P13651 – MPI Wax Melter
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Change from design review
System Architecture/subsystems
Feasibility
Test plan
Risk assessment
BOM
MSD II Plan
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CN2
Accommodates flakes, pellets, or solid blocks of wax
CN13
Accommodates non soluble wax
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
Accept wax
Hold wax
Melt wax
Transport wax
Item
Motor Type
Enclosure
HP
Number of
Speeds
General Purpose Motor
Split-Phase
Open Dripproof
1/3
Nameplate RPM
1725
NEMA/IEC Frame
48Z
Voltage
Hz
Phase
115
60
1
Full Load Amps
7.0
Mounting
Thermal
Protection
Cradle/Stud
Insulation Class
B
Service Factor
Bearings
Ambient (C)
Rotation
Shaft Dia. (In.)
1.35
Ball
40
CW/CCW
1/2
Shaft Length (In.)
1-7/8
Stud Pattern (In.)
3.625 x 3.625
Stud Location
Stud Quantity
RPM Range
Shaft End
4
1400-1800
UL Recognized (E47479), CSA Certified
(156060)
Standards
1
None
Hopper > hand-fed solid wax
• Reduce operator intervention
• Increase processing speed
• Better control feed into reactor
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KC 4088D properties:
Thermal conductivity – 0.685 W/mK
Thermal Diffusivity - 0.360 mm2/s
Specific Heat - 1.908 MJ/m3K
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Thermal analysis:
◦ Porous material model: Wax analogy
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Ratio of specific heats = 1
Thermal Conductivity = .211 W/(m*K)
Density = 950 kg/m3
Heat capacity = 2.3 J/(kg*K)
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Ratio of specific heats = 1
Thermal Conductivity = .16 W/(m*K)
Density = 860 kg/m3
Heat capacity = 2.5 J/(kg*K)
◦ Liquid material model:
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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
1 sec
10 sec
30 sec
60 sec
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Linear actuated trapdoor vs. actuated valve
◦ Reduce chances of wax solidifying inside the valve
◦ Communicates with reservoir
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Model flow rate out of reservoir: 50 lbs/hour
No.
Importance Specifications
ES 6
13.29
ES 8
10.07
ES 10
8.11
Operating temperature range
Temperature difference across
melt surface within operating range
(no wax)
Temperature difference across
plate while melting blocks, flakes,
pellets
ES 15
7.62
Wax burns or seperates
ES 1
7.3
Flow rate
ES 13
5.28
Weight of wax remaining on melter
after melting one hopper
ES 5
5.08
Power requirements(
ES 14
4.95
Weight of wax remaining on funnel
after melting one hopper
ES 11
4.56
ES 9
3.49
Volume melted in a batch
Diameter of critical dimension of
flakes/pellets allowed to pass
unmelted
Targets
Unit of
Measure
Marginal
Value
Ideal
Value
100-250 F
degrees F
170-220
100-250
Thermocouple
<= 1 °C
degrees C
<=1
<=1
Thermocouple
<= 1 °C
degrees C
<=1
<=1
Thermocouple
yes/no
boolean
no
yes
lb/hour
50
>=50
lbs
>0
0
0 lbs
240 VAC
VAC
negotiable
240
0 lbs
lbs
>0
0
>= 20 gal
gallons
0 inches
inches
<20
>=20
0
Comments/Status
Test
Equipment
Working with onephase power, due to
difficulty in finding lab
space
Proximity
sensor
Dimensions (LWT)
Material
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
Tank Supports
4 x .5"D x 2"
Cold Finish Stainless Round 304/304L
Hopper
Price
$25.73
$3.76
Total
$862.84
Electrical Subsystem
Supplier
Model
Tube Heater
Tutco
TBA
Sticky Heaters
Omega
Logic Gates
Digikey
KH-1212/5
4 AND, 2 NOR, 2 OR, 4 Inverter
packages
20 A breaker
Lowes
12/2 Wire
# of
Price per unit units
Price Lead time
TBA
1
TBA TBA
$95.00
2
$ 190.00 5 weeks
$0.42
12
Square D Qo 20A breaker
$6.44
1
Lowes
50' of 12 AWG 12-2
33.24
1
Signal wire
1% resistors for booster
circuit
On hand
20 gauge signal wire of various colors
Free
10'
$0.50
10
Primary Drive Motor
Grainger
Dayton motor 1/3 HP GP
$130.00
1
Light Switch
MOSFETs for booster
circuits
Lowes
Single standard 15 A light switch
$5.00
1
$
5.00
$0.60
4
$
2.40
Linear actuator for valves
Firgelli automation
$160.00
2
120 V Relays
Digikey
$2.07
2
Digikey
Digikey
Z774-ND
Total:
$
5.04 5 days
Ready to
$ 6.44 purchase
Ready to
$ 33.24 purchase
$
$
- On Hand
5.00 3-5 days
$ 130.00 3 days
$ 320.00
$
4.14
$ 701.26
Likelihood
Severity
Importance
ID
Risk Item
Cause
Effect
Action to
minimize risk
Owner
Solution
Technical Risks
A
Wax gets damaged
B
Parts don't arrive on time
C
Our fabrication skill set
D
E
Excessive
temperatures
Room fills with dangerous levels
of CO2
Ensure adaquate
temperature controls
2 3 6 and safety systems
Mike
Parts are ordered too
late
Parts required for
design are beyond
our ability to make or
beyond budget
Machine cannot be assembled in
time
Order parts before
1 2 2 winter quarter
Rachael
Talked with reps from
Paramelt, and they are
confident that we will not be
handling enough CO2 to be
dangerous; CO2 detector?
