cummins power - insulating materials mentor: robert rossini patrick cleaver justin fernandez ethan...
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Cummins Power - Insulating Materials
Mentor: Robert Rossini
Patrick Cleaver
Justin Fernandez
Ethan Taylor
Cummins Inc.
Headquarters:
Columbus, IN Employees: 33,000+ worldwide Earnings: $11.4 billion (2006)
Business Units
Engine, Power Generation, Components Distribution
Cummins Power Generation
Products: Generators for RVs, Yachts, and
residential standby Emergency standby power
Stationary, mobile, open, and sound attenuated enclosures offered for all generator sets
Current Insulating Material
Mineral Wool In used because:
Cheap, operating temperature Disadvantages
Difficult to work with, Requires supporting material, Requires extra manufacturing
Needs/WantsNeeds Operation at high temperatures (900 °F), must not burn
or degrade Must not absorb water, must resist mold
Wants Higher thermal resistance (R > 4.3) Better acoustic dampening (STC > 10) Better workability
Self Supporting Material Fewer Processing steps
Product Design Specifications1. Thermal- Continuous operation at 900 °F- Acceptable surface burning, 5/5 or better (ASTM E-84)2. Sound- Sound Transfer Coefficient comparable to mineral wool (STC 10)3. Mechanical- Compressive strength greater than mineral wool is desired (>1.7 psi)4. Environmental- Must not adsorb water (<1 % by volume)- Must not allow for mold growth5. Workability- One step installation process- Reduction in manufacturing steps6. Cost- No more than 2x cost of mineral wool ($14.8/ft3)
Weighting Factors
Selection Criteria Weight
Thermal 0.2
Acoustic 0.3
Mechanical 0.05
Environmental 0.05
Workability 0.3
Cost 0.1
Selection Criteria Weight
Thermal 0.4
Acoustic 0.1
Mechanical 0.05
Environmental 0.05
Workability 0.3
Cost 0.1
Selection MatrixNeed/Want Value Weighing Factor Mineral Wool Score Expanded Perlite Score Calcium Silicate Score
ThermalOperating Temperature Need 900 °F 0.14 1200 °F 10 1200 °F 10 1200 °F 10Surface Burning Need "5/0" 0.1 "5/0" 7 "0/0" 10 "0/0" 10Thermal Expansion Want <2.0 % 0.04 <1.0 % 10 <2.0 % 10 <2.0 % 10Thermal Resistance Want (hr·ft2·°F)/Btu 0.12 4.3 8 4.9 10 3.7 6
*/4 3.46 4 3.52SoundSound Attenuation Want STC 10 0.1 STC 10 5 STC 11 6 STC 8 4
*/1 0.5 0.6 0.4MechanicalCompressive Strength Want psi 0.025 1.7 psi 1 80 psi 8 100 psi 10Flexural Strength Want psi 0.025 - 1 50-60 psi 8 65 psi 10
*/0.5 0.05 0.4 0.5EnvironmentalWater Absorbtion Need <1 % vol 0.025 <1 % 10 <1 % 10 <1 % 10Mold Resistance Need Yes 0.025 Yes 10 Yes 10 Yes 10
*/0.5 0.5 0.5 0.5WorkabilityEase of Installation Want - 0.12 2 step 1 1 step 10 1 step 10Processing Want - 0.18 3 step 1 2 step 6 2 step 6
*/3 0.3 2.28 2.28
Cost Want $/ft3 0.1 14.8 10 16.3 9 17.8 8*/1 1 0.9 0.8
Total */10 5.76 8.28 7.5
Design Solution
For a 35kW level II enclosure:• 11 pieces are to be cut from received
board• Installed into walls/doors• Installed above generator and around
exhaust system
Cutting/Forming
Done with circular saws 57.5 feet of cutting per enclosure Ventilation is required to eliminate spread
of dust
Thickness will remain the same
Thermal conductivity of expanded perlite:
.85 Btu in/hr ft2 °F Thermal conductivity of mineral wool:
1.06 Btu in/hr ft2 °F Same thickness will be used Thermal insulation will improve
Thermal conductivity
heat flow rate thickness
thermal conductivity area
*Assuming a heat flow of 3000 Btu/hr
∆T = 735 °F
• For mineral wool with k = 1.06 Btu in/hr ft2 °F
∆T = 590 °F
Further Testing
Acoustical testing Mechanical testing
Ability for material to withstand vibrations Impact testing
Regional Market Worldwide leader in auxiliary
generator sets for RVs, commercial vehicles and recreational marine applications.
Caterpillar and Volvo are the primary competitors
$2.42 billion in 2006 9.1 % increase
Potential Increase
Increase earnings due to new products and manufacturing efficiency gains
7-9% of sales Potential increase of $170-218 million
Capital Investment
Ventilation System: $75,000
Circular Saws (5): $5,000
Engineering Testing: $14,000
Total: $94,000
Variable Costs
Assumptions: Energy used for ventilation: $3,000 per
year Energy costs for operating saws: $540 per
year Blade costs $10 each 30% overhead
Variable Cost per Enclosure
Item Cost/EnclosureInsulating Material $178Perforated Steel $47Manufacturing Labor $605Cutting Labor $15Saw Operating $0.06Saw Blade Replacement $0.57Ventilation $0.34Subtotal $845.97Overhead $253.79Total $1,099.76
Breakeven Analysis II
235, $352500
$0
$200,000
$400,000
$600,000
$800,000
$1,000,000
$1,200,000
$1,400,000
$1,600,000
0 100 200 300 400 500 600 700 800 900 1000# of Enclosures
Cost
Sales
Cost ComparisonItem Expanded Perlite Mineral Wool Cost Difference
Ventilation System $75,000 $0 -$75,000Circular Saws (5) $5,000 $0 -$5,000Engineering $14,000 $0 -$14,000Total $94,000 $0 -$94,000
Insulating Material $178 $160 -$18Perforated Steel $47 $140 $93Manufacturing Labor $605 $605 $0Cutting Labor $15 $0 -$15Saw Operating $0.06 $0 $0Saw Blade Replacement $0.29 $0 $0Ventilation $0.34 $0 $0Subtotal $845.69 $905.00 $59Overhead $253.71 $271.50 $18Total $1,099.40 $1,176.50 $77
Variable Costs
Capital Costs
Breakeven Analysis I
-$200,000
-$100,000
$0
$100,000
$200,000
$300,000
$400,000
$500,000
$600,000
$700,000
0 2000 4000 6000 8000 10000
Savi
ngs
Units Sold