P13651: FINAL DESIGN
Contents
• Revised Design
• Subsystem design
• Power requirements
• BOM/Budget
Hold Wax: Hopper
• Designed to hold an entire bag of
wax flakes
• Reduces operator work during
operation
• Hopper held within base with
springs to reduce affects of
vibrations from vibrator
For drawings see attached
Transport Wax: Chute
• Goal: Transport 2 gallons of
wax at a time into the tank
• Wax flow controlled by a
door operator by a linear
actuator
• Ideal chute angle to
transport wax flakes: 45°
• Vibrator is attached to the
backside of chute to
improve transfer
Super-Quiet Low-Impact Electric Vibrator
Nonadjustable Force, 115 VAC,
1.4 Amps, 25 lbs Force
http://www.mcmaster.com/#catalog/119/517/=lsgnla
Melt Wax: Melting Tank
• Goal: Melt 2 gallon batch of wax
within 10 minutes
• Aluminum tank structure
• heaters around exterior wall of tank is
sole provider of heat to melt the wax
• Aluminum shaft and 2 stirrers induce
flow and increase melt rate
• Insulation surrounding tank prevent
heat loss to surroundings
Heat Requirements
• Melted varying quantities of
three sample wax in a home
wax melting unit
• Determined melter efficiency by
comparing results from testing
to known material, paraffin
• Used data to determine amount
of energy required to achieve
customer requirement of 50
lb/hour
Energy Required to Melt 50 lb of Wax
50 lb/hr
KC 4088
100 lb/hr
983
1967
Cerita 28-8
1148
2296
Solucore 1149
1711
3422
Testing Melter Efficiency
39%
Sample Calculations
Raw Data
Analyzed Data
Power Required
Trial
Amt (lbs)
Melt Time
(min)
Time (s)
Weight (kg)
Melt Rate
(kg/s)
Heat of Fusion
(J/kg)
50 lb/hr
100 lb/hr
1
0.6
16.58
995
0.2722
0.00027
213E+3
1341
2682
2
0.6
11.82
709
0.2722
0.00038
152E+3
956
1911
3
0.6
14.98
899
0.2722
0.00030
192E+3
1212
2423
4
0.6
16.83
1010
0.2722
0.00027
216E+3
1361
2723
5
1
26.17
1570
0.4536
0.00029
202E+3
1270
2539
6
1
20.63
1238
0.4536
0.00037
159E+3
1001
2002
7
1
20.38
1223
0.4536
0.00037
157E+3
989
1978
8
1
24.37
1462
0.4536
0.00031
188E+3
1182
2365
9
1.4
35.02
2101
0.6350
0.00030
193E+3
1214
2427
10
1.4
27.50
1650
0.6350
0.00038
151E+3
953
1906
Average
182E+3
1148
2296
Power (W)
58.23
Required Melt
Rate (lb/hr)
50
Required Melt
0.0063
Rate (kg/s)
Required Melt
Rate (lb/hr)
100
Required Melt
0.0126
Rate (kg/s)
System Heaters
• System will require 4
heaters to provide enough
energy and cover the tank
• Heaters will come up to
2.25in down from the top of
the tank
• Heat density of 100W/in2
Watlow Band/Barrel Heaters
http:/www.watlow.com/downloads/en/catalogs/band-barrel.pdf/
Melted Wax Transport
• Goal: Achieve 50 lb/hour flowrate
• Flow rate out of tank controlled by a door
operated by a linear actuator
• Outlet through current baseplate into
reservoir
BOM: Metal
Description
Cold Roll Mild Steel Sheet A366/1008,
20"x20" 16 Gauge
Metals
Part
Chute wall of
Hopper
Vendor
online
metals
Cold Roll Mild Steel Sheet A366/1008,
10"x60" 16 Gauge
Hopper bottom
wall (3 sides)
online
metals
Item #
Quantity
13
1
14
1
15
2
16
4
17
1
18
1
Cold Finish Mild Steel Rectangle 1018,
6"x30"x1/8"
Hopper support
(Angled)
19
1
Cold Finish Mild Steel Rectangle 1018 ,
1/4"x2"x36"
Hopper support
(Horizontal)
20
4
21
1
22
1
23
1
24
1
25
1
26
1
Cold Roll Mild Steel Sheet A366/1008,
12"x40" 16 Gauge
Cold Roll Mild Steel Sheet A366/1008,
12"x24" 16 Gauge
Cold Roll Mild Steel Sheet A366/1008,
12"x12" 16 Gauge
Hopper box
Heater box
walls
Heater box top
DOM Mild Steel Tube A513 TYPE 5, length
36", OD=3/4", ID=0.53" with wall
Support Rods
thickness 0.109 "
Cold Finish Alloy Sheet Steel 4130
L Brace
Annealed, 10"x10"x.19"
Extruded Aluminum Round 6061 T6511,
Heater base
length 2-1/4", OD=8"
Aluminum 6061-T6 Bare Sheet, 18" x 26",
Heater tank
thickness=1/8"
Extruded Aluminum Round 6061 T6511,
Stir shaft
length 24", dia 3/4"
Extruded Aluminum Round 6061 T6511,
Stir blades
length 24" L, dia 1.5"
Mild Steel BLANCHARD GROUND Plate
Base plate
1018, 24"x24"x1/2"
Code/Part Number
Lead Time
-
-
$
