Final Design

One design approach was to evaluate the current bosses and see whether any modifications to the current design were possible. Taking the manufacturing process into consideration, any design that was derived from the current bosses would entail similar installation procedures and procurement. This design approach led to the development of the Z-Boss Slider Assembly shown in Figure1 and Figure 2. This design concept allowed adjustability in the z axis due to the threaded bosses which in turn changes the height of the mounting surface. This adjustment is necessary when the bosses are welded into the drip pan at the wrong height. Due to the angle of the drip pan, the Z-Bosses must be inserted through the drip pan completely. For structural strength purposes, the Z-Boss must be welded on both sides of the drip pan.

Figure 1: Z-Boss Slider Assembly Figure 2: Aluminum prototype of Z-Boss Slider

on is encased in the top plate which allows the top plate to freely rotate and also pivot on the Hemi’s spherical surface. This process creates two opportunities. First is that as the plate rotates, it gives the mounting slot on the top plate freedom to move in a radial direction increasing the adjustability on the X-Y axis. The ability of the top plate to pivot allows the top plate to level itself to the bottom surface of a component or module as it is placed on top of the Hemi mount boss. Another advantage of this design due to its self-leveling capabilities is that the boss alternative only needs to be attached onto a single side of the drip pan thus reducing the need to cut through the drip pan and reducing the process of welding on both sides to welding on a single side of the drip pan. The top plate of the Hemi Mount boss incorporates a slot that accepts required bolt sizes used for mounting and provides primary adjustment in the X-Y axis for component mounting positions.

Figure 3: CAD of Final design for Hemi mount

Key Features:

Adjustment in the x-y-z axis
Ability to self-level once component is placed on top
Requires only to be welded on top of the drip pan
Easy installation onto the drip pan

Animation: Z-boss slider assembly

Functional Requirements of Design

Primary functional requirements for boss alternatives involve the capability to support up to 11,000 lbs. over 8 support points without critically impeding the flow of fluid onto or around the drip pan. The primary functional requirement is to allow the bosses to adjust its mounting position in the x, y, and z-direction. Secondly, the new designs must not trap corrosive fluids which may leak from the components and modules. It also must not raise the components any higher than 4 inches off the drip pan and add excessive mass to the frame.

Appealing considerations for the Z-Boss Slider Assembly alternative is that it does not require changes in the manufacturing process of the frames at TurboFab. This screw boss imitates the lower section of the existing bosses by requiring the same process of the drip pan being cut th

rough and the boss being welded on both sides of the drip pan. Fluid entrapment is not an issue with this design as fluid is able to freely flow across and around as it is with the current existing boss design utilized by Solar Turbines. The rest of the boss assembly is a simple design that is an inexpensive option that provides manual adjustment of the height by the incorporation of the screw top. This screw top adjustment gives this alternative the ability to adjust +/- an inch in height. The sliders are also an easy to manufacture and inexpensive casted part attachment that allows for adjustment in the X-Y axis up to +/- 3inches.

Key Features

Adjustment in x-y-z axis
Manufacturing process is simple
No changes to manufacturing process in relation to boss installation
Does not trap fluid

Hemi Mount

Main consideration for the Hemi Mount boss (Figure 3) is the mount’s specific ability to self-level. This self-leveling is handled by the unique Hemi mid-section. This floating secti

Animation: Assembly of Hemi mount