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Method drastically reduces preparation time pentaerythritol diformal from several hours to time span of 3 to 20 minutes with yields greater than 90 percent. Other advantages include elimination of solvents, decrease in labor and energy needs, adaptability to continuous operations, and overall simplicity and convenience.
Solar Array Manufacturing Industry Simulation (SAMIS) program is a standardized model of industry to manufacture silicon solar modules for use in electricity generation. Model is used to develop financial reports that detail requirements, including amounts and prices for materials, labor, facilities, and equipment required by companies.
The discussion defines a thermoplastic resin and compares the structural and environmental properties and the fabrication and repairability of the thermoplastic composite with a typical epoxy composite. Low labor costs exhibited by the thermoplastic composites make them a priority consideration for use in space structure.
The factors relevant to SPS costing and selection of preferred SPS satellite configurations were studied. The issues discussed are: (1) consideration of economic factors in the SPS system that relate to selection of SPS satellite configuration; (2) analysis of the proper rate of interest for use in SPS system definition studies; and (3) the impacts of differential inflation on SPS system definition costing procedures. A cost-risk comparison of the SPS satellite configurations showed a significant difference in the levelized cost of power from them. It is concluded, that this difference is the result more of differences in the procedures for assessing costs rather than in the satellite technologies required or of any advantages of one satellite configuration over the other. Analysis of the proper rate of interest for use in SPS system is 4 percent. The major item of differential inflation to be expected over this period of time is the real cost of labor. This cost is likely to double between today and the period of SPS construction.
It is suggested that asymptotic results for the behavior of thin shells can be incorporated in a general computer code for the analysis of a complex shell structure. The advantage when compared to existing finite difference or finite element codes is a substantial reduction in computational labor with the capability of working to a specified level of accuracy. A reduction in user preparation time and dependance on user judgment is also gained, since mesh spacing can be internally generated. The general theory is described in this paper, as well as the implementation in the computer code FAST 1 (Functional Algorithm for Shell Theory) for the analysis of the general axisymmetric shell structure with axisymmetric loading.
Cost-driving parameters of space industrialization are discussed, specifically cost of transportation from earth to low earth orbit and productivity of labor in space. A design procedure for a space manufacturing facility (SMF) is outlined, and the design of a reference SMF is described. This SMF receives lunar materials and converts them to components of space structures such as solar power satellites. The effect of machine reliability is discussed. The SMF appears versatile and productive, and the space environment has some beneficial characteristics which may simplify manufacturing processes. Technology demonstration programs are needed, but prototypes of SMF equipment can be small devices.
Computer program models coal-mining production, equipment failure and equipment repair. Underground mine is represented as collection of work stations requiring service by production and repair crews alternately. Model projects equipment availability and productivity, and indicates proper balance of labor and equipment. Program is in FORTRAN IV for batch execution; it has been implemented on UNIVAC 1108.
Tool removes sleeve remnants without distorting or damaging tubes, unlike pliers and other conventional handtools. Tubes can be reused, saving time, labor, and material in many applications. Sleeve-removal fixture consists of pressure screw, swing arm, locking screws, and base. It removes sleeve remnant from tubing after welded joint has been sawed through.
Simple tools assist in setting up and welding tubes. Welder aids can be easily made to fit given tube diameter. Finished set can be used repeatedly to fix electrode-to-weld gap and mark sleeve and joint positions. Tools are readily made in tube-manufacturing plants and pay for themselves in short time in reduced labor costs and quality control: Conventional measurements are too slow for mass production and are prone to errors.
The design, development, fabrication, testing, and transport of two 100 foot metal blades for the MOD-1 WTS are summarized. Because the metal blade design was started late in the MOD-1 system development, many of the design requirements (allocations) were restrictive for the metal blade concept, particularly the maximum weight requirement. The design solutions required to achieve the weight goal resulted in a labor intensive (expensive) fabrication, particularly for a quantity of only two blades manufactured using minimal tooling.
In an attempt to develop guidelines for classification by degree of intensity of various kinds of physical work performed by women, the effects of different work loads on women as compared to men were studied under industrial and experimental conditions, including response of the cardiovascular and respiratory systems to specified physical exercises of increasing intensity. Physiological criteria for assessing female labor in terms of intensity are proposed.
