART 2: Wrapping Chair Parts
1.Put 18 long screws in a small zip lock bag and 26 short screws in another zip lock bag (3). Roll up, label and tape the
bags of screws “large” and “small” as shown (4):
Tape
5
Here
6
2.Arrange arms as shown on a 2’X3’ sheet of small bubble wrap (5) and wrap as shown with small brace and large brace
Included (6)(7)(8).
10
7
8
9
Fold over
and tape
here
Tape
Here
Fold over
and tape
here
3. With arms wrapped together, place a piece of tape on center of bubble wrap to keep it from unwrapping (8). Then,
fold over the bubble wrap on both ends of the arm and tape it closed (8).
4. Arrange seat back and seat back support onto chair base as shown (9)(10):
11
12
5. Place assembly onto 8’X2’ sheet of large bubble wrap (11) and wrap as shown (12)(13):
13
14
15
Tape
Here
6. Place wrapped assembly onto another 8’X2’ sheet of large bubble wrap (14) and wrap as shown (15)(16):
16
18
17
Fold both ends of wrapping
over chair and tape
Tape
Here
6. Securely tape wrapped arms to bottom of chair base as shown (17). Place a piece of tape across the center of the arm
wrapping connecting it to the chair wrapping and place a strip of tape at the top and bottom of the arm wrapping,
holding it tightly to the wrapped chair:
19
Tape
Here
PART 3: Putting chair in box
1. Two corners of the box have already been cut down. Cut down the other two corners eleven inches as shown (18)(19).
NOTE: Make sure that the distance from the bottom of the box to the bottom of the cut created is no more than 38
inches. If so, continue cutting down sides of box until distance from bottom of box to bottom of cut is 38 inches.
20
21
2. Place the chair into the box with the seat back facing in the direction of the cuts previously made (20).
3. Fold and place assembly instructions into an envelope.
3. Fold a box flap over the back of the chair legs and tape as shown (21).
4. Tape assembly instructions and large and small screws to box flap (21). Continue packing as shown folding other box
flap inside box (22) and then folding the last two flaps over the top of the box (23):
NOTE: when folding the box flap over the back of the chair legs, make sure that the flap wraps tightly over the chair
legs.
22
23
Tape
Here
24
25
5. Tape the box closed by placing two strips of packing tape across the top of the box and down the sides. Also, tape the
flaps on the sides. Repeat taping procedure on the bottom of box (24)(25).
26
27
Tape
Here
Top of box
Tape
Here
Bottom of box
Your chair is now ready for shipping. Take the packaged box to a USPS dealer, and have it shipped out.
APPENDIX GG
ASSEMBLY
INSTRUCTIONS
Figure GG-1.0 Assembly Instructions
ASSEMBLY INSTRUCTIONS
NOTE: DO NOT USE A DRILL TO INSTALL SCREWS. USE A SCREWDRIVER AND DO NOT OVERTIGHEN SCREWS
Upon receiving your chair and unpacking, you will have the following things (1)(2):
a. Seat back
b. Seat back support
c. Chair base
d. Arm (2)
e. Large Brace (2)
f. Small brace (2)
g. Small Screw (26)
h. Large screw (18)
i. Putty
NOTE: #2 Phillips screw driver needed for assembly
A. Install seat back support onto seat back making sure that slanted side of seat back support faces upward. (3)(4).
4 large screws
3
4
B. Position the seat back onto the chair base making sure to align the screw holes (5). Install screws where shown on
either side of the chair (6)(7). 4 large screws, 10 small screws
5
6
7
C. Screw the back of the arm into the seat back support by first resting the front of the arm on the arm support and
then installing two small screws through the arm brace into the middle set of screw holes on the seat back support
(8)(9). Then, install two small screws on the other side of the seat back support into the arm (10). 8 small screws
8
9
10
D. Install the small brace to support the back of the arm using two small screws (11). 4 small screws
11
E. Install large arm brace and screw arm into brace and arm support making sure that the rounded side of the large arm
brace faces forward. (12)(13)(14). 10 large screws 4 small screws
12
13
F. Repeat steps 3, 4 and 5 for the arm on the other side of the chair.
G. Fill open screw holes with the putty provided.
14
Your final assembly will look like this (M):
15
Enjoy your new Adirondack Chair from CCS!!

Adirondack Chair : Center For Comprehensives Services Saluki Engineering Company, Team 58

Transcription

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