1. By: Chris Boise Eric Cawley Matt Cross Megan Guarnieri-Cleary Jose Paredes Gideon Oladunjoye 12-10-13Team 140541

2.  Model Update  Chimney Movement  Actuator Precision  Cart Selection  Tubing Selection  Particle Deposition  Computer Update  VI Modification  Pump Comparison  Pump Characteristics  EcoFlo  Mainstream Feedback Loop  Ventilation  Impinger  IR Sensors  Electrical System Schematic  Dual H-Bridge  Thermocouple Conditioning  Ignition Coil  Lighting Fixture  Industry Comparison  BOM  Risk Assessment  Test Plan  MSD II Review  Follow Up Team  Schedule  Remaining Items 12-10-13Team 140542

3.  Incorporation of electronic cigarettes  3 modular design components  Lung Cast  Cambridge Filter  2 nd Impinger 12-10-13Team 140543

4.  10” stroke mini track actuator  Mounting bracket and clamps required 12-10-13Team 140544

5.  2 actuators in design  Controlled by rotating a power screw  Built in limit switches (hard)  1” - 2” per second  Reverse polarity for travel direction  0” -.250” stopping range  Limit - time increment of LabVIEW  Delay time of about 4 seconds 12-10-13Team 140545

6.  Rubbermaid: RCP4520-88BEI  $159.96  L= 36” W= 24” H= 33” Distance Between shelves= 28”  Max weight- 500lb 12-10-13Team 140546

7. TypeFlexibility (in) HardnessColorConnecti on Type Methanol Resistant Cost (per foot) Tygon PVC1SoftClearBarbedYes$1.50 Chemical resistant PVC 1.5SoftClearBarbedYes$0.34 Rigid Polypropylene 1.25Hard Semi- clear Push-to- connect Yes$0.64 Crack resistant Polyethylene 2Hard Semi- clear Push-to- connect Yes$0.20 Perfluoroalkoxy (PFA) 1HardClear Push-to- connect Yes$8.48  Best tubing choice?  All tubing is 3/8 OD, 1/4 ID 12-10-13Team 140547

8.  Sedimentation  Particles settle due to gravity  Diffusion  Deposition due to random particle movement  Impaction  Deposition due to particle collisions with walls or objects  Neglected impaction  Straight tubing 12-10-13Team 140548

9.  Assumptions  Incompressible flow  Sea level with standard atmosphere  Continuous fluid  Particles are modeled as spheres  Constant and uniform velocity  2-dimensional analysis  Ideal flow  Constant properties 12-10-13Team 140549

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16.  Sedimentation  When ε = 0.01  2 % of particles have settled  Between 0-1µm  Highest ε = 0.009  Negligible deposition due to sedimentation  Diffusion  When Δ = 0.0001  2 % of particles have settled  Our results are all below 4.0E-5  Negligible deposition due to diffusion 12-10-13Team 1405416

17. TypeOperating System LabVIEW Version Processor (GHz) RAM (GB) CurrentWindows XP SP2 8.52.52 Pentium 4.512 IdealWindows 82013Core 2 Duo2 UsedWindows 720092.4 Core 2 Duo2 Our ModelWindows 72013Core 2 Duo AMD 4  Computer Found by ME department  Well Suited to run latest version of LabVIEW  Windows 7, 256 MB RAM, 382 MB of disk space  FREE!!! 12-10-13Team 1405417

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23. ISO standard. Servo controlled. Creates a smoother puffing profile. Sinusoidal puffing profile with constant motor speed. DC step motor controlled. Theoretically more accurate puffing profile. Steady state puffing profile with constant motor speed.

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25. “A typical Techno servo gantry system sells for about $2,700 more than a stepper system.” “[servo motors] tend to be10% to 30% more expensive than similar stepper systems. Brushless servo motor systems tend to be 50% to 100% more.” http://www.techno-isel.com/Tic/H834/PDF/H834P041.pdf Browsing online cost range: $250-$5,000.

26.  Talked with Dr. Kempski  Devised a simple test to determine Restricting Parameters for dynamic response  A measured mass simulates required force to move syringe  Used to determine time constant response 12-10-13Team 1405426

27.  Sum of forces  Standard form  Vss ; Impedance  Time Constant 12-10-13Team 1405427

28.  Vss found to be 0.00559 m/s  Measured distance off syringe  Time constant Eqn.  F – Fsystem is the same as ‘mg’ from the test  ‘m’ measured to be 0.4137 kg 12-10-13Team 1405428

29.  Time constant Eqn.  Evaluating through, need to estimate carriage weight ‘m’  Estimated 0.3 kg  Time constant is 0.000413 sec  Under worst case of m=1 kg, τ = 0.00137 sec 12-10-13Team 1405429

