Design Project
Parabolic Solar Cooker
Introduction
n teams
Each team will design their own frame.
Each team will fabricate another team’s parts according to the specifications given.
Each team will build their own cooker
Primary Goals
Develop understanding of the design process.
The iterative nature
The role of modeling & prototyping
The role of design constraints
Design for manufacturing
The cost of change
90 minute timeframe
Secondary Goal
A STEM project that is easily replicated.
90 minutes from concept to product
Design Problem: Design and build a solar trough heater/cooker that can be constructed from sticks (truss construction).
CONSTRAINTS
Profile is this parabola:
Truss Frame Construction
CONSTRAINTS
Materials:
Truss frame members 48” long qty: 20
Wooden dowels (¾”)
Machine screws & nuts (#8-32)
Drywall screws (⅝”)
Conduit hangers (10)
Masonite, reflective Mylar, glue
Aluminum filler rod (for spit)
CONSTRAINTS
Frame Members
Standard hole placement - DFM constraint.
Can also have holes at any other place in between.
CONSTRAINTS
3 Truss member layers
maximum.
CONSTRAINTS
Cross members are dowels. Held in place with wood screws. Masonite attaches with conduit hangers.
5
DOWELS
MAX
CONSTRAINTS
Truss holds wire spit at the focus.
No connectors allowed at the focus.
Constraints
Trough must have a target so it can be aimed properly.
Trough must have support element to position it in the proper orientation.
PHASE 1
Sketch various design ideas.
Must sit such that the device is aimed at the sun.
PHASE 2
Create 2D CAD model.
Don’t worry about the actual length of the member, just the distance between holes/dowels.
MUST BE ACCURATE!
Documentation
Your team will NOT be making their own parts.
Your documentation packet will need to be self explanatory.
If there is a problem, it will be either your problem (if the print is wrong) or the supplier’s problem (if they do not make parts according to the print).
A 5 POINT PENALTY PER TEAM FOR EACH INSTANCE OF REWORK.
NOTE: CHANGE TOLERANCE TO PLUS OR MINUS 1/16 INCH ON ALL DIMENSIONS.
Documentation
Be sure to label your assembled view with each part number labeled.
SAVE all your work! You will need it if you need to make changes or troubleshoot a problematic assembly.
PHASE 3
Fabricate
Mark truss members for length and hole locations.
Snip to length, drill holes. Match drill masonite.
Phase 4 - Assemble
When you receive your parts, you may begin constructing your device.
Remember, if something is not right, you need to document what the error is.