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

Standards UL 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 RisksID 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