P13651 – MPI Wax Melter. Change from design review System Architecture/subsystems Feasibility ...
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Transcript of P13651 – MPI Wax Melter. Change from design review System Architecture/subsystems Feasibility ...
Detailed Design Review
P13651 – MPI Wax Melter
Change from design review System Architecture/subsystems Feasibility Test plan Risk assessment BOM MSD II Plan
Agenda
Revised Project Goal◦ Processes water-soluble waxes, that only
come in flake form◦ Provide enough wax to keep up with a max
reservoir speed of 50 lb/hr◦ Process at most 2 gallons of wax at a time
Refined Project Goal
CN2 Accommodates flakes, pellets, or solid blocks of wax
CN13 Accommodates non soluble wax
System Architecture
Accept wax
Hold wax
Melt wax
Transport wax
Mechanical Components
Hopper
Chute
Stirrer
Tank
Electrical Components
Electrical Block Diagram
Control Logic
Timing Diagram
Item General Purpose MotorMotor Type Split-PhaseEnclosure Open DripproofHP 1/3Number of Speeds
1
Nameplate RPM 1725
NEMA/IEC Frame 48Z
Voltage 115Hz 60Phase 1
Full Load Amps 7.0
Mounting Cradle/StudThermal Protection
None
Insulation Class B
Service Factor 1.35Bearings BallAmbient (C) 40Rotation CW/CCWShaft Dia. (In.) 1/2
Shaft Length (In.) 1-7/8
Stud Pattern (In.) 3.625 x 3.625
Stud Location Shaft EndStud Quantity 4RPM Range 1400-1800
StandardsUL Recognized (E47479), CSA Certified (156060)
Motor Specs
Feasibility Analysis
Hopper > hand-fed solid wax• Reduce operator intervention• Increase processing speed• Better control feed into reactor
Feasibility: Hopper
KC 4088D properties:Thermal conductivity – 0.685 W/mK Thermal Diffusivity - 0.360 mm2/s Specific Heat - 1.908 MJ/m3K
Thermal analysis:◦ Porous material model: Wax analogy
Ratio of specific heats = 1 Thermal Conductivity = .211 W/(m*K) Density = 950 kg/m3 Heat capacity = 2.3 J/(kg*K)
◦ Liquid material model: Ratio of specific heats = 1 Thermal Conductivity = .16 W/(m*K) Density = 860 kg/m3 Heat capacity = 2.5 J/(kg*K)
Wax Properties
Thermal analysis done to determine the temperature of the system during operation
Start-up time: Evaluate the time to reach steady state with solid wax
Feasibility: Heat Transfer
1 sec 10 sec
30 sec 60 sec
Time to Steady State
Linear actuated trapdoor vs. actuated valve◦ Reduce chances of wax solidifying inside the
valve◦ Communicates with reservoir
Model flow rate out of reservoir: 50 lbs/hour
Feasibility: Transport Wax
Test PlanNo. Importance Specifications Targets
Unit of Measure
Marginal Value
Ideal Value Comments/Status
Test Equipment
ES 6 13.29 Operating temperature range 100-250 F degrees F 170-220 100-250 Thermocouple
ES 8 10.07
Temperature difference across melt surface within operating range (no wax) <= 1 °C degrees C <=1 <=1 Thermocouple
ES 10 8.11
Temperature difference across plate while melting blocks, flakes, pellets <= 1 °C degrees C <=1 <=1 Thermocouple
ES 15 7.62 Wax burns or seperates yes/no boolean no yes
ES 1 7.3 Flow rate lb/hour 50 >=50
ES 13 5.28Weight of wax remaining on melter after melting one hopper 0 lbs lbs >0 0
ES 5 5.08 Power requirements( 240 VAC VAC negotiable 240
Working with one-phase power, due to difficulty in finding lab space
ES 14 4.95Weight of wax remaining on funnel after melting one hopper 0 lbs lbs >0 0
ES 11 4.56 Volume melted in a batch >= 20 gal gallons <20 >=20 Proximity sensor
ES 9 3.49
Diameter of critical dimension of flakes/pellets allowed to pass unmelted 0 inches inches 0
Bill of Materials: MechanicalDimensions (LWT) Material Price
Hopper 1 x 15" x 30" x .12" Stainless 2B Sheet 304 Annealed $103.50
4 x 15" x 8" x .12" Stainless 2B Sheet 304 Annealed $110.40
Hopper Support Plate 1 x 63" x 3" x .25" Cold Finish Mild Steel Rectangle 1018 $46.62
Hopper Rails 2 x 55" x .5" x .5" Cold Finish Mild Steel Square 1018 $24.20
Chute 1 x 20" x 4" .125" Cold Finish Mild Steel Rectangle 1018 $12.60
2 x 10" x 3" x .125 Cold Finish Mild Steel Rectangle 1018 $10.40
Tank 1 x 8" OD x .125" Wall x 16" Extruded Aluminum Bare Tube 6061 T6 $75.52
Bottom Support Plate 1 x 24" x 24" x .5" Mild Steel Blanchard Ground Plate 1018 $284.51
Box 4 x 10" x 18" x .12" Stainless 2B Sheet 304 Annealed $165.60
Tank Base 1 x 8"D x 1" Extruded Aluminum Bare Round 6061 T6511 $25.73
Tank Supports 4 x .5"D x 2" Cold Finish Stainless Round 304/304L $3.76
Total $862.84
Bill of Materials: ElectricalElectrical Subsystem Supplier Model Price per unit
# of units PriceLead time
Tube Heater Tutco TBA TBA 1 TBATBA
Sticky Heaters Omega KH-1212/5 $95.00 2 $ 190.00 5 weeks
Logic Gates Digikey4 AND, 2 NOR, 2 OR, 4 Inverter packages $0.42 12 $ 5.04 5 days
20 A breaker Lowes Square D Qo 20A breaker $6.44 1 $ 6.44 Ready to purchase
12/2 Wire Lowes 50' of 12 AWG 12-2 33.24 1 $ 33.24 Ready to purchase
Signal wire On hand 20 gauge signal wire of various colors Free 10' $ - On Hand1% resistors for booster circuit Digikey $0.50 10 $ 5.00 3-5 days
