Improvement to Auxiliary Fuel Tank Fabrication

1
Concept

• Target Metrics
• Hold one BBJ (Boeing 737 Business Jet) auxiliary
  fuel tank (size and weight) plus two workers and
  equipment (approx. 1000 lbs)
• Rotate tank through 360-degrees on one axis
• Raise and lower tank 48 inches.
• As safe as (or safer than) current process to
  tank and workers

• Tests
• Lift and rotate tank successfully 50 times
• Minimize deflection between uprights (less than
  1/2 in.)
• Adequate winch and rotating hand wheel
  ergonomics
• Overall safety

Improvement to Auxiliary Fuel Tank Fabrication

• Tanks Lifted by electric pulley
• Rotating and clamping system
• Removable side tables for workers to stand on
  while working

• Simplified version of our concept
• Detachable tables not included
• Manual pulley system

• Outer shell of tank is completed first
• Installing inner components requires moving tank
• Each tank is lifted and rotated multiple times
  during fabrication
• All movement is done manually with 2 workers
• Tank is painted on one side and then flipped to
  be painted on the other side

• Results
• Lifting and rotating system 96 reliable
  changes to final design will improve this
• Average deflection between uprights is .15 in.
  which is acceptable
• Good rotating hand wheel ergonomics
• Winch gear ratio can be increased to reduce of
  rotations because force required is only 1.32
  lbf.
• Safety training is necessary
• Pinch points can be covered on pulley for final
  design

• Frame
• Steel Bar with Pulley System
• Manual winch on both sides
• 4 ft. stroke

• Clamping/Rotation System
• Hand wheel
• Clamp with 4 Bolts
• 360 Rotation
• Polyethylene contact surfaces

• Build final design
• Train workers in use and safety
• Implement into manufacturing process

Problem
Prototype Material and Machining
3,034.00 Implementation Material and Machining
6,000.00 Total cost
9,034.00

• Tanks can be damaged during movement which may
  result in scrapping part
• Workers can be injured during lifting
• Process needs improvement in order to better
  exhibit lean manufacturing

The team would like to thank Dr. Hartman for his
advisement, Matt Porter, Joe Reinhardt, and Caleb
Janssen of PATS Aircraft, and Steve Beard for
help in the machine shop.