RUCHIN IITK THESIS

1. 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

2. Masters of Design Thesis 2005- IIT Kanpur “Form follows.. - Anonymous evolution”

3. Masters of Design Thesis 2005- IIT Kanpur Contents Project Chronology Sponsor's Introduction Project Context Product Issues Need Statement Project Methodology Design Methodology Future Scope Acknowledgements References Thank you Slide !

14. Masters of Design Thesis 2005- IIT Kanpur 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

28. Masters of Design Thesis 2005- IIT Kanpur 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

29. Masters of Design Thesis 2005- IIT 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

30. Masters of Design Thesis 2005- IIT Kanpur 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

36. Masters of Design Thesis 2005- IIT Kanpur 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”

37. Masters of Design Thesis 2005- IIT Kanpur 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

43. Masters of Design Thesis 2005- IIT Kanpur 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

44. Masters of Design Thesis 2005- IIT Kanpur Primary Elements of a Tent Shelter

45. Masters of Design Thesis 2005- IIT Kanpur Various permutations and dimensions for three men placement (All dimensions are in mm) Human Configuration

46. Masters of Design Thesis 2005- IIT Kanpur Human Configuration Various permutations and dimensions for three men placement tightly arranged in sleeping bags (All dimensions are in mm)

47. Masters of Design Thesis 2005- IIT Kanpur Human Configuration

48. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

49. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

50. Masters of Design Thesis 2005- IIT Kanpur Existing Designs

51. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

52. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

56. Masters of Design Thesis 2005- IIT Kanpur ▪ 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 Sample-3 (Open market tent, 3 men)Existing Designs

57. Masters of Design Thesis 2005- IIT Kanpur ▪ 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 Sample-3 (Open market tent, 3 men)Existing Designs

59. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

61. Masters of Design Thesis 2005- IIT Kanpur Option-1 (Existing DMSRDE Tent)Form /Shape

62. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

63. Masters of Design Thesis 2005- IIT Kanpur ▪ 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

64. Masters of Design Thesis 2005- IIT Kanpur 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

65. Masters of Design Thesis 2005- IIT Kanpur 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

66. Masters of Design Thesis 2005- IIT Kanpur Option-3 (Square) study modelForm /Shape

67. Masters of Design Thesis 2005- IIT Kanpur 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

68. Masters of Design Thesis 2005- IIT Kanpur 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

69. Masters of Design Thesis 2005- IIT Kanpur Option-4 (Hexagonal 1) study modelForm /Shape

70. Masters of Design Thesis 2005- IIT Kanpur 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)Form /Shape

71. Masters of Design Thesis 2005- IIT Kanpur 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)Form /Shape

72. Masters of Design Thesis 2005- IIT Kanpur Option-5 (Hexagonal 2) study modelForm /Shape

73. Masters of Design Thesis 2005- IIT Kanpur 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

74. Masters of Design Thesis 2005- IIT Kanpur 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

75. Masters of Design Thesis 2005- IIT Kanpur Option-6 (Tunnel) study modelForm /Shape

76. Masters of Design Thesis 2005- IIT Kanpur 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)

77. Masters of Design Thesis 2005- IIT Kanpur 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)

78. Masters of Design Thesis 2005- IIT Kanpur Form /Shape Validation

79. Masters of Design Thesis 2005- IIT Kanpur 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 Unsup p.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

80. Masters of Design Thesis 2005- IIT Kanpur 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

81. Masters of Design Thesis 2005- IIT Kanpur 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

82. Masters of Design Thesis 2005- IIT Kanpur Materials Structure study

83. Masters of Design Thesis 2005- IIT Kanpur Materials Structure study

84. Masters of Design Thesis 2005- IIT Kanpur Sample-1 Tensile loading (Ultimate) =05 KN Flexure loading (Ultimate) =0.4KN Sample-2 Tensile loading (Ultimate) =12 KN Flexure loading (Ultimate) =0.6KN Materials Structure study

85. Masters of Design Thesis 2005- IIT Kanpur 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

86. Masters of Design Thesis 2005- IIT Kanpur 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

87. Masters of Design Thesis 2005- IIT Kanpur 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

88. Masters of Design Thesis 2005- IIT Kanpur 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

89. Masters of Design Thesis 2005- IIT Kanpur 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-2Prototype Development

90. Masters of Design Thesis 2005- IIT Kanpur 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

91. Masters of Design Thesis 2005- IIT Kanpur 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

92. Masters of Design Thesis 2005- IIT Kanpur Final Prototype Selection S.No. Weight(Kg ) Pole Inner Fly Outer Fly Erectio n T (Min.) 1 10.15 Aluminu m-1.75k g PU coated cotton-3 kg PU coated polyester-4.7kg 15 2 9.65 GFRP-1. 25kg PU coated cotton-3kg PU coated polyester-4.7kg 12 3 8.1 CFRP-0. 40kg PU coated cotton-3kg PU coated polyester-4.7kg 9 4 7.85 CFRP-0. 35kg PU coated Nylon- 3.5Kg PU coated Nylon- 4Kg 7

93. Masters of Design Thesis 2005- IIT Kanpur Final Prototype Specifications Fabric 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

97. Masters of Design Thesis 2005- IIT Kanpur Working Drawings

98. Masters of Design Thesis 2005- IIT Kanpur Future Scope

99. Masters of Design Thesis 2005- IIT Kanpur Acknowledgements

100. Masters of Design Thesis 2005- IIT Kanpur 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

101. Masters of Design Thesis 2005- IIT Kanpur 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

102. Masters of Design Thesis 2005- IIT Kanpur Thank you !

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