A conceptual design of a free piston solar Stirling engine-linear alternator which can be designed and developed to meet the requirements of a near-term solar test bed engine with minimum risks was developed. The conceptual design was calculated to have an overall system efficiency of 38% and provide 15kW electric output. The free piston engine design incorporates features such as gas bearings, close clearance seals, and gas springs. This design is hermetically sealed to provide long life, reliability, and maintenance free operation. An implementation assessment study performed indicates that the free piston solar Stirling engine-linear alternator can be manufactured at a reasonable price cost (direct labor plus material) of $2,500 per engine in production quantities of 25,000 units per year. Opportunity for significant reduction of cost was also identified.
Stack tests indicate that the discrepancies between calculated and measured temperature profiles are due to reactant cross-over and a lower than expected thermal conductivity of cells. Preliminary results indicate that acceptable contact resistance between cooling plane halves can be achieved without the use of paper. The preliminary design of the enclosure, definition of required labor and equipment for manufacturing repeating components, and the assembly procedures for the benchwork design were developed. Fabrication of components for a second 5-cell stack of the MK-2 design and a second 23-cell stack of the MK-1 design was started. The definition of water and fuel for the reforming subsystem was developed along with a preliminary definition of the control system for the subsystem. The construction and shakedown of the differential catalytic reactor was completed and testing of the first catalyst initiated.
Procedures to be used in determining the cost of producing and installing a parabolic dish collector in annual production volumes of 10,000, 50,000, 100,000, and 1,000,000 units include (1) evaluating each individual part for material cost and for the type and number of operations required to work the raw material into the finished part; (2) costing labor, burden, tooling, gaging, machinery, and equipment; (3) estimating facilities requirements for each production volume; and (4) considering suggestions for design and material alterations that could result in cost reduction.
The development and flight evaluation of an advanced composite empennage component is presented. The recommended concept for the covers is graphite-epoxy hats bonded to a graphite-epoxy skin. The hat flare-out has been eliminated, instead the hat is continuous into the joint. The recommended concept for the spars is graphite-epoxy caps and a hybrid of Kevlar-49 and graphite-epoxy in the spar web. The spar cap, spar web stiffeners for attaching the ribs, and intermediate stiffeners are planned to be fabricated as a unit. Access hole in the web will be reinforced with a donut type, zero degree graphite-epoxy wound reinforcement. The miniwich design concept in the upper three ribs originally proposed is changed to a graphite-epoxy stiffened solid laminate design concept. The recommended configuration for the lower seven ribs remains as graphite-epoxy caps with aluminum cruciform diagonals. The indicated weight saving for the current advanced composite vertical fin configuration is 20.2% including a 24 lb growth allowance. The project production cost saving is approximately 1% based on a cumulative average of 250 aircraft and including only material, production labor, and quality assurance costs.
The relative manufacturing costs were estimated for large high technology fan blades prepared by advanced composite fabrication methods using seven candidate materials/process systems. These systems were identified as laminated resin matrix composite, filament wound resin matrix composite, superhybrid solid laminate, superhybrid spar/shell, metal matrix composite, metal matrix composite with a spar and shell, and hollow titanium. The costs were calculated utilizing analytical process models and all cost data are presented as normalized relative values where 100 was the cost of a conventionally forged solid titanium fan blade whose geometry corresponded to a size typical of 42 blades per disc. Four costs were calculated for each of the seven candidate systems to relate the variation of cost on blade size. Geometries typical of blade designs at 24, 30, 36 and 42 blades per disc were used. The impact of individual process yield factors on costs was also assessed as well as effects of process parameters, raw materials, labor rates and consumable items.
Reflectors for concentrating solar collectors are assembled quickly and inexpensively by method that employs precontoured supports, plastic film, and adhesive to form a segmented glass mirror. New method is self-focusing, and does not require skilled labor at any stage. Contoured ribs support film and mirror segments of reflector. Nine mirror segments are bonded to sheet. Combined mirror surface closely approximates a spherical surface with a radius of curvature of 36 inches (0.91 m).
New method for testing peel strength of particular thermal-control tape used on Space Shuttle orbiter radiators requires only half amount of tape of method previously employed. Thermal-control tape consists of layers of FEP, silver, Inconel metal, adhesive, Kapton Film, and second adhesive layer. Method also avoids cost of labor and materials to prepare second test coupon and can be adapted for testing other types of double-faced adhesive tapes in military, industrial and consumer applications.