1. P13651 – MPI Wax Melter

2.  Change from design review  System Architecture/subsystems  Feasibility  Test plan  Risk assessment  BOM  MSD II Plan

3.  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 CN2 Accommodates flakes, pellets, or solid blocks of wax CN13 Accommodates non soluble wax

4. Accept wax Hold wax Melt wax Transport wax

15. ItemGeneral Purpose Motor Motor TypeSplit-Phase EnclosureOpen Dripproof HP1/3 Number of Speeds 1 Nameplate RPM1725 NEMA/IEC Frame48Z Voltage115 Hz60 Phase1 Full Load Amps7.0 MountingCradle/Stud Thermal Protection None Insulation ClassB Service Factor1.35 BearingsBall Ambient (C)40 RotationCW/CCW Shaft Dia. (In.)1/2 Shaft Length (In.)1-7/8 Stud Pattern (In.)3.625 x 3.625 Stud LocationShaft End Stud Quantity4 RPM Range1400-1800 Standards UL Recognized (E47479), CSA Certified (156060)

17. Hopper > hand-fed solid wax Reduce operator intervention Increase processing speed Better control feed into reactor

18.  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)

19.  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

20. 1 sec10 sec 30 sec60 sec

22.  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

23. No.ImportanceSpecificationsTargets Unit of Measure Marginal Value Ideal ValueComments/Status Test Equipment ES 613.29Operating temperature range100-250 Fdegrees F170-220100-250 Thermocouple ES 810.07 Temperature difference across melt surface within operating range (no wax)<= 1 °Cdegrees C<=1 Thermocouple ES 108.11 Temperature difference across plate while melting blocks, flakes, pellets<= 1 °Cdegrees C<=1 Thermocouple ES 157.62Wax burns or seperatesyes/nobooleannoyes ES 17.3Flow rate lb/hour50>=50 ES 135.28 Weight of wax remaining on melter after melting one hopper0 lbslbs>00 ES 55.08Power requirements(240 VACVACnegotiable240 Working with one- phase power, due to difficulty in finding lab space ES 144.95 Weight of wax remaining on funnel after melting one hopper0 lbslbs>00 ES 114.56Volume melted in a batch>= 20 galgallons<20>=20 Proximity sensor ES 93.49 Diameter of critical dimension of flakes/pellets allowed to pass unmelted0 inchesinches 0

24. Dimensions (LWT)MaterialPrice Hopper1 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 Plate1 x 63" x 3" x.25"Cold Finish Mild Steel Rectangle 1018$46.62 Hopper Rails2 x 55" x.5" x.5"Cold Finish Mild Steel Square 1018$24.20 Chute1 x 20" x 4".125"Cold Finish Mild Steel Rectangle 1018$12.60 2 x 10" x 3" x.125Cold Finish Mild Steel Rectangle 1018$10.40 Tank1 x 8" OD x.125" Wall x 16"Extruded Aluminum Bare Tube 6061 T6$75.52 Bottom Support Plate1 x 24" x 24" x.5"Mild Steel Blanchard Ground Plate 1018$284.51 Box4 x 10" x 18" x.12"Stainless 2B Sheet 304 Annealed$165.60 Tank Base1 x 8"D x 1"Extruded Aluminum Bare Round 6061 T6511$25.73 Tank Supports4 x.5"D x 2"Cold Finish Stainless Round 304/304L$3.76 Total$862.84

25. Electrical SubsystemSupplierModelPrice per unit # of unitsPriceLead time Tube HeaterTutcoTBA 1 Sticky HeatersOmegaKH-1212/5$95.002 $ 190.005 weeks Logic GatesDigikey 4 AND, 2 NOR, 2 OR, 4 Inverter packages$0.4212 $ 5.045 days 20 A breakerLowesSquare D Qo 20A breaker$6.441 Ready to purchase 12/2 WireLowes50' of 12 AWG 12-233.241 $ 33.24 Ready to purchase Signal wireOn hand20 gauge signal wire of various colorsFree10' $ -On Hand 1% resistors for booster circuitDigikey$0.5010 $ 5.003-5 days Primary Drive MotorGraingerDayton motor 1/3 HP GP$130.001 3 days Light SwitchLowesSingle standard 15 A light switch$5.001 MOSFETs for booster circuitsDigikey$0.604 $ 2.40 Linear actuator for valvesFirgelli automation$160.002 $ 320.00 120 V RelaysDigikeyZ774-ND$2.072 $ 4.14 Total: $ 701.26

