P13651: Soluble Wax MelterProject Team:

Rachael Hamilton – Team LeaderMichael Blachowicz – Lead

EngineerValentina Mejia – EngineerJonathan Waldron – EngineerAlex Kibbe – EngineerSean Sutton - Engineer

Agenda• Project Description• Final Design Concept• Project Development• Testing Results• Current state of project• Objective project evaluation• Conclusions• Questions

Project DescriptionProject Goal: Design a device that will

successfully melt and transport soluble and non-soluble wax

Original Design for MPI 55 C-series Wax MelterScaled back project to focus on

wax processingAchieve 5o lbs/hour flow rateDoes not burn, separate waxNo clogging of wax

Design SpecificationsNo. Importance Specifications

ES 6 13.29Operating temperature range(170-220 F mimimum, 100-250 F ideal)

ES 8 10.07Temperature difference across melt surface within operating range (no wax) <=1C

ES 15 7.62 Wax burns or seperates ES 1 7.3 Flow rate of 50lb/hr

ES 13 5.28Weight of wax remaining on melter after melting one hopper (minimize, <current)

ES 5 5.08 Power requirements (240 VAC, low current)

ES 14 4.95Weight of wax remaining on funnel after melting one hopper(minimize<current)

ES 9 3.49Diameter of critical dimension of flakes/pellets allowed to pass unmelted(minimize, ideal 0)

ES 7 3.22 Time to reach set temperature from room temp(<= current)

ES 12 3.16 Withstands abrasions from wax with glass fibers

ES 4 2.28 Maximum diameter of wax blocks accommodated > 12 inches ES 3 1.27 Width <= 20 inches

Product DevelopmentRealized Schedule: issues with

Finalizing design: Scaled-back project in MSD II Week 3

Construction set-backsMSD I Winter MSD II

Stage 1Concept Development

Stage 2 Detailed Design

Stage 3Feasibility Analysis

Stage 4 Final Design

Stage 5 Construction

Stage 6 Testing

Stage 7Final Review

Final Design Concept

Final Design Concept

Realized machine: A known amount of wax is hand fed into the top of the tank, it is allowed to melt until contents appear completely melted, hand actuated door at base of tank is opened to let out wax to bucket placed under the machine

Testing ResultsTime to steady state with no wax

Issue with PID controller initially, led us to just use on/off control.

Time to steady state was around four minutes from room temperature and with a Tsp of 180°F.

Steady state was about reached here in this test, but the control was not set up properly and began to cause the temperature to fluctuate.

Testing ResultsTested the temperature difference across the surface

around the inside of the tank (melting surface).Tested the difference from the base to the top while

heatingConcluded that there is a temperature difference from

the base of the tank to the top because of heat loss due to convection at the top

Tested radial difference from the base to the topConcluded that there was a minimal temperature

difference along a radial axis in the tank, +-5 °FWith thermocouple variation, the temperature is close

to uniform along a radius

Testing Resultsat Base 3 inches up 3 inches upT Tactual T Tactual T Tactual

269 275.4031 220 224.1295 210 213.6655266 272.2639 225 229.3615 210 213.6655266 272.2639 226 230.4079 216 219.9439268 274.3567 225 229.3615 210 213.6655266 272.2639 221 225.1759

3 inches up 3 inches up(2 from top)T Tactual T Tactual

202 205.2943 173 174.9487200 203.2015 178 180.1807204 207.3871 171 172.8559202 205.2943 174 175.9951

175 177.0415

Z Gradient241 246.1039 base231 235.6399232 236.6863203 206.3407 inch from top

Here you can see the radial test temperatures are all within a reasonable range with each other. The significant difference between the bottom and the top is due to the tests being conducted at different times while heating. The first temperature is the temperature read by the thermocouple and the second is the adjusted temperature from calibration.

Testing ResultsTest melt 1 was melting exactly one gallon of

KC-4088D. This was 8 pounds 6 pounces in weight

Tsp was set at 180°FTook temperature readings every 10 secondsTemperature saw an increase when the wax

transitioned from solid to mostly liquidTime to melt 1 gallon was 10 minutes

Testing Results

Testing ResultsTest melt 2 involved adding 1 gallon of wax to

the melter and adding a second gallon of wax on top once the first batch was mostly liquid.8 pounds 6 ounces was added both times

Tsp was set to 200°FTotal time to melt 16 pounds and 12 ounces

was 27 minutes. This translates to 37.22 pounds per hour

Testing Results

Testing ResultsThe goal of Test melt 3 was to see how long it

took to melt 25 pounds of wax8 pounds 9 ounces added initially, then 8

pounds 6 ounces followed by another 8 pounds 6 ounces

Tsp was set to 205°FThe total time to melt 3 gallons of wax

(25.4167 lbs) was 45 minutes. This translates to a melt rate of 33.889 pounds per hour.

Testing Results

Issues While TestingPhysically holds 1 gallon of solid wax at a timeTorque from the motor caused the sprocket on the

shaft to start spinning and stop mixing in the systemCaused by motor torque and binding of the sprocket

and shaftFixed by dropping a pin through the sprocket to keep

it from slipping on the shaftMelted wax leaving the system would come in

contact with chainA chain guard or some sort of protection should be

used to prevent this

Objective Analysis of ProjectNo. Specifications Targets Achieved Characteristics

ES 1 Flow rate 50 lb/hr 30-35 lbs/hr

ES 2 Mounts directory to 55 Series C Frame yes/no No

ES 3 Ramp Width <= 20 inches N/A

ES 4 Maximum diameter of wax blocks accommodated > 12 inches Processes Flakes only

ES 5 Power requirements( 240 VAC 240 VAC

ES 6 Operating temperature range 100-250 F 180-205 °F

ES 7 Time to reach set temperature from room temp Minimize ~ 4 minutes w/o wax

ES 8 Temperature difference across melt surface within operating range (no wax) <= 1 °C >= 1°C

ES 9 Diameter of critical dimension of flakes/pellets allowed to pass unmelted 0 inches Minimized

ES 10 Temperature difference across plate while melting blocks, flakes, pellets <= 1 °C N/A

ES 11 Volume melted in a batch >= 20 gal No hopper for batch testing

ES 12 Withstands abrasions from wax with glass fibers yes/no Yes

ES 13 Weight of wax remaining on melter after melting one hopper 0 lbs > 0 lbs

ES 14 Weight of wax remaining on funnel after melting one hopper 0 lbs > 0 lbs

ES 15 Wax burns or separates yes/no No

ES 16 Loads by vacuum loader or by hand yes/no No

Current State of ProjectCurrent machine capable of melting soluble wax

with fibersNo issues with cloggingWax does not separate or burnStirring mechanism succeeds in inducing flow

during operationTemperature variation above spec, but even heating

to produce a thoroughly melted batchInsignificant testing to determine hourly outputTesting procedure did not achieve 50 lbs/hourCleaning an issue if testing different waxes

Further WorkOptimize tank loading to achieve maximum flow rate

1 gallon achieved average hourly flow rate of 51 lbs/hour

Higher loading: ~ 34 lbs/hourOptimize placement and shape of stirring bladesImprove PID control of heaterModify design to improve ease of cleaning

Make water-tight for cleaning processAllow testing with other waxes

Incorporate a novel aspect to the designHeat stir rods and/or stirring shaft

ConclusionsDesign does not meet all customer specs and

is not a novel designSystem is capable of processing water-

soluble wax, has potential to meet desired flow rate

Things to do differentlyBetter communication amongst group and with

customerUse acquired experience to better develop and

utilize risk assessment

Questions?