P14417: B9 Plastics - Particle Filter Detailed Design Review

P14417: B9 Plastics - Particle Filter Detailed Design Review
Dan Anderson / Thomas Heberle / Perry Hosmer / Karina Roundtree / Kelly Stover December 10, 2013

Agenda Problem Definition (5 minutes)
Updated Design and Bill of Materials Justification (15 minutes) Assembly Procedure (5 minutes) Technical Analysis of Design (20 minutes) Test Plans (20 minutes) Project Management (10 minutes)

Problem Definition

Problem Statement Current State:
In order to use the Better Water Maker (BWM) users must first pour the water through a cloth before being treated. Desired State: The device should clear particles from water to allow the BWM to operate more effectively. The device should be simple to use and operable by both women and children. Project Goals: Analyze the design selected by P13418 Decrease Turbidity and Total Suspended Solids Improve the effectiveness of the Better Water Maker Notable Constraints: Must be usable by both women and children Only locally available materials may be consumed Must not negatively impact the smell and taste of water

Project Scope & Deliverables
Eliminate particles greater than 5 microns in size Produce a design that is economically viable for use in developing countries Design the device to be reusable, and use only consumable parts that are locally available Deliverables to date Functional prototype Bill of Materials Design Drawings Assembly and manufacturing plan Test plan and results Documentation*

Customer Requirements
Category Description Importance CR1 Ease of Use Easy to prepare for use 9 CR2 Lightweight for user transport / shipping 3 CR3 Has a minimal startup period CR4 Operates using only naturally available energy CR5 Economics Inexpensive CR6 Usable by a family of 5, for 2-5 years without full replacement CR7 Requires no consumables for operation (other than cheap and locally available materials) CR8 Functionality Improves UV transmission CR9 Decreases turbidity CR10 Decreases total suspended solids CR11 Does not negatively affect taste CR12 Safety Does not negatively affect safety of water CR13 Filters enough water for a family of 5, daily

Engineering Requirements
Category Score Customer Requirement Function Metric Units Marginal Target Ease of Use 3 Easy to clean / recharge Easy to prepare for use Time to clean minutes 10 5 Number of tools required for cleaning by the end user - 2 1 Lightweight for transport Minimize weight of filter Weight in lbs lbs Has a minimal start-up period. Minimize start-up Time elapsed between beginning of pour and first water that enters the bucket seconds 30 Operates using only energy available naturally (gravity, human power, etc.) Doesn't need power source Binary (Yes/No) No Economics Filter is inexpensive Minimize cost of filter Total cost to produce US $ 25 20 Usable by a family of 5, for 2-5 years w/out full replacement Maximize durability of filter Mean Time To Failure # of uses 730 3650 9 Requires no consumables for operation, except for very cheap & locally available materials (salt, soap, sand, etc.) Minimize cost to maintain Annual cost to operate Functionality Decreases turbidity Turbidity is decreased Percentage Decrease % >50% >75% Decreases total suspended solids Total suspended solids decreased Does not negatively affect the taste of the water No negative taste of water Percent of people who say water tastes the same or better Safety No hazardous releases Doesn't produce hazardous release, no chemicals added Use Scenarios Provides enough water for family of 5, daily Flowrate lpm 0.0394 0.6309

Updated Design and Bill of Materials

Updated Drawing – CAD Drawing

Updated Drawing – Exploded BOM
1 3 2 After this we’ll go part by part justifying why we selected each 4

Bottomless Bucket

Bottomless Bucket Bucket in BOM chosen was inexpensive
Most buckets would work

Lid Matches bucket bottom, reusable Inexpensive

5 Micron Mesh

5 Micron Mesh Stainless steel- limits corrosion
Material often used in filters

Bucket

Bucket Inexpensive 5 gallon deemed a good size
Same as bottomless bucket

Spacer

Spacer and Rods Used to seal in mesh in assembly and to provide space between mesh and lid

Indented BOM

Assembly Procedure

Technical Analysis of Design

Mesh Corrosion Stainless steel is in a family of alloy steels containing a minimum of 10.5% chromium. All stainless steels have a higher resistance to corrosion than their mild steel counterparts. This resistance to attack is due to the naturally occurring chromium-rich oxide film formed on the surface of the steel. The film is rapidly self-repairing in the presence of oxygen. Damage by abrasion, cutting or machining is quickly repaired.

