Team 12 Amelia House Paul Jaffa Johanna Miller Brian Ortega

Introduction Develop, manufacture and sell laboratory instruments which photometrically analyze 1 μL samples For measuring absorbance of DNA, RNA, dyes, protein

Current Procedure Fill syringe with product Use compressed air to dispense into 2mL vials Time consuming, significant waste, expensive Very viscous material

Objective

Project Goal To design and develop a device that will fill and label 2 mL vials with a cleaning substance while eliminating tedious tasks and to provide a more efficient system

Project Scope Original scope intended for a completely automated system that: –Filled vials –Capped vials –Labeled vials Redefined scope as filling vials for project

Customer Wants 1.A higher output of vials 2.Easier to Fill the container than Current Method (Syringe) 3.Minimize Operator Handling Time 4.Minimize the product waste 5.Fit on a Desk Top 6.Have a Labeling Process

Background Research Researched various processes used for dispensing viscous fluids Too large a scale to apply to project Figure 1 Figure 2

Metrics and Target Values MetricTarget Values Current StateFuture State Vial Fill Rate30 per day100 per hour Operator Handling Time per Vial10 minLess than 10 seconds Vial Fullness70-100%90% Full Waste of Product per VialOver 100%Less than 15% Load Time and Cleaning1 hourLess than 10 min

Initial Concepts Implement gravity and pressure Utilize shipping container as pressure vessel Peristaltic pump Heating to reduce the viscosity of the product

Initial Concepts Implement gravity and pressure Utilize shipping container as pressure vessel Peristaltic pump Heating to reduce the viscosity of the product

Concept Selection & Description Heating is advantageous – proved by experimentation Viscosity at 70° F = 4500 mPa*s Viscosity at 130° F = 100 mPa*s Gravity for dispensing Controls through PLC and current LabView system

Heating Subsystem Aluminum container to conduct heat Pinhole to prevent vacuum Band heating element that will be self controlled

Heating Subsystem Temperature Reading < 130°F> 130°F Turn ON Heater Turn OFF Heater

Temperature Control Objective: –To control the temperature so the operator can focus primarily on filling the vials. –Regulate the temperature in the container so that the liquid inside does not get too hot and separate, or get too cold and clog the machine.

Wiring Schematic A – Power source from wall B – Power control to band heater C – Input from thermocouple D – Temperature controller A B C D

Wiring A B C D

Wiring - Back View A B

Wiring – Front View D

Container 5 inch diameter aluminum pipe Bottom cap adhered to pipe Top cap fits firmly Band heater at bottom

Clamp Rear portion thick to support container Flanges for system to bolt together Front made from bent aluminum Two clamps, one for the top and one for the bottom

Stand Triangular bases for stability Mounted to sheet metal base Thick to prevent bending due to weight of container

Placement Places vial in exact location for no mess filling Vials slides in so nozzle is close to opening Hole so vial cannot slide back toward user Mounted to sheet metal base

Dispenser

Final Prototype

Dispensing Subsystems Product placed in aluminum vat for dispensing Utilizes a valve and solenoid LabView Program developed to control valve

Dispensing Advancement Temp reading of 130°F Push start Input x number of vials Spout opens Time < T Time >= T Conveyor advances L Number of vials < x Delay t seconds Spout closes Spout stays open Number of vials >= x Program turns OFF

Main Focus: Dispensing Spout opens Time < T Time >= T Spout closesSpout stays open

Dispensing Advancement Temp reading of 130°F Push start Input x number of vials Spout opens Time < T Time >= T Conveyor advances L Number of vials < x Delay t seconds Spout closes Spout stays open Number of vials >= x Program turns OFF

LabView Program User inputs desired time Starts program Will end when completed Run as many times as needed

Wiring for Dispensing LabView program only allows for 5 V signal Solenoid valve requires a 12 V signal –Received from power source Relay opens or closes due to program –Able to control flow as a result

Wiring for Dispensing Power Source Relay LabView Board

Wiring for Dispensing

Testing Initially performed with water Trying to establish a basis Valve alone Used tubing to create head pressure Water Testing With a Constant Flow Rate Time (s)Volume Filled (mL)

Testing Testing determined that the valve suggested by the manufacturer did not yield desired results Plate vs. Pinch valve testing required –Current system is a plate valve

Cost Analysis ProductCost Junction Box$250 Solenoid Valve$150 Band Heater$300 Machining$1,800 Total Cost of Prototype$2,500 Engineering Labor$50,000 Total Cost$52,500

Benefit to Customer CurrentProjected Load Time (min)815 Vials per hour30100 Clean Up Time (min)155 CurrentProjected Labor Cost for 100 Vials12035 Income from 100 Vials2500 Profit from 100 Vials Clean up time will be decreased three times Set up time increased –Does not require user to be present Average savings of $100 per filling of 100 vials

Benefit to Customer CurrentProjected 100 vials per week for a year Profit Increase $ 4250 Anticipated increase in vial demand ~100 per week Mechanism will pay for itself in one year

Path Forward This design can be improved by: Inserting a flow meter Having a nozzle Pressurizing the system Implementing an advancement system Labeling system Modify the LabView program to accommodate these changes

Recommended Products ProductCompanyQuantityCost EachTotal Cost Converyor Belte-bay.com Needle Nozzlethetoolwarehouse.com Flow Rate IndicatorCole Parmer Flow SensorCole Parmer Labeling System 120,000

Questions?