26. IDRisk ItemCauseEffect Likelihood Severity Importance Action to minimize riskOwnerSolution Technical Risks AWax gets damaged Excessive temperatures Room fills with dangerous levels of CO2236 Ensure adaquate temperature controls and safety systemsMike Talked with reps from Paramelt, and they are confident that we will not be handling enough CO2 to be dangerous; CO2 detector? BParts don't arrive on time Parts are ordered too late Machine cannot be assembled in time122 Order parts before winter quarterRachael Prompt ordering before winter quarter gives significant time to get parts COur fabrication skill set Parts required for design are beyond our ability to make or beyond budget Machine cannot be assembled in time122Limit part complexityMike Attempting a design with simple machining DLab space cannot be secured Fume hoods and 240 V outlets tend not to go togetherMachine cannot be tested339 Ask everyone on campusTeam 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 EDesign is too complex Team overcomplicates the designs Machine is very expensive, large, and hard to maintain122 Collaborate with customer and guide to ensure design is practicalMike Attempting to pursue a simple design FInvalid assumptions Insufficient knowledge of non- Newtonian fluid with fibers Design decisions based on false assumptions236 Consult experts when neededTeam Working with worst case scenarios for modeling; purchase heating and stirring equipment with room for error GUnable to melt all wax in vat Flake density is greater than the melted wax Solid wax makes it through the systems236 MSD II Test plan allows for optimization of designTeam Decrease size of vat; can change stirring rate

27. I Bearings - Bind up over time, must withstand spinning Bearings get contaminated and jamBearings fail prematurely133 Correctly spec bearingsMike JVibrations - Break welds over time Natural vibrations due to motors and moving parts Welds holding the melter together fracture and fail236 Test system and use bushings to dampen vibrations if necessary Mike/Vale ntina KPower - Too much is needed Not enough power to fuel system May have to reduce heat into system, increase warm-up time, and tripping breakers regularly326 Find maximum power consumption of each component and ensure it is less than the available powerJon/Alex M Hole 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 shaft224 Get sealed rugged bearings that can handle the harsh conditions Mike/Vale ntina N Mixing - Getting solid wax quickly and entirely into liquid state Insufficient heating power or stirring Unable to produce melted wax from the system236 Design involves heating less wax per batch, built in variability in heating and stirring capabilitiesTeam OTrap door Solidied wax collects in openingReduce flow rate our of system224 Bottom of tank is insulated to prevent heat lossTeam P Excessive 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 system339 Insulate the heaters from the rest of the system and ensure adaqute external airflow for the components that need to be cooledTeam IDRisk ItemCauseEffect Likelihood Severity Importance Action to minimize riskOwnerSolution Technical Risks

28. Winter QuarterWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9Week 10Week 11 TasksResponsible MTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSS 1. Delivery of parts - RachaelRachael 2. Machining of components - Michael and Valentina Michael/Val entina 3. Construct of system components - TeamTeam 4. Construct electrical components - Jon and AlexJon/Alex 5. Contruct entire systemTeam 6. Incorporation of mechanical and electrical stuffMichael 7. DebuggingTeam 8. Test systemValentina 9. System design verification testingMichael 10. Write project technical paper Rachael/Sea n 11. Participate in paper exchange sessionTeam 12. Develop project posterTeam 13. Submit poster for printingRachael 14. Participate in poster sessionTeam 15. Project PresentationTeam 16. Project ReviewTeam

29.  Method for attaching blades to the stirrer shaft  Are there any concerns with the maximum height of the machine?