24.00 $
24.00
-
-
$
24.00 $
24.00
-
-
$
19.20 $
38.40
-
-
$
9.31 $
37.24
-
-
$
4.82 $
4.82
online
metals
-
-
$
30.30 $
30.30
online
metals
-
-
$
17.20 $
17.20
online
metals
-
-
$
10.09 $
40.36
$
38.00 $
38.00
online
metals
online
metals
online
metals
online
metals
online
metals
online
metals
online
metals
online
metals
online
metals
Unit Price Total Price
-
-
$
57.89 $
57.89
-
-
$
60.84 $
60.84
-
-
$
4.74 $
4.74
-
-
$
18.95 $
18.95
-
-
$
284.51 $
284.51
Metal Sub-Total $
681.25
BOM: Electrical
Description
Electrical Components
Part
Vendor
Item #
Quantity
Code/Part Number
Lead Time
1
12
Logic Gates
Electrical
Component
2
10
1% resistors for booster circuit
3
4
4
Unit Price Total Price
DigiKey
4 AND, 2 NOR, 2 OR, 4
Inverter packages
5 Days
$
0.42 $
5.04
Electrical
Component
Digikey
-
3-5 Days
$
0.50 $
5.00
MOSFETs for booster circuits
Electrical
Component
Digikey
-
-
$
0.60 $
2.40
2
120 V Relays
Electrical
Component
Digikey
Z774-ND
-
$
2.07 $
4.14
5
1
20 A breaker
Electrical
Component
Lowes
Square D Qo 20A
breaker
Ready to
purchase
$
6.44 $
6.44
6
1
12/2 Wire
Electrical
Component
Lowes
50' of 12 AWG 12-2
Ready to
purchase
$
33.24 $
33.24
7
1
Light Switch
Electrical
Component
Lowes
Single standard 15 A
light switch
Ready to
purchase
$
5.00 $
5.00
8
1
Primary Drive Motor
Electrical
Component
Grainger
Dayton motor 1/3 HP
GP item #5K917
Purchased
$
130.00 $
130.00
9
2
Linear actuator for valves
Electrical
Component
Firgelli
automation
-
-
$
160.00 $
320.00
10
1
Signal wire
Electrical
Component
-
20 gauge signal wire of
various colors, 10ft
On hand
11
1
K-A-Watt
Electrical
Component
-
-
-
12
4
Heater
Electrical
Component
Watlow
ME7L3AP1
$
-
$
-
$
40.00 $
40.00
Purchased 2
$
weeks ago
130.00 $
520.00
Electrical Components Sub-Total $ 1,071.26
BOM: Auxilliary
Item #
Quantity
Description
27
2
High-Temp Cast Iron Mounted STL Ball
Bearing 2-Bolt Flange Mount, for 3/4"
Shaft Diameter
28
1
Right-Angle Speed Reducer Shaft Input,
30:1 Ratio, 1.33" Center, Left Output
29
Auxiliary Components
Part
Vendor
Code/Part Number
Lead Time
McMasterCarr
6665K33
2 Weeks
$
112.72 $
225.44
Speed reducer/ McMasterGear box
Carr
5887K321
3 Days
$
357.87 $
357.87
2
Steel Machinable-Bore Sprocket for #25 Bore sprockets McMasterChain, 1/4" Pitch, 30 Teeth, 3/8" min Bore for roller chain
Carr
6793K19
In stock
$
10.35 $
20.70
30
1
Standard ANSI Roller Chain #25, Single
Strand, 1/4" Pitch, .13" Dia, 4ft length
31
1
32
Bearing
Unit Price Total Price
Chain
McMasterCarr
6261K171
In stock
$
14.92 $
14.92
Very HI-Temp Mineral Wool Insulation
Wire Mesh One Side, 1" Thick, 24" X 48"
Sheet
Insulation
McMasterCarr
9328K21
In stock
$
18.79 $
18.79
10
Reusable SS Harsh-Environment Cable Tie
45" Length, bundle dia 12 1/2"
Insulation
holder
McMasterCarr
1853T64
In stock
$
2.36 $
23.60
33
1
Tape Made with Kapton® Polyimide High
Temperature, 6" W, 5 Yards, .0025" Thk
Electrical
Insulator
McMasterCarr
7648A718
In stock
$
57.94 $
57.94
34
1
2 oz., highly conductive two part epoxy to
500°F
Thermally
Conductive
Epoxies
Omega
OB-200-2
In stock
$
17.00 $
17.00
35
1
Super-Quiet Low-Impact Electric Vibrator
McMasterNonadjustable Force, 115 VAC, 1.4 Amps, Hopper vibrator
Carr
25 lbs Force
5802K13
In stock
$
264.63 $
264.63
36
8
High Load Plastic Compression Spring 250
in-lbs Energy Cap, 1.11" Overall Diameter
9677K12
In stock
$
8.14 $
65.12
Springs
McMasterCarr
Auxiliary Sub-Total $ 1,066.01
Manufacturing Costs
Manufacturing Cost
Item #
Quantity
37
1
38
39
Description
Part
Vendor
Code/Part Number
Lead Time
Unit Price Total Price
CNC
Tank Base
Brinkman
Lab
-
2 weeks
$
500.00
$
500.00
1
Water jet
Base Plate
Brinkman
Lab
`
1 week
$
50.00
$
50.00
1
Water jet
L-Brace
Brinkman
Lab
`
1 week
$
50.00
$
50.00
Manufacturing Sub-Total
$
600.00
Budget Breakdown
Budget Breakdown
Project Budget
$ 5,000.00
Metal Parts
$
Electrical Parts
$ 1,071.26
Auxilliary Parts
$ 1,066.01
Machining Costs
$
Total
681.25
600.00
$ 3,418.52
Remaining in
Budget $ 1,581.48