esco-nestable crate paul silver gary hicks chad freitag anwar al-alawi
Post on 19-Dec-2015
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Design Brief
The project was to design a reusable crate that would be collapsible, stackable, and/or nestable, such that it can be returned to ESCO once the product has been shipped using minimal cargo space.
Four Step Process
Product Design Specification External Search Internal Search Concept Evaluation & Decision
Each step applied to all major components of project
Sizing/Proportion Analysis
Must fit logically/spatially into 20’ cargo container
Packing density of 55-gallon drum Spacing around crates for easy
movement with forklift Crate size/proportions computed 20 crates per 20’ cargo container
Material Selection
Durable, lightweight, recyclable Low maintenance Exposure to harsh environment Commonly available Proven performer
Material Selection
High Density Polyethylene (HDPE) Structural foaming agent Opportunity to learn about plastics
Structural Analysis
EDS IDEAS CHEST Maximum Von Mises-3900 psi Maximum deflection-0.139” LID Maximum Von Mises-3750 psi Maximum deflection-0.323” COMBINED WEIGHT - 176 lb
Structural Analysis
HDPE yield strength - 4800 psi
Chest Safety Factor - 1.23
Lid Safety Factor - 1.28
Manufacturing
Low Pressure Injection Molding Aluminum tooling vs. steel tooling Aluminum is less expensive and
requires less lead time Influence on design process
Economic Analysis
Crate vs. 55-gallon drum Drums - $9 Crate - $187
Based on 5-year span Drums - $302,400 Crates - $478,720
Economic Analysis
Crates cost more Difficult to place price on long term
environmental savings What are you willing to pay for
environmental preservation? Salvage value - can be used for
less strenuous tasks Storage Material movement
Further Development
Design optimization Reduce weight Decrease stress concentration
Different loading conditions Impact Crane straps
Quotes for initial production run
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