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    During my time at PSI, I was fortunate to wear many hats. As an engineer, I appreciate all processes and thoroughly enjoy rolling up my sleeves t… Read More
    During my time at PSI, I was fortunate to wear many hats. As an engineer, I appreciate all processes and thoroughly enjoy rolling up my sleeves to fabricate something. This write-up provides a rough outline of just that, the build of an Adjustable Test Rig to evaluate a broad range of physical joints. Read Less
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INTRODUCTION
During my time at PSI, I was fortunate to wear many hats. As an engineer, I appreciate all processes and thoroughly enjoy rolling up my sleeves to fabricate something. This write-up provides a rough outline of just that, the build of an Adjustable Test Rig to evaluate a broad range of physical joints.
GENERAL SCOPE OF THE PROJECT
The Aluminum Association hired Parametric Solutions Inc. (PSI) to help define Florida Building Code and an Aluminum Design Manual for exterior aluminum structures. 

Brett Epstein, Jim Wilson and I were selected for the job.
Design: Collaborative
Modeling: Brett
FEA: Jim
Fabrication: Myself

 
We needed to be able to collect force and deflection data in each of these joints, compare with FEA and define structural limits on many different joint configurations. Finally, the integrity of the whole system could be established.
DAQ system included: 
1. One hydraulic cylinder
2. One Pressure transducer
3. One linear variable differential transducer (LVDT)
DESIGN AND MODELING
FABRICATION
Once the design was finalized, I went to work.
 
Base
 
Completed base with casters.
 
Adding the uprights.
 
Here are all the uprights tacked into place with extra bracing to make sure everything stayed square.
A final confirmation of dimensions and I completed the welding. It took most of the day.
TESTING
The rig was then painted, wheeled into our office, outfitted with everything we needed for data aquisition and the testing began.
See the portfolio page on PSI's website here: http://www.psnet.com/Projects-Industrial-Aluminum-Structure-Design.asp
SPECIAL THANKS GOES TO:
Joel Haas and Parametric Solutions Inc. for just being an amazingly inteligent group. Jim Wilson for your incredible ANSYS skills, Brett Epstein for modeling the assembly and Pettit Racing for letting me build this monster in their shop.