RUCHIN IITK THESIS

Masters of Design Thesis 2005- IIT Kanpur

Light weight back pack High Altitude Shelter for Indian Army

Investigator/Guide- Dr. Amit Ray Co-investigator- Ruchin Chaudhary Sponsoring agency- DMSRDE, Kanpur


“Form follows..

- Anonymous

evolution”


Contents

Project Chronology Sponsor's Introduction Project Context Product Issues Need Statement Project Methodology Design Methodology Future Scope Acknowledgements References Thank you Slide !


Contents



Contents



Contents



Contents



Contents



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Contents



Project Chronology

Dec 2003-Jan 2004 Feb 2004 March 2004 May-Jun 2004 July 2004 Aug 2004 Sep 2004 Oct 2004 Nov-Dec 2004 Jan 2005 Feb-Mar 2005 Apr 2005 May 2005

Preliminary Research/ Interest areas Interaction with DMSRDE, Project possibilities Project Research/ Draft Proposal Literature Review Formal Proposal to DMSRDE Project Design Methodology/ Official Formalities Concept Generation/Case studies Concept validation/Iteration/study models Prototype Development-Structure Prototype Development-Fabric Prototype Validation & Testing Detailing/ Iteration/ Prototype Development Final Prototype development


Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Project Chronology




Sponsor's Introduction

• DMSRDE: The Defence Materials & Stores Research & Development Establishment • One of the prestigious 51 labs of DRDO • Established in 1976 • To facilitate interdisciplinary R&D and speedy supply of indigenously developed items to the three services. • High level of expertise in the area of non-metallic materials encompassing development activities as widely different as carbon-carbon composites and cold weather clothing • Based at Kanpur


Project Context

• Saltoro Ridge (W) to karakoram range (E) • World’s highest battlefield • Mean height from sea level-5400 Mts. • Length of the glacier- 78 Kms • Temperature range- -30 to -65 C • Wind velocity range- 50 to 125 Km/hr • Troop Deployment- 3000 Indian Soldiers/ 7 Battalions • Our soldiers patrol the glacier mostly on foot • Each team consists of three to four men • The only refuge for our soldiers is a back-pack tent shelters


Product Issues

▪ 3-4 men temporary halt shelter ▪ Extreme climatic conditions (-600c, 18,000ft, 125Kmph)

▪ Current weight-15.2 Kgs ▪ Hoisting time 15-20 minutes ▪ Collapsed package cumbersome to carry-Needs 3 men


Product Issues




Product Issues




Product Issues




Product Issues




Product Issues




Need Statement

“to minimize the gross weight of the shelter, as minimum as possible, so that it can be easily carried by a single soldier, and must not compromise on comfort”


Project Methodology

• Research and information compilation • Analysis of existing design & products in market • Formulation of specifications for the project • Designing and Testing of the scaled prototypes • Final prototype and field testing


Project Methodology



Project Methodology



Project Methodology



Project Methodology



Project Methodology



Design Methodology

• The total weight of the system including the hardware • Comfort factor with respect to human ergonomics & climatic protection • Ease of erection and time required for that • Number of people served with one such back-pack • Structural stability of the system in extreme climatic conditions

Human Configuration Form Materials

Issues


Primary Elements of a Tent Shelter

http://en.wikipedia.org/wiki/Image:Dining_fly_%28tent%29.png

http://en.wikipedia.org/wiki/Image:Dome_tent.png


Various permutations and dimensions for three men placement (All dimensions are in mm)

Human Configuration


Human Configuration

Various permutations and dimensions for three men placement tightly arranged in sleeping bags (All dimensions are in mm)


