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Hydrogen Properties for Energy Research (HYPER) Lab Dr. Jacob Leachman

Manic Manufacturing

Squad
From left to right: Adam Lensegrav, Mohammed Albreriki, Taylor Sanderson, Zijue (Sam) Wang, and Maxwell Welton

Goal:

To make sure the manufacturing process is as efficient and sustainable as possible.

Challenge:

To utilize materials and professional resources available in Uganda.


Paradigms

Manufacture in Uganda:

Hot thing

In regards to solely manufacturing the rock crusher assembly in Uganda, our team plans to send over a parts list along with a detailed instruction set. We would make certain that the parts are easily assembled and instructions are clear for ease of manufacturing.

Pros:

  • Hands on experience for Ugandan women

The benefits of assembling the rock crusher in Uganda are that it allows for hands on experience for the Ugandans, and the crusher would be more self-sustaining. Hands on experience is important because it allows the women to work with the rock crusher and become familiar with its parts and functions. This will become key when parts break down and need to be replaced.

Cons:

  • More complicated construction
  • Less resources/personnel

Uganda

On the downside, this method of assembly will be more complicated for the women of Uganda. They would need to find materials, machine them, and assemble them based on instructions that are provided. There are also less resources available in Uganda, so key parts of the system may be more difficult to find and utilize.

Manufacture in the United States:

Manufacturing solely in the United States means that every part of the rock crusher design would be manufactured here at the University and then shipped to Uganda with minimal assembly needed.

Merica

Pros:

  • More resources/personnel available
  • Simple
  • Reliable

This design paradigm possesses a large amount of benefits as this method will be simple and reliable while having access to many resources. Shipping all of the necessary parts to Uganda will make it easier for the women to assemble the crusher as they will not have to search for parts to use on their own. This design will be reliable as we will have tested the parts utilized in the design. Lastly, we have access to a vast selection of materials and machining methods, making the assembly of this crusher much easier.

Cons:

  • Less hands on experience for Ugandan women
  • Some materials may not be readily available in Uganda
  • Shipping is difficult and expensive

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One drawback of manufacturing solely in the United States is that it does not provide hands on experience for the women of Uganda. Additionally some materials and manufacturing needs may not be readily available in Uganda, meaning that when a part breaks down, finding a replacement part may be much more difficult than if the system was made from easily available parts in Uganda. Finally, during our research, we had very little luck finding a viable shipping method. We looked into using a postal carrier as well as shipping the assembly by both. Due to the size and weight of the assembly, shipping will certainly be expensive.

Manufacture in both the United States and Uganda:

Our third paradigm includes a combination of manufacturing in the United States and Uganda. Ideally nearly all of the materials would be sourced from Uganda as well as the machining and manufacturing of the rock crusher. Rather than putting the rock crusher together, the University would act as a safety net so to speak that would supply certain materials/parts or complete small tasks if it cannot be found or completed in Uganda.

Pros:

  • Hands on experience for Ugandan women
  • Difficult tasks would be resolved here at the University
  • Minimal shipping

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Some pros of this manufacturing method are that it will provide hands on experience for Ugandan women and any difficult tasks would be resolved here and then sent to Uganda. Using this process there would also be little to no shipping difficulties experienced and therefore costs would also remain lower.

Cons:

  • Potential for a more complicated process
  • Less resources/personnel

 

Similar to having a large group working on a single project or multiple groups working on individual pieces of a larger assembly, complications can arise. The women of Uganda are on a different continent, speak a different language, use a different measurement system, and live in a society completely different from ours. Clearly there could be miscommunications and complications that arise in the process. Additionally, in order to ensure that the majority of the rock crusher could be assembled there, extra considerations and modifications to the design would have to be made to accommodate the available resources in Uganda.


Decision

We recommend using our final paradigm of manufacturing the rock crusher in both Uganda and the United States. This method has the greatest amount of positives and will prove to be the most sustainable solution for Ugandan women.


Integration

In order to integrate this paradigm we first compiled a list of the materials and manufacturing services needed by each group.

Materials Needed

DOVER AIR FORCE BASE, Del. -- Airman 1st Class Jonathan Trammell welds a part on the remodeled mortuary transfer vehicle. Airmen from the metal technology shop here redesigned the inside of the truck to increase the capacity from two to six transfer cases. Airman Trammell is assigned to the 436th Equipment Maintenance Squadron. (U.S. Air Force photo by William M. Plate Jr.)

Rock Crusher:

  • Metal tubing
  • Metal plating
  • Bottle jack
  • Connectors/bolts
  • Some welding

Sorting:

  • Wood
  • Metal mesh
  • Connectors/bolts

lumber

Transportation:

  • Bicycle tires/tubes
  • Wood
  • Metal rods
  • Screws

Power:

  • Bicycles
  • Miscellaneous bike parts
  • Bike stand

Next we compiled a list of the materials we could find in Uganda over the internet.

Materials available in Uganda

table

Notes:

  • Wood products are available but without supporting websites.
  • We were unable to find any quality bike shops online, so bicycles could be one of the items we need to handle here at the University and then send over.
  • Ultimately, most industries in Uganda do not have a website so it is likely that Rebecca would know of quality options for the materials we need.

Sample of Jaw Crusher Bin

After examining our paradigms and researching materials we tried to envision a way to simplify the materials used in the design. One design that is being pursued by the crusher team is a jaw crusher. We obtained a CAD file for a jaw crusher and actually 3D printed a model of it. We then recreated the bin for this jaw crusher using CAD software and substituted wood for the frame and used metal sheets as protective measures to increase the working life of the bin. Below are pictures of the jaw crusher design that is being emulated.  Below that are pictures of the 3D model we printed and simulations we ran with different materials. Finally are pictures of what we came up with as an alternative design.

view1  view2

 

Bin

3D printed model:

Pasted image at 2016_05_03 11_31 AM  Pasted image at 2016_05_03 11_36 AM

Simulation with Steel (1045 Alloy):

1045 steel

Simulation with wood:

wood

It may be difficult to see in the pictures seen here, but the results of the simulation pictures demonstrate that the displacement of the bin using steel is much less than the displacement using wood. In order to pursue this option of using wood as an alternative, additional designs for reinforcement would have to be considered and tested in order to achieve an acceptable factor of safety.

 

Our alternative design:

Box  Pasted image at 2016_04_26 07_03 PM


 

Washington State University