Stress Analysis Establish Mesh Von Mises Displacement Contact Regions
Pressure and Structural Support Mesh Establish and then Refine Von Mises Displacement

Contact Regions

Pressure and Supports

Von Mises

Displacement

Category Score Customer Requirement Function Metric Units Marginal Target Ease of Use 3 Easy to clean / recharge Easy to prepare for use Time to clean minutes 10 5 Number of tools required for cleaning by the end user - 2 1 Lightweight for transport Minimize weight of filter Weight in lbs lbs Has a minimal start-up period. Minimize start-up Time elapsed between beginning of pour and first water that enters the bucket seconds 30 Operates using only energy available naturally (gravity, human power, etc.) Doesn't need power source Binary (Yes/No) No Economics Filter is inexpensive Minimize cost of filter Total cost to produce US $ 25 20 Usable by a family of 5, for 2-5 years w/out full replacement Maximize durability of filter Mean Time To Failure # of uses 730 3650 9 Requires no consumables for operation, except for very cheap & locally available materials (salt, soap, sand, etc.) Minimize cost to maintain Annual cost to operate Functionality Decreases turbidity Turbidity is decreased Percentage Decrease % >50% >75% Decreases total suspended solids Total suspended solids decreased Does not negatively affect the taste of the water No negative taste of water Percent of people who say water tastes the same or better Safety No hazardous releases Doesn't produce hazardous release, no chemicals added Use Scenarios Provides enough water for family of 5, daily Flowrate lpm 0.0394 0.6309 These will cycle through, each will have it’s own slide.

Time to Clean Pilot study: select 30 participants, provide cleaning instructions, time the process Hypothesis test (95% confidence) on the average time to clean product H0: µ >= 5 minutes HA: µ < 5 minutes Adjustments in sample size (i.e. additional observations) may be necessary depending on the variance in the observed results If the cleaning time is over the target value of 5 minutes, test for marginal success of 10 minutes

Number of Tools Required for Cleaning
Count of tools required Nylon sponge or brush is best material to clean stainless steel mesh

Weight/assembly (lbs)
Component Quantity Weight/assembly (lbs) Bucket 2 3.60 Lid 1 .38 5 micron mesh .35 Total 4.33

Start-up Time Pilot study: collect 30 observations of start up time
Hypothesis test (95% confidence) on the average start up time H0: µ >= 10 seconds HA: µ < 10 seconds Adjustments in sample size (i.e. additional observations) may be necessary depending on the variance in the observed results If the cleaning time is over the target value of 10 seconds, test for marginal success of 30 seconds

No Power Source Needed

Labor Cost Estimations
Machining Bucket Cut out bottom of bucket: ~5 minutes Drilling holes (with template): ~ 5 minutes Cutting Mesh: ~ 1 minute Hot air welding: ~ 5 minutes Total time: 16 minutes Assuming a $15 / hr wage, total cost is $4

Total Cost of Components
Quantity Cost/assembly Bucket 2 $5.94 Lid 1 $1.47 5 micron mesh $6.32 Brush $2.19 Labor Cost n/a $4.00 Total $19.92

Mean Time to Failure

Operating Costs All components will last longer than the required 2 years. Operating costs will be $0/year

Turbidity Turbidity is caused by particles suspended or dissolved in water that scatter light making the water appear cloudy or murky Particulate matter such as clay, silt, and fine organic and inorganic matter contribute to a high turbidity value Turbidity measurements are often made using optical equipment in the field or lab Sediment often tops the list of substances or pollutants causing turbidity

Percentage Decrease in Turbidity
Pilot study: collect 30 observations of turbidity Collect before/after, compute % difference Hypothesis test (95% confidence) on the average % difference H0: µ >= .75 HA: µ > .75 Adjustments in sample size (i.e. additional observations) may be necessary depending on the variance in the observed results If turbidity does not meet target, test at 50% for marginal success

Percentage Decrease in Total Suspended Solids
Pilot study: collect 30 observations of TSS Collect before/after, compute % difference Hypothesis test (95% confidence) on the average % difference H0: µ >= .75 HA: µ > .75 Adjustments in sample size (i.e. additional observations) may be necessary depending on the variance in the observed results If turbidity does not meet target, test at 50% for marginal success

Taste of Water Recruit at least 100 RIT students
Have each drink tap water that has not been treated with the filter and water that has been treated by the filter (blind) Ask each student if the water tastes better, worse, or about the same Target: 75% respond with better or about the same Marginal: 50% respond with better or about the same

Hazardous Releases

Mock Up Flow Testing Water was collected and used at different times from the Genesee River to drive flow in a replica gravitational, 5-gallon filter In an effort to replicate the flow of river water through the particle filter, a mock up was made to see how effective the mesh is The created mockup uses a mesh diameter of approximately 2.5 in with 18 fl ounces of water put in the filter The max pressure scenario here is about that of 2.5 gallon over an 8.5 in diameter mesh

Mock Up Flow Testing

Low Turbidity Flow Calculations

Mock Up Flow Testing

High Turbidity Flow Testing
In a very high turbidity scenario, the water put into the system had a turbidity value of 210 NTU, about 7 times the worst water turbidity used in the low turbidity flow testing. The flow rate in this scenario was 0.61 ounces per minute, which extrapolates to 0.22 L/min, which still meets our marginal flow rate target. The final turbidity was reduced by about 85 percent, in this scenario, which meets our target requirement.

