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

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 Energy Required to Melt 50 lb of Wax 50 lb/hr100 lb/hr KC Cerita Solucore Testing Melter Efficiency39% 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

Sample Calculations Raw DataAnalyzed DataPower Required TrialAmt (lbs) Melt Time (min) Time (s)Weight (kg) Melt Rate (kg/s) Heat of Fusion (J/kg) 50 lb/hr100 lb/hr E E E E E E E E E E Average182E Power (W)58.23 Required Melt Rate (lb/hr) 50 Required Melt Rate (kg/s) Required Melt Rate (lb/hr) 100 Required Melt 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/in 2 Watlow Band/Barrel Heaters

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 Metals Item #QuantityDescriptionPartVendorCode/Part NumberLead TimeUnit PriceTotal Price 131 Cold Roll Mild Steel Sheet A366/1008, 20"x20" 16 Gauge Chute wall of Hopper online metals -- $ Cold Roll Mild Steel Sheet A366/1008, 10"x60" 16 Gauge Hopper bottom wall (3 sides) online metals -- $ Cold Roll Mild Steel Sheet A366/1008, 12"x40" 16 Gauge Hopper box online metals -- $ $ Cold Roll Mild Steel Sheet A366/1008, 12"x24" 16 Gauge Heater box walls online metals -- $ 9.31 $ Cold Roll Mild Steel Sheet A366/1008, 12"x12" 16 Gauge Heater box top online metals -- $ Cold Finish Mild Steel Rectangle 1018, 6"x30"x1/8" Hopper support (Angled) online metals -- $ Cold Finish Mild Steel Rectangle 1018, 1/4"x2"x36" Hopper support (Horizontal) online metals -- $ DOM Mild Steel Tube A513 TYPE 5, length 36", OD=3/4", ID=0.53" with wall thickness " Support Rods online metals -- $ $ Cold Finish Alloy Sheet Steel 4130 Annealed, 10"x10"x.19" L Brace online metals $ Extruded Aluminum Round 6061 T6511, length 2-1/4", OD=8" Heater base online metals -- $ Aluminum 6061-T6 Bare Sheet, 18" x 26", thickness=1/8" Heater tank online metals -- $ Extruded Aluminum Round 6061 T6511, length 24", dia 3/4" Stir shaft online metals -- $ Extruded Aluminum Round 6061 T6511, length 24" L, dia 1.5" Stir blades online metals -- $ Mild Steel BLANCHARD GROUND Plate 1018, 24"x24"x1/2" Base plate online metals -- $ Metal Sub-Total $

BOM: Electrical Electrical Components Item #QuantityDescriptionPartVendorCode/Part NumberLead TimeUnit PriceTotal Price 112Logic Gates Electrical Component DigiKey 4 AND, 2 NOR, 2 OR, 4 Inverter packages 5 Days $ 0.42 $ % resistors for booster circuit Electrical Component Digikey-3-5 Days $ 0.50 $ MOSFETs for booster circuits Electrical Component Digikey-- $ 0.60 $ V Relays Electrical Component DigikeyZ774-ND- $ 2.07 $ A breaker Electrical Component Lowes Square D Qo 20A breaker Ready to purchase $ /2 Wire Electrical Component Lowes50' of 12 AWG 12-2 Ready to purchase $ Light Switch Electrical Component Lowes Single standard 15 A light switch Ready to purchase $ Primary Drive Motor Electrical Component Grainger Dayton motor 1/3 HP GP item #5K917 Purchased $ Linear actuator for valves Electrical Component Firgelli automation -- $ $ Signal wire Electrical Component - 20 gauge signal wire of various colors, 10ft On hand $ - 111K-A-Watt Electrical Component --- $ Heater Electrical Component WatlowME7L3AP1 Purchased 2 weeks ago $ $ Electrical Components Sub-Total $ 1,071.26

BOM: Auxilliary Auxiliary Components Item #QuantityDescriptionPartVendorCode/Part NumberLead TimeUnit PriceTotal Price 272 High-Temp Cast Iron Mounted STL Ball Bearing 2-Bolt Flange Mount, for 3/4" Shaft Diameter Bearing McMaster- Carr 6665K332 Weeks $ $ Right-Angle Speed Reducer Shaft Input, 30:1 Ratio, 1.33" Center, Left Output Speed reducer/ Gear box McMaster- Carr 5887K3213 Days $ Steel Machinable-Bore Sprocket for #25 Chain, 1/4" Pitch, 30 Teeth, 3/8" min Bore Bore sprockets for roller chain McMaster- Carr 6793K19In stock $ $ Standard ANSI Roller Chain #25, Single Strand, 1/4" Pitch,.13" Dia, 4ft length Chain McMaster- Carr 6261K171In stock $ Very HI-Temp Mineral Wool Insulation Wire Mesh One Side, 1" Thick, 24" X 48" Sheet Insulation McMaster- Carr 9328K21In stock $ Reusable SS Harsh-Environment Cable Tie 45" Length, bundle dia 12 1/2" Insulation holder McMaster- Carr 1853T64In stock $ 2.36 $ Tape Made with Kapton® Polyimide High Temperature, 6" W, 5 Yards,.0025" Thk Electrical Insulator McMaster- Carr 7648A718In stock $ oz., highly conductive two part epoxy to 500°F Thermally Conductive Epoxies OmegaOB-200-2In stock $ Super-Quiet Low-Impact Electric Vibrator Nonadjustable Force, 115 VAC, 1.4 Amps, 25 lbs Force Hopper vibrator McMaster- Carr 5802K13In stock $ High Load Plastic Compression Spring 250 in-lbs Energy Cap, 1.11" Overall Diameter Springs McMaster- Carr 9677K12In stock $ 8.14 $ Auxiliary Sub-Total $ 1,066.01

Manufacturing Costs Manufacturing Cost Item #QuantityDescriptionPartVendorCode/Part NumberLead TimeUnit PriceTotal Price 371CNCTank Base Brinkman Lab -2 weeks $ Water jetBase Plate Brinkman Lab `1 week $ Water jetL-Brace Brinkman Lab `1 week $ Manufacturing Sub-Total $

Budget Breakdown Project Budget $ 5, Metal Parts $ Electrical Parts $ 1, Auxilliary Parts $ 1, Machining Costs $ Total $ 3, Remaining in Budget $ 1,581.48