30.  Pump specs (NE OEM 570)  Able to reach 45 mL/s  Valid for normal cigarettes  Matched sent flow rates  Unable to test dynamic response (time too reach) flow rates  Looking at E-cig’s  Need to reach ~120 mL/s  Pump DOES NOT MEET REQUIREMENT 12-10-13Team 1405430

31. Syringe sizes: Up to 60 cc, 140 mL partially filled Motor steps per revolution: 200 Microstepping: 1/8 to 1 depending on motor speed Motor to drive screw ratio: 60/15 Drive screw pitch: 16 rev/in Advance per step: 3.96875 μm to 31.75 μm depending on motor speed Syringe diameter: ~37.5 mm Volume per step: (31.75 μm)[1/1000 mm/μm]*pi*((37.5 mm)/2)^2 = 35.07 μL/step = 0.03507 mL/step

32. Machines have Wifi and Bluetooth to connect to Machines can not replace sidestream centrifugal pumps because the flow rate is too high EcoFlo 5 – 100 CFM in 1 CFM increments Replace side stream pump Only need 3 L/min = 0.1 CFM Machine is too large to replace Syringe & centrifugal pump exhale into unit Machines can easily be used for ventilation

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35. Note: EcoFlo has 2 blowers. This means that it can draw more air than it is supplying causing a negative pressure chamber. This way smoke does not leak out of chamber.

36. Centrifugal pump controlled by flowmeter to 3 L/min. Key Instruments FR4A40BVBN ($95): Range: 0.4-5 L/min Accuracy: ±3% of Full Scale = ±0.15 L/min Smaller model available with ±0.25 L/min accuracy. ($75) http://www.keyinstruments.com/standard-products/variable-area-flow-meters/4 flo-rite-series-fr-acrylic-body-flowmeters

37. Using: P*V = n*R*T Assuming: ṁ 1 = ṁ 2 Q 1 = Q 2 *[P 2 *T 1 /(P 1 *T 2 )]

38.  Vent: Current State  Leaks  Removal of all smoke  Running during testing 12-10-13Team 1405438

39.  Vent: Proposed-  Run pump exhaust tubing into the Eco-flo system  Eco-flo system will be operation during testing  Access doors 12-10-13Team 1405439

40.  Cage: Current State-  Lock in design between extruded aluminum and plastic with silicon sealant  No Gaskets  Not Removable 12-10-13Team 1405440

41.  Cage: Proposed-  Same lock in design  Use foam gaskets  Removable cage 12-10-13Team 1405441

42. Impiger most likely filled with methanol for all tests Impinger may be surrounded by dry ice or liquid nitrogen to motivate particles to condense Cooling the impinger is not needed for vapor phase, e-cigs. Other cigarette studies have inserted “a small plug of quartz wool and soda lime glass balls filled to a depth of approximately 6cm. The impingers are held in a polystyrene box filled with sufficient dry-ice to cover the main body of the impinger.” ● Notable design challenge: ○ If a liquid nitrogen bath is needed then a sufficient bath container will be needed

43. Failed to get past IR sensors to work. Talked with multiple professors with no luck. Question for customer: Would you like to buy new IR sensors for the automatic termination of the cigarette at its butt or terminate the cigarette after a set number of puffs? Past IR sensors were bought for $175 but we would recommend researching more robust IR sensors. http://www.eaton.com/Eaton/ProductsServices/Electrical/ProductsandServices/Automation andControl/SensorsLimitSwitches/PhotoelectricSensors/index.htm

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47.  Eliminates delay present in previous design.  Provides direction controls  1 driver for 2 actuators as oppose to 4 relays for 2 actuators. 12-10-13Team 1405447

48.  Specifications  Capable of driving 2 motors  Delivering 2 amps per motor  12 volts  Uses the L298n driver 12-10-13Team 1405448

49.  Circuit specifications  Reference Temperature Compensation(using the ADT7320)  High Gain instrumentation amplifier(gain of 100) 12-10-13Team 1405449

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55. Components  1: Sliding base  Using existing piece from previous project  2: Acrylic Shim  Electrically separates components 1 & 4 from 3  Need to machine  3: Aluminum Stand/Riser  Supports the from of the lighting coil  Connected to positive lead  Need to machine  4: Steel Body  Cutting down a piece from the original unit  Connected to negative lead  5: Lighting Coil 12-10-13Team 1405455

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57. Device: CH's CSM-SSM: Single Cigarette Smoking Machine Borgwaldt KC’s LX1 VITROCELL’s VC 1P14054 Price:$17,500$36,000$54,000$1,000 Pump:Piston PumpSyringe PumpPiston Pump Syringe Pump Pump Controler:Servo ControlledDC Step Motor Servo Controlled DC Step Motor Dead Volume:Low Footprint (m^2):0.20~0.20.280.56 Very Modular:YesNo Yes Enclosed Environment:No Yes Records a Smoker's Puffing Profile:No Yes

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65.  Total Unit Cost- $5,959.42  Does not include data sensors $14,387.50  Cost for this project- $1,371.96  2 nd impinger, Rubbermaid cart  Team is over the $1,000.00 budget! 12-10-13Team 1405465