Human Configuration


▪ Portable tent made on double layer principle ▪ Outer fly made of polyester fabric 320GSM,PVC coated ▪ Inner liner of Nylon fabric PVC coated 340 GSM white ▪ Frame structure of aluminum alloy ▪ Floor space- 1.95 m x 1.80 m ▪ Height: front-1.50 m, rear- 1.20 m ▪ Weight: 15.2 Kgs ▪ Pack load 1-inner liner with attached ground sheet-4.3 Kg ▪ Pack load 2-outer fly-6.25 Kgs ▪ Pack load 3-poles and pins-4.65Kgs

Sample-1 (Tent Glacier 3-4 men) Existing Designs


▪ Portable tent made on double layer principle ▪ Outer fly made of polyester fabric 320GSM,PVC coated ▪ Inner liner of Nylon fabric PVC coated 340 GSM white ▪ Frame structure of aluminum alloy ▪ Floor space- 1.95 m x 1.80 m ▪ Height: front-1.50 m, rear- 1.20 m ▪ Weight: 15.2 Kgs ▪ Pack load 1-inner liner with attached ground sheet-4.3 Kg ▪ Pack load 2-outer fly-6.25 Kgs ▪ Pack load 3-poles and pins-4.65Kgs

Sample-1 (Tent Glacier 3-4 men) Existing Designs


Existing Designs


▪ Brand name: Prospector ▪ 3-seasons ▪ Weight: 3.8 Kg ▪ LxBxH: 2.1x2.1x1.35Mts. ▪ Ground sheet: Polyester ▪ Outer fly: Polyester ▪ Poles: Glass fiber Dia-9mm ▪ Hoisting time: 5-7min ▪ No. of people housed: 3

Sample-2 (Open market tent, 3 men) Existing Designs


▪ Brand name: Prospector ▪ 3-seasons ▪ Weight: 3.8 Kg ▪ LxBxH: 2.1x2.1x1.35Mts. ▪ Ground sheet: Polyester ▪ Outer fly: Polyester ▪ Poles: Glass fiber Dia-9mm ▪ Hoisting time: 5-7min ▪ No. of people housed: 3



Existing Designs


Existing Designs


Existing Designs


▪ Area: 48 ft² (4.5 m²) ▪ Weight: 11 lbs. 3 oz (5.08kg) ▪ LxBxH: 2.1x2.1x1.35Mts. ▪ Fabric (Canopy): 40 denier, 240T nylon ripstop ▪ Fabric (Fly): 75 denier, 185T polyester ripstop coated with 1500 mm PU ▪ Fabric (floor): 70 denier, 210T nylon taffeta coated with 10,000 mm ▪ No. of people: 3 ▪ PU Hoisting time: 5-7min ▪ Pole Diameter: 9 mm



▪ Area: 48 ft² (4.5 m²) ▪ Weight: 11 lbs. 3 oz (5.08kg) ▪ LxBxH: 2.1x2.1x1.35Mts. ▪ Fabric (Canopy): 40 denier, 240T nylon ripstop ▪ Fabric (Fly): 75 denier, 185T polyester ripstop coated with 1500 mm PU ▪ Fabric (floor): 70 denier, 210T nylon taffeta coated with 10,000 mm ▪ No. of people: 3 ▪ PU Hoisting time: 5-7min ▪ Pole Diameter: 9 mm



Existing Designs


▪ Filling: 150 gr. 90% WGD – 630 fill power ▪ Outer fabric: 260T Small Ripstop ▪ Inner fabric: 300T Polyester ▪ Size: 215 x 80 x 50 cm. ▪ Weight: 565 gr. ▪ Packing Size: 13 x 25 cm. ▪ Extreme temperature: -2°C

Sample-4 (Open market sleeping bag) Existing Designs


Existing Designs


Option-1 (Existing DMSRDE Tent)Form /Shape


▪ Inner fly surface area: 7.2m2 ▪ Rains fly surface area: 7.2m2 ▪ Ground sheet surface area: 4.52m2 ▪ Total surface area :18.92sq.mts ▪ Volume enclosed by the system: 4m3 ▪ Total strut length: 3.8M

