Overview of Project Context
UTC Aerospace currently uses conventional wooden shipping boxes to ship their parts
Many of these boxes must be shipped back empty, leading to inefficient use of space and high shipping costs
Want to develop a collapsible shipping container to reduce return shipping costs
Project Objectives
High Priority Objectives
Reducing shipping cost
Other Constraints and Issues
Side walls are to withstand force of 9G (due to hard landing of an airplane)
Top is to withstand force of 2G (to be stacked)
Inner supports to hold a thrust reverser in place are fixed on the bottom
can be redesigned
Containers are to be stackable when collapsed (maximum of 2)
Fit within trailer dimension (stepdeck trailer)
Achieve 75% reduction in volume
WOW Design Solution
The sponsors do not have specific dream design solution. They just want to minimize shipping cost.
They specifically mentioned that they did not want to limit our creativity.
Risk Reduction Objectives
Finite Element Analysis
Simulation of different structural mechanisms/materials under required loading conditions
Different container shapes
Simulation of containers with contents inside (expanded container) and also without any contents (collapsed container)
Intermediate Milestones
Finish Brainstorming Ideas (3/3/18)
Produce Risk Matrix with Sponsors (3/7/18)
Perform Free Body Diagram of the Container and Inner Support (3/14/18)
CAD of Different Designs (3/14/18)
FEA of the Designs-Sliding Wall, Scissor Link, Folding Wall (3/21/18)
Risk Reduction (3/21/18)
Produce Design Idea Criteria Matrix with Sponsors (3/21/18)
Individual Component Analysis (4/6/18)
Calculation of the Angle for the Inner Support (4/8/18)
1st 1:20 Scale Prototype (4/17/18)
Redesign with No Overhang (4/20/18)
CAD of Redesign (4/24/18)
FEA of the Redesign (4/27/18)
Assembled and Fabricated the 1:4 Scale Prototype Container Base Frame (4/27/18)
Integrate Inner Support to the Full Scale CAD (4/30/18)
Ordering 1:4 Scale Model Component
Structure Enhancement Design with Angle Braces and Locking Mechanism after FEA Result (5/21/18)
CAD of the Structure Enhancement Design for both Full Scale and 1:4 Scale (5/25/18)
FEA of the Full Scale Design (5/30/18)
Finish Building 1:4 Scale Prototype (5/30/18)
Part List and Budget List of Full Scale Design (6/1/18)
Full Scale Design Construction Manual (6/4/18)
Final Adjustment of the 1:4 Scale Prototype (6/4/18)
Final Design Review with the Sponsor (6/6/18)
Final Poster (6/8/18)
Final Report (6/8/18)
Individual Component Analysis Topics
hinges
lifting hooks
sliding mechanism
material
structural beams/columns
Risk Reduction Strategy
Finite element analysis
Material strength analysis
Weekly Meeting Time with sponsor:
Phone/video call meeting every Tuesday from 1 to 2 pm