Flowrate Pilot study: collect 30 observations of the flow of 5 gallons of water through the filter Collect time elapsed to filter all 5 gallons, compute flow rate in lpm Hypothesis test (95% confidence) on the flow rate H0: µ >= lpm HA: µ > lpm Adjustments in sample size (i.e. additional observations) may be necessary depending on the variance in the observed results If turbidity does not meet target, test at lpm for marginal success

Project Management

Risk Assessment ID Risk Item Importance Action to Minimize Risk Owner
Date Opened Date Closed (or expected) 1 Cleaning is difficult 9 Supply cleaning instruction, minimize number of parts, error-proof up/down instructions. Tom 9/17/13 2/14/14 2 Costs more than $25/unit Cost is < $20. Kelly 11/28/13 3 Stress concentration 6 Spread load out around edge of filter Perry 11/21/13 4 Load Bearing Capacity Calculate necessary force rating 5 Flow rate is too slow Increase surface area of filter, find more porous materials, define minimum flow rate to test against (use scenario) Test Plan 10/1/13 2/25/14 User not detecting tear in filter Instruct user to inspect both sides of the filter and closely examine the filtered water. Dan 2/17/14 7 Corrosion Stainless steel is not going to corrode. Karina 10/16/13 8 Weight is too much At under 5lbs, weight is not a risk item. 10/21/13 Incorrect usage, sandwich inserted upside-down Use visuals whenever possible, minimize text, poka-yoke 10/3/13 12/5/13 10 Stability issues with bucket Design proper attachments, make sure surface is level prior to use, worse case - will the bucket withstand that? Prototype will be tested. 3/3/14 11 Filter introduces bad taste to water Design is made of non-corrosive materials, test plan will determine taste results. 10/24/13 3/7/14 12 Leakage Hot-Air Welding significantly reduces the likelihood of leakage occuring 11/19/13

Plan for MSD II Strategy for closure of msd II
Plan for early completion Blown up view of first part of next semester

Next Steps Immediate Actions from DDR Review & Finalize Prototype BOM
Address by Tuesday, 12/10/13 Review & Finalize Prototype BOM Already completed, pending DDR feedback 12/10/13 Complete & Submit Purchase Orders for Prototype By or before Wednesday, 12/11/13 Continue Experiments & Testing Through the start of break Begin Statistical Analysis of Experimental & Test Data As soon as possible. (sufficient amount of experimental or test data)

Best Case Scenario To have all the components for a prototype by January 28th. (Start of next semester) Have prototype built by by Friday, 2/14/13. (End of Week 3) We feel this timeframe is feasible, due to the highly available components that make up our Bill of Materials. In addition, our experiences from testing and experimentation show that the machining and assembly is not very time consuming. By having a completed prototype by this date, we have plenty of time to experiment with it and get real usage information to compare to our Engineering Metrics and Specifications.

Senior Design Process & Lessons Learned
Possible Improvements Accessing SMEs sooner would have been helpful Clearer expectations at times would have helped More planned workshop time for groups during class in the beginning Positives Guides gave plenty of feedback, both good and bad Overall structure is well-organized Follow-On Suggestion Start working on mock ups sooner and order parts as soon as possible Encourage groups to contact industry professionals

Action Items Items Owner Due Date Post DDR Feedback Action Items
Kelly Stover 12/10/13 Finalize Prototype Bill of Materials Thomas Heberle Complete Purchase Orders 12/12/13 Statistical Analysis of Collected Data Daniel Anderson, Kelly Stover Continuous Continuing Turbidity & Total Suspended Solids Testing Perry Hosmer Continuing Mesh Durability and Cleaning Testing Karina Roundtree Build Prototype 2/14/13 Update assembly drawings 12/12/13 Define “clean” Kelly Stover, Karina Roundtree 12/15/13 Work with Kate to better define B9 assembly operation Daniel Anderson 1/27/14 FMECA on assembly Daniel Anderson 1/27/14 Life analysis of entire assembly Karina Roundtree 2/11/14 Life analysis of nylon brush 2/11/14 Include temp of hot air weld on the assembly procedure Include cleaning instructions in assembly procedure Add probability of water circumventing mesh to FMEA Add an engineering requirement for shipping cost Talk to Liz from P14418 for cheaper buckets and lids Kelly Stover 12/18/13 Cost/Benefit of using screwcap vs snap fit bucket lid (durability wise) 3/1/14 Create Risk Curve

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P14417: B9 Plastics - Particle Filter Detailed Design Review

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