66. IDRisk ItemEffectCauseLikelihoodSeverityImportance Action to Minimize RiskOwner Contingency Plan 1 System catching on fire Destruction of unit Misuse of Lighting method, Pump overheating, electrical short, cigarette ash133 Have a fire extinguisher in room, proper use of lighting methodMegan Salvage parts and rebuild ASAP 2 Over bearing of cart Destruction of system, loss of mobility, Weight exceeds cart tolerance, caster wheels failure, cart handle failure133 Follow cart specified FOSChris Salvage parts and rebuild ASAP 3 Cart instability Fragile equipment might break, flow performance Improper distribution of equipment133 Measure and proper distribution of equipmentChris Salvage parts and rebuild ASAP 12-10-13Team 1405466

67. 4 Smoke containment failure Fire alarm goes off, health concerns Improper sealing, poor ventilation, improper use of system212 Use of hand-held smoke detector, proper ventilation, proper sealant, possible time delay for opening doorEric Increase lab ventilation 5 Fragile equipment failure Faulty data, no data, expensive to replace, injury during removal Transportation, recklessness, proximity to heat source, pump vibration236 Use of Proper Protective Equipment, insulate fragile equipmentMatt Salvage parts and rebuild ASAP 6Faulty wiring Faulty data, no data, noisy data, equipment failure, electrical shorts Improper coating, improper wire gauge, burn out near heat source, improper grounding212 Double check against schematicGideon Salvage parts and rebuild ASAP 7 Collision of moving parts Damaged equipment, pinch hazards, technician injury Improper programming, faulty sensors, power surge212 Manually test systemJose Salvage parts and rebuild ASAP 12-10-13Team 1405467

68. 8Pump failure No flow, experimental failure, expensive to replace Loss of power, improper filtering, over use, incorrect gauging, improper set up111 Proper filtration, proper cleaning, proper coolingEric Troubleshoot problem then salvage parts and rebuild ASAP 9Contamination Faulty data, equipment destruction, lab hazards Leaks in tubing, faulty seals, backflow, improper sterilization236 Insuring proper seal, checking from pressure drop, use of hand-held smoke detectorMatt Disclaim that data may be faulty and pursue methods of improving 10Power failure No data, uncontrolled cigarette burn, no user interface Power grid failure, breaker trip, computer unplugged from wall313Secure power cordMeganPlug back into wall 11Over budget An angry Hanzlik and customer Unforeseen costs313 Use cheaper optionsChris Talk with customer about increasing budget 12 Human injury due to machining parts Dead team member Machine eating team member133 Use proper protection and become educated with local expertsEricGo to the hospital 13 Damaging machine due to machining parts Mad machinists and increased expenses Uneducated use of machine212 Ask experts for assistance before machiningMegan Inform technicians in lab 14 Machining faulty parts Increased expenses and schedule delayed Not checking proper dimensions313 Ask experts for assistance before machiningChris Rework and machine ASAP 12-10-13Team 1405468

72.  Chris-  Purchase all required items  Cage construction  Execute test plan to ensure all engineering requirements are meet  Eric-  Program pump  Pump to LabVIEW interface  Cage construction  Megan-  Ecoflo setup and manipulation  Lung Cast Bracket  LabVIEW feedback loops  Matt-  Supervising risk assessment document  Ecoflo setup and manipulation  Centrifugal pump & side stream construction  Jose-  LabVIEW programing and troubleshooting  Programing actuator movements  Lung Cast Bracket  Gideon-  Test each components for functionality  H-Bridge motor drivers  Design thermocouples conditioning circuitry  Valves and relays  Wire Organization 12-10-13Team 1405472

73.  Yes a follow-up team/CO-OP is needed.  What they will be focused on-  Manuals for-  Test procedures  Data collection  Maintenance/cleaning schedules  Operation/work instructions  LabVIEW optimization  Patent Research for reverse engineering for reproducibility  Humidification of the mouth/lung casting  Team should consist of - 2 ME & 1 ISE 12-10-13Team 1405473

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75.  Mounting bracket for main stream impinger, lung cast, or pelt filters  LabVIEW feedback loops  Purchasing all remaining components  Integration of Mainstream and Sidestream units 12-10-13Team 1405475

76.  Model Update  Chimney Movement  Actuator Precision  Cart Selection  Tubing Selection  Particle Deposition  Computer Update  VI Modification  Pump Comparison  Pump Characteristics  EcoFlo  Mainstream Feedback Loop  Ventilation  Impinger  IR Sensors  Electrical System Schematic  Dual H-Bridge  Thermocouple Conditioning  Ignition Coil  Lighting Fixture  Industry Comparison  BOM  Risk Assessment  Test Plan  MSD II Review  Follow Up Team  Schedule  Remaining Items 12-10-13Team 1405476

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