Prompt ordering before
winter quarter gives
significant time to get parts
Machine cannot be assembled in
time
1 2 2Limit part complexity
Mike
Attempting a design with
simple machining
Lab space cannot be secured
Fume hoods and 240
V outlets tend not to
go together
Machine cannot be tested
Design is too complex
Team
overcomplicates the Machine is very expensive, large,
designs
and hard to maintain
F
Invalid assumptions
G
Unable to melt all wax in vat
Insufficient
knowledge of nonNewtonian fluid with
fibers
Flake density is
greater than the
melted wax
Design decisions based on false
assumptions
Solid wax makes it through the
systems
Ask everyone on
3 3 9 campus
Team
Collaborate with
customer and guide to
ensure design is
1 2 2 practical
Mike
Consult experts when
2 3 6 needed
Team
MSD II Test plan allows
for optimization of
2 3 6 design
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
Attempting to pursue a
simple design
Working with worst case
scenarios for modeling;
purchase heating and
stirring equipment with
room for error
Decrease size of vat; can
change stirring rate
Risk Item
Technical Risks
Cause
Effect
Bearings get
Bearings - Bind up over time, must contaminated and
withstand spinning
jam
Bearings fail prematurely
Likelihood
Severity
Importance
ID
Action to
minimize risk
Correctly spec
1 3 3 bearings
Test system and use
Natural vibrations
bushings to dampen
due to motors and Welds holding the melter
vibrations if
J Vibrations - Break welds over time moving parts
together fracture and fail
2 3 6 necessary
Find maximum
power consumption
May have to reduce heat into
of each component
system, increase warm-up
and ensure it is less
Not enough power time, and tripping breakers
than the available
K Power - Too much is needed
to fuel system
regularly
3 2 6 power
The induction
Get sealed rugged
heater needs a wire Wax can leak through bottom
bearings that can
Hole in bottom of tank with
run through the
of tank and jam bearings for
handle the harsh
M bearings to jam
bottom of the tank stirrer shaft
2 2 4 conditions
Design involves
heating less wax per
batch, built in
variability in heating
Mixing - Getting solid wax quickly Insufficient heating Unable to produce melted wax
and stirring
N and entirely into liquid state
power or stirring
from the system
2 3 6 capabilities
Bottom of tank is
Solidied wax
insulated to prevent
O Trap door
collects in opening Reduce flow rate our of system 2 2 4 heat loss
Insulate the heaters
from the rest of the
Heaters and
system and ensure
electronic
adaqute external
components are all Shortened life span for many
airflow for the
Excessive temperatures inside
in a single closed
of the components in the
components that
P heater assembly
box
system
3 3 9 need to be cooled
I
Owner
Mike
Mike/Vale
ntina
Jon/Alex
Mike/Vale
ntina
Team
Team
Team
Solution
Winter
Quarter
Tasks
Responsible
1. Delivery of parts - Rachael
Rachael
2. Machining of components Michael/Val
Michael and Valentina
entina
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
Rachael/Sea
10. Write project technical paper n
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
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Week 11
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Method for attaching blades to the stirrer
shaft
Are there any concerns with the maximum
height of the machine?