Primary Drive Motor Grainger Dayton motor 1/3 HP GP $130.00 1 $ 130.00 3 days
Light Switch Lowes Single standard 15 A light switch $5.00 1 $ 5.00 MOSFETs for booster circuits Digikey $0.60 4 $ 2.40
Linear actuator for valves Firgelli automation $160.00 2 $ 320.00
120 V Relays Digikey Z774-ND $2.07 2 $ 4.14
Total: $ 701.26
Risk Assessment: Mitigated Risks
ID Risk Item Cause Effect
Likelihood
Severit
y
Import
ance
Action tominimize risk Owner Solution
Technical Risks
A Wax gets damagedExcessive temperatures
Room fills with dangerous levels of CO2 2 3 6
Ensure adaquate temperature controls and safety systems Mike
Talked with reps from Paramelt, and they are confident that we will not be handling enough CO2 to be dangerous; CO2 detector?
B Parts don't arrive on timeParts are ordered too late
Machine cannot be assembled in time 1 2 2
Order parts before winter quarter Rachael
Prompt ordering before winter quarter gives significant time to get parts
C Our fabrication skill set
Parts required for design are beyond our ability to make or beyond budget
Machine cannot be assembled in time 1 2 2Limit part complexity Mike
Attempting a design with simple machining
D Lab space cannot be secured
Fume hoods and 240 V outlets tend not to go together Machine cannot be tested 3 3 9
Ask everyone on campus Team
Lab space has been secured; need to do a walkthrough end of MSD I (week 11); need shrowd it for safety; talk with Health and Safety
E Design is too complexTeam overcomplicates the designs
Machine is very expensive, large, and hard to maintain 1 2 2
Collaborate with customer and guide to ensure design is practical Mike
Attempting to pursue a simple design
F Invalid assumptions
Insufficient knowledge of non-Newtonian fluid with fibers
Design decisions based on false assumptions 2 3 6
Consult experts when needed Team
Working with worst case scenarios for modeling; purchase heating and stirring equipment with room for error
G Unable to melt all wax in vat
Flake density is greater than the melted wax
Solid wax makes it through the systems 2 3 6
MSD II Test plan allows for optimization of design Team
Decrease size of vat; can change stirring rate
Future Risks
IBearings - Bind up over time, must withstand spinning
Bearings get contaminated and jam Bearings fail prematurely 1 3 3
Correctly spec bearings Mike
J Vibrations - Break welds over time
Natural vibrations due to motors and moving parts
Welds holding the melter together fracture and fail 2 3 6
Test system and use bushings to dampen vibrations if necessary
Mike/Valentina
K Power - Too much is neededNot enough power to fuel system
May have to reduce heat into system, increase warm-up time, and tripping breakers regularly 3 2 6
Find maximum power consumption of each component and ensure it is less than the available power Jon/Alex
MHole in bottom of tank with bearings to jam
The induction heater needs a wire run through the bottom of the tank
Wax can leak through bottom of tank and jam bearings for stirrer shaft 2 2 4
Get sealed rugged bearings that can handle the harsh conditions
Mike/Valentina
NMixing - Getting solid wax quickly and entirely into liquid state
Insufficient heating power or stirring
Unable to produce melted wax from the system 2 3 6
Design involves heating less wax per batch, built in variability in heating and stirring capabilities Team
O Trap doorSolidied wax collects in opening Reduce flow rate our of system 2 2 4
Bottom of tank is insulated to prevent heat loss Team
PExcessive temperatures inside heater assembly
Heaters and electronic components are all in a single closed box
Shortened life span for many of the components in the system 3 3 9
Insulate the heaters from the rest of the system and ensure adaqute external airflow for the components that need to be cooled Team
ID Risk Item Cause Effect
Likelihood
Severit
y
Importance
Action tominimize risk Owner Solution
Technical Risks
MSD II ScheduleWinter Quarter Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11
Tasks Responsible MTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSS1. Delivery of parts - Rachael Rachael 2. Machining of components - Michael and Valentina
Michael/Valentina
3. Construct of system components - Team Team 4. Construct electrical components - Jon and Alex Jon/Alex 5. Contruct entire system Team 6. Incorporation of mechanical and electrical stuff Michael 7. Debugging Team 8. Test system Valentina 9. System design verification testing Michael
10. Write project technical paperRachael/Sean
11. Participate in paper exchange session Team 12. Develop project poster Team 13. Submit poster for printing Rachael 14. Participate in poster session Team 15. Project Presentation Team 16. Project Review Team
Method for attaching blades to the stirrer shaft
Are there any concerns with the maximum height of the machine?
Design Question
Questions