Option-2 (Circle)Form /Shape


▪ Inner fly surface area: 7.2m2 ▪ Rains fly surface area: 7.2m2 ▪ Ground sheet surface area: 4.52m2 ▪ Total surface area :18.92sq.mts ▪ Volume enclosed by the system: 4m3 ▪ Total strut length: 3.8M

Option-2 (Circle)Form /Shape


Inner fly surface area: 7.68m2 Rains fly surface area: 7.68m2 Ground sheet surface area: 4.62m2 Total surface area :19.98m2 Volume enclosed by the system: 2.45m3 Total strut length: 7.75M

Option-3 (Square)Form /Shape


Inner fly surface area: 7.68m2 Rains fly surface area: 7.68m2 Ground sheet surface area: 4.62m2 Total surface area :19.98m2 Volume enclosed by the system: 2.45m3 Total strut length: 7.75M

Option-3 (Square)Form /Shape


Option-3 (Square) study modelForm /Shape


Rains fly surface area: 6.72m2 Inner fly surface area: 6.72m2 Ground sheet surface area: 4.65m2 Total surface area :18.09m2 Volume enclosed by the system: 5m3 Total strut length: 10.5M

Option-4 (Hexagonal 1)Form /Shape


Rains fly surface area: 6.72m2 Inner fly surface area: 6.72m2 Ground sheet surface area: 4.65m2 Total surface area :18.09m2 Volume enclosed by the system: 5m3 Total strut length: 10.5M



Option-4 (Hexagonal 1) study modelForm /Shape


Inner fly surface area: 9m2 Rains fly surface area: 9m2 Ground sheet surface area: 5.18m2 Total surface area : 23.18m2 Volume enclosed by the system: 5m3 Total strut length: 11.8M



Inner fly surface area: 9m2 Rains fly surface area: 9m2 Ground sheet surface area: 5.18m2 Total surface area : 23.18m2 Volume enclosed by the system: 5m3 Total strut length: 11.8M



Option-5 (Hexagonal 2) study modelForm /Shape


Inner fly surface area: 8.47m2 Rains fly surface area: 9.93m2 Ground sheet surface area: 3.78m2 Total surface area : 22.18m2 Volume enclosed by the system: 4.41m3 Total strut length: 5.6M

Option-6 (Tunnel)Form /Shape


Inner fly surface area: 8.47m2 Rains fly surface area: 9.93m2 Ground sheet surface area: 3.78m2 Total surface area : 22.18m2 Volume enclosed by the system: 4.41m3 Total strut length: 5.6M

Option-6 (Tunnel)Form /Shape


Option-6 (Tunnel) study modelForm /Shape


Form /Shape

Inner fly surface area: 9sq.mts Rains fly surface area: 9sq.mts Ground sheet surface area: 5.18sq.mts Pneumatic poles surface area: Total surface area (Fabric area of the system): 23.18sq.mts Volume enclosed by the system: 5 cubic meters

Option-7 (Pneumatic)


Form /Shape

Inner fly surface area: 9sq.mts Rains fly surface area: 9sq.mts Ground sheet surface area: 5.18sq.mts Pneumatic poles surface area: Total surface area (Fabric area of the system): 23.18sq.mts Volume enclosed by the system: 5 cubic meters

Option-7 (Pneumatic)


Form /Shape Validation


S.N Inner fly surface area(m2)

Outer fly surface area(m2)

Ground sheet surface area(m2)

Total surface area(m3)

Volume enclosed (m3)

Pole length m

Unsupp.pole lt. max.

