Bracket Design for Large Freon Compressor and High Output Alternator

Photo of Phillip Denkler, Julie Meyer, James Nelson, Benjamin Stewart Students: Phillip Denkler, Julie Meyer, James Nelson, Benjamin Stewart

Sponsor: Cummins, Inc.

Date: Spring 2012

Requirements:
The Megabracket is currently in production, and therefore its geometry cannot be changed. The requirements include designing additional supports to help the Megabracket withstand the static, dynamic, and vibration loads. Cummins has budgeted $300 per unit, and requests the following deliverables: static, fatigue, bolted joint, and vibration analyses.

Problem:
Design supports for the existing "Megabracket" that will help carry the loads associated with a larger alternator and compressor.

Solution:
The recommended solution adds mounting brackets and side, bottom, and tie rod supports which improve the natural frequency by 166% and the stress by 55%. The mounting brackets correct the misaligned holes allowing the two components to attach to the Megabracket. The bottom and tie rod supports alleviate the stress from the alternator and compressor. Finally, the side support increases the natural frequency of the assembly away from the frequency of the engine vibration. Using manufacturing methods such as machining, investment casting, and welding in addition to applying a production learning curve of 80%, the total cost of the assembly is $418.55.

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