Sensata Pallet Design

Project Context

This project was a sponsored design challenge from Sensata Technologies, where my team of four engineering students was tasked with developing a sensor-holding pallet that met strict weight, cost, and structural integrity requirements. The goal was to create a lightweight yet durable pallet capable of securely housing multiple MSG sensors while withstanding standardized mechanical tests.

To ensure real-world feasibility, the pallet had to:

Prevent sensor displacement during testing.
Withstand a 225 lbf Instron force test without exceeding acceptable deformation limits.
Be cost-effective and manufacturable using CNC machining and 3D printing for inserts.
Minimize material waste while ensuring structural integrity through design optimization.

Technical Scope

My role, along with my team members, encompassed designing, analyzing, manufacturing, and testing the pallet. We focused on several key engineering aspects:

Material Selection: Evaluated 6061-T6 aluminum and low-carbon steel, ultimately selecting aluminum due to its favorable strength-to-weight ratio and machinability.
Finite Element Analysis (FEA): Used ANSYS to simulate load conditions, predict deflection, and validate the pallet's mechanical performance.
Manufacturing Process Optimization: Developed an efficient CNC machining plan to minimize tool changes, material waste, and production time.
Assembly and Insert Design: Designed 3D-printed plastic inserts that securely held the sensors in place, reducing the need for additional fasteners and improving ease of use.
Instron Load Testing: Conducted physical tests to compare real-world deflection against simulated results, ensuring alignment with performance requirements.

Design Process and Workflows

We followed an iterative engineering approach to ensure the final product met Sensata’s functional and manufacturability standards.

Understanding Design Constraints: Defined weight, material, and structural requirements based on Sensata's specifications.
Material Selection and Machining Planning: Chose 6061-T6 aluminum and optimized tool paths for milling, drilling, and cutouts to reduce material removal time.
FEA Simulation and Structural Validation: Conducted stress analysis and deflection testing in ANSYS, ensuring the pallet withstood 225 lbf with <0.1 inch deflection.
Prototype Manufacturing and Assembly: Fabricated the pallet using CNC milling and tested 3D-printed inserts for sensor fitment and stability.
Instron Load Testing and Performance Evaluation: Measured actual deflection (0.058 inches) and validated against predicted simulation values (0.05796 inches).

Project Outcomes

Weight Optimization: The final pallet weighed 0.412 lbs (0.187 kg), balancing strength and weight reduction.
Structural Integrity: Passed the Instron 225 lbf force test, staying within the 0.1-inch deflection limit.
Manufacturing Efficiency: The CNC machining process required minimal tool changes (four total) and avoided unnecessary part rotations, reducing production complexity.
Cost Analysis: The total manufacturing cost was $76.57, including raw material, machining, and tool changes, making it a competitive and cost-efficient design.
Assembly Optimization: The 3D-printed plastic inserts simplified sensor installation while maintaining a secure fit.

Reflections

One of the biggest challenges was balancing material removal for weight reduction with structural integrity. Through multiple iterations and FEA-driven refinements, we optimized the cutout design while maintaining durability. Another key takeaway was the importance of validating simulation results with real-world testing, as the final Instron load test closely matched the ANSYS predictions.

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