1 12.7 19.5 3.5 35.7 2.5 9 2

2 7.2 7.2 4.52 18.92 4 3.8 3.8

3 7.68 7.68 4.62 19.98 2.45 7.7 1.9

4 6.72 6.72 4.65 18.09 5 10.5 1.9

5 9 9 5.18 23.18 5 12.8 1.5

6 8.47 9.93 3.78 22.18 4.41 5.6 2.8

7 9 9 5 5 NA NA

Form /Shape Validation


Fabric study

The fabric surface area is divided into following: • Inner fly • Outer fly/Rain fly • Ground sheet

• GORE-TEX® • Pertex Quantum® • Ripstop polyester • Ripstop nylon • Nylon, PU coated • DWR breathable nylon • Nylon fabric, PVC coated • Polyester fabric, PVC coated • Silnylon

Short listed fabrics

Materials


Fabric study

The fabric surface area is divided into following: • Inner fly • Outer fly/Rain fly • Ground sheet

• GORE-TEX® • Pertex Quantum® • Ripstop polyester • Ripstop nylon • Nylon, PU coated • DWR breathable nylon • Nylon fabric, PVC coated • Polyester fabric, PVC coated • Silnylon

Short listed fabrics

Materials


Materials Structure study




Sample-1 Tensile loading (Ultimate) =05 KN Flexure loading (Ultimate) =0.4KN Sample-2 Tensile loading (Ultimate) =12 KN Flexure loading (Ultimate) =0.6KN



S.NO MATERIALS (standard tube of OD-12 mm, ID-4mm) WEIGHT (gms/meter)

1 Alloy steel 653

2 Cast carbon steel 662

3 Cast stainless steel 653

4 Chromium stainless steel 663

5 Galvanized steel 668

6 Aluminum alloys 229

7 Magnesium alloy 695

8 Titanium 390

9 ABS 86

10 PVC rigid 110

11 PP Copolymer 76

12 Nylon 6-10 118

13 FRP-A 205

14 FRP-S 210

15 Carbon FRP 151

16 Teak wood 53

17 Pine wood 29

Structure studyMaterials


Accessories study

• Reflective guy lines • Zippers and accessories glow in dark • Zipper opens up bottom-up • Ground sheet to be padded with insulating layer • Gap between inner and outer fly-insulation • If possible pneumatic ground pad • Door of outer fly slightly outward • Color coded struts and sleeves

Materials


Accessories study

• Reflective guy lines • Zippers and accessories glow in dark • Zipper opens up bottom-up • Ground sheet to be padded with insulating layer • Gap between inner and outer fly-insulation • If possible pneumatic ground pad • Door of outer fly slightly outward • Color coded struts and sleeves

Materials


Prototype-1

Total Weight 8.65 kgs Aluminum poles wt-1.75kg PU coated cotton inner fly wt-1.5kg PU coated polyester outer fly-4.7kg Accessories (ropes, pegs) wt- 0.6kg Water proof Erection time-15 minutes

Prototype Development


Total Weight 8.15 kgs Glass fiber poles wt-1.25kg PU coated cotton inner fly wt-1.5kg PU coated polyester outer fly-4.7kg Accessories (ropes, pegs) wt- 0.6kg Water proof Erection time-12 minutes

Prototype-2 Prototype Development


Total Weight 7.1 kgs Carbon fiber poles wt-0.4kg PU coated cotton inner fly wt-1.5kg PU coated polyester outer fly-4.7kg Accessories (ropes, pegs) wt- 0.5kg Water proof Erection time-9 minutes

Prototype-3Prototype Development


Total Weight 5.5 kgs Carbon fiber poles wt-0.4kg PU coated composite inner fly wt-1.5kg PU coated Nylon ripstop outer fly-3.1kg Accessories (ropes, pegs) wt- 0.5kg Water proof Erection time- approx <7 minutes

Prototype-4Prototype Development


Final Prototype Selection

S.No. Weight(Kg)

Pole Inner Fly Outer Fly Erection T (Min.)

1 10.15 Aluminum-1.75kg

PU coated cotton-3 kg

PU coated polyester-4.7kg

15

2 9.65 GFRP-1.25kg

PU coated cotton-3kg


12

3 8.1 CFRP-0.40kg

PU coated cotton-3kg


9

4 7.85 CFRP-0.35kg

PU coated Nylon- 3.5Kg

PU coated Nylon- 4Kg

7


Final Prototype SpecificationsFabric specifications Ground sheet area-5.20 sq.mts Inner fly area- 9 sq.mts Rain fly area- 11sq.mts Sleeve area-1.5 sq.mts Total fabric area-26.70 sq.mts Volume enclosed- 5.00 cubic mts Final weight of the fabric- 7.5 Kg Pole specifications Number of poles-3 Cross section of the strut- 8mm diameter Strut length- 520mm Pole length-varies, 2x 4440mm, 1x 4210mm Shock cord length- 60% of the pole length Estimated weight of the poles- 0.410 kg Accessories specifications Number of stakes required-8 Length of stake- 300mm Length of guy lines- 4 mts(at 45 degrees) Estimated weight of the Accessories- 0.500 Kg








Working Drawings


Future Scope


Acknowledgements


References

• Principles of structures, Ariel Hanaor, Blackwell Science Pvt.Ltd, London, U.K, 1998 • The plastic architect, Arthur Quarmby, Pall Mall press, London, U.K, 1974 • Pneumatic structures: Handbook for architects and engineers, Thomas Herzog, Crosby Lockwood Staples, London, U.K, 1971 • The magic of tents: Transforming spaces, Alejandro Bahamon, Loft publications, Barcelona, Spain, 2004 • Tensile structures, Volume-1 & 2, Frei Otto, The MIT press, London, U.K, 1971 • The encyclopedia of vernacular architecture of the world, Oliver Paul, Cambridge University press, Cambridge, U.K., 1997 • Anthropometric data for Indians, D.K. Chakrabarty. NID Publications, Ahemadabad, India,1992 • http://www.sierradesigns.com • http://www.thenorthface.com • http://www.marmotmountain.com • http://www.greatoutdoorsdepot.com • http://www.wildequipment.com.au • http://military.eurekatents.com • http://www.pertex.com • http://www.seattlefabrics.com •http://www.google.com •http://www.wikipedia.org

http://www.sierradesigns.com/

http://www.thenorthface.com/

http://www.marmotmountain.com/

http://www.greatoutdoorsdepot.com/

http://www.wildequipment.com.au/

http://military.eurekatents.com/

http://www.pertex.com/

http://www.seattlefabrics.com/

http://www.google.com/

http://www.wikipedia.org/



References

• Principles of structures, Ariel Hanaor, Blackwell Science Pvt.Ltd, London, U.K, 1998 • The plastic architect, Arthur Quarmby, Pall Mall press, London, U.K, 1974 • Pneumatic structures: Handbook for architects and engineers, Thomas Herzog, Crosby Lockwood Staples, London, U.K, 1971 • The magic of tents: Transforming spaces, Alejandro Bahamon, Loft publications, Barcelona, Spain, 2004 • Tensile structures, Volume-1 & 2, Frei Otto, The MIT press, London, U.K, 1971 • The encyclopedia of vernacular architecture of the world, Oliver Paul, Cambridge University press, Cambridge, U.K., 1997 • Anthropometric data for Indians, D.K. Chakrabarty. NID Publications, Ahemadabad, India,1992 • http://www.sierradesigns.com • http://www.thenorthface.com • http://www.marmotmountain.com • http://www.greatoutdoorsdepot.com • http://www.wildequipment.com.au • http://military.eurekatents.com • http://www.pertex.com • http://www.seattlefabrics.com •http://www.google.com •http://www.wikipedia.org

http://www.sierradesigns.com/

http://www.thenorthface.com/

http://www.marmotmountain.com/

http://www.greatoutdoorsdepot.com/

http://www.wildequipment.com.au/

http://military.eurekatents.com/

http://www.pertex.com/

http://www.seattlefabrics.com/

http://www.google.com/




Thank you !

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RUCHIN IITK THESIS