1. P14417: B9 Plastics - Particle Filter Subsystem Design Dan Anderson / Thomas Heberle / Perry Hosmer / Karina Roundtree / Kelly Stover October 29, 2013

2. Customer Requirements (On Edge)On Edge Category Customer Req. # ImportanceDescription Ease of UseCR19 Easy to prepare for use Ease of UseCR23 Lightweight for transport Ease of UseCR33 Has a minimal start-up period Ease of UseCR49 Operates using energy available naturally EconomicsCR59 Filter is inexpensive EconomicsCR69 Usable by a family of 5, for 2-5 years w/out full replacement EconomicsCR79 Requires no consumables for operation, except cheap & locally available materials FunctionalityCR89 Improves UV transmission Functionality CR99 Decreases turbidity FunctionalityCR109 Decreases total suspended solids FunctionalityCR113 Does not negatively affect the taste of the water SafetyCR129 Does not negatively affect the safety of drinking water FunctionalityCR133 Filters enough water for a family of 5

3. Engineering Requirements (On Edge)On Edge

4. Filter Clean / recharge filter Access Water Collect Water (bucket) Introduce water and filter Separate water and particles Generate different forces on the particles and the water Convert energy to work to separate Isolate and contain filtered water Restrict contamination Engineering Metrics & Specifications: Functional Decomposition: Customer RequirementFunctionMetricsDirectionUnitsMarginalTargetTest Plan Easy to Clean/Recharge Easy to prepare for useTime to clean v Minutes105Test #1 Easy to Clean/Recharge Easy to prepare for use Number of Tools Required for (dis)assembly by the end user v -21Test #2 Lightweight for transport. Minimize weight of filterWeight in LBs v LBs (Pounds)105Test #3 Has a minimal start-up period.Minimize start-up Time elapsed between beginning of pour and first water that enters the bucket v s (seconds)3010Test #4 Operates using only energy available naturally (gravity, human power, etc.) Doesn't need power sourceBinary (Yes/No) - --NoTest #5 Filter is Inexpensive Minimize cost of filterTotal cost to produce v $ (dollars)2520Test #6 Usable by a family of 5, for 2-5 years w/out full replacement Maximize durability of filterMean Time To Failure ^ Number of Uses7303650Test #7 Requires no consumables for operation, except for very cheap & locally available materials (salt, soap, sand, etc.) Minimize cost to maintainAnnual cost to operate v $ (dollars)20Test #8 Removes Particles (turbidity/total suspended solids), improves UV TRANSMISSIONTurbidity is decreasedPercentage Decrease v %>50%>75%Test #9 Removes Particles (turbidity/total suspended solids), improves UV TRANSMISSION total suspended solids decreasedPercentage Decrease v %>50%>75%Test #9 Removes Particles (turbidity/total suspended solids), improves UV TRANSMISSION remove particles larger than 5 umPercentage Decrease v %>50%>75%Test #9 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 - %>50%>75%Test #10 No hazardous releases Doesn't produce hazardous release, no chemicals addedBinary (Yes/No) - --NoTest #11 Usable by a family of 5, for 2-5 years w/out full replacement Support World Health Org. Est. on Use needs for consumption (equated to flow rate); for 5 person home for 2-5 years Flowrate ^ lpm0.03945 gal in.5hr *Items in Red are Metrics and Specs that map to Customer Requirements or Risk Assessment Tasks

5. Filter Assembly

7. Water Characterization Key metrics for consideration: o Turbidity: “cloudiness or haziness of a fluid caused by individual particles, normally invisible to the naked eye.” o Total Suspended Solids: measurement of water quality, dry weight of particles that would be trapped by a filter. Water source used: Genesee River Water o Represents possible use conditions in the developing world. o Used as litmus test for Better Water Maker to determine process improvement.

8. Water Characterization Resource contacted: Dr. Scott Wolcott (RIT Professor) Testing: Several samples were taken from the Genesee during varying conditions that could affect turbidity and TSS. Three samples collected and tested. o Gen 1: Collected Oct. 5 th, hadn’t rained in a while, tested on Oct. 19 th. o Gen 2: Collected Oct. 18 th, moderate rain, tested on Oct. 19 th. o Gen 3: Collected Oct. 23 rd, frequent rain preceding days, test on Oct. 24 th. o Also considered brewery waste water provided by Dr. Wolcott in analysis.

9. Water Characterization

11. Possible sources of error: time between insertion/removal from oven, minor spillage, etc.

12. Identification of Critical Subsystems Mesh Fasteners Seal Sandwich Assembly Outer Walls

13. Component Feasibility Mesh

14. Materials Cheese Cloth o #90 grade(44 x 36 Vertical x Horizontal threads per inch) o Cheap and easily adaptable o Not easy to clean effectively Plastic Mesh o Cheaper o Not as small a mesh o Easily deformable Stainless Steel Mesh o Small mesh size o Durable

15. Stainless Steel 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.

16. Flow Rate Considerations

17. Comparison and Conclusions: o ΔP, in this case = 1 psi = 6,895 Pa o Based on new specification for flow rate (Q= 0.394 L/min), we would achieve 14,102 times the marginal flow rate value. It can be concluded that using 5 micron steel mesh is a good course of action to reach desired flow rate. o Max ΔP in our case is approximately 2,632 Pa Assumes max possible volume in upper bucket = 5 gallons Using approximate dimensions for the filter assembly (i.e. D = 30 cm)

18. Flow Rate Considerations

19. Max possible pressure = 2,620 Pa, about 2.6 times less than the pressure difference used in the S.S. specification. Pressure is a function of open area available (diminishes through clogging of filter) and weight of water above filter. Difficult to determine a mathematical model since there is some inherent variable in the water properties.

20. Test Plan: Flow Rate Use available “pond pump” to generate a steady flow of a known rate over a simple filter mesh assembly at Genesee River. Determine based on rate of pump output, how long it will take to introduce five gallons of water to assembly. Determine adequacy of five micron Stainless Steel mesh. Introduce filter complexity to improve process.

21. Stress Testing F w =pVg=185.7N F s =pVg=1826.5N P mesh =(F w +F s )/A mesh =48.83kPa

22. Stress Modeling - Von Mises

23. Stress Testing - Displacement

24. Stress Modeling - Factor Safety

25. Cleaning Cleanliness is essential for maximum resistance to corrosion. Never use abrasive powders or materials on stainless. Always use a soft cloth. Mild detergents and soap can be used but those containing chloride detergents should be avoided.

26. Risks Bacteria forming on sand o Rapid sand filtration - 20m/hour  Chemically pre-treated o Slow sand filtration - 0.4m/hour  Just scrape off the biofilm on sand surface

27. Component Feasibility Seal

28. Seal Considerations Type of seal application: o Low temperature – T max = 120 F o Low pressure: W water, max = 185 N = 41.6 lb Need two seals for top and bottom of sandwich assembly Desire low compressibility Supplier Contacted:

29. Seal Considerations Determination: Rubber Gasket application Example:

30. Seal Considerations Specifications: o Max Temp. = 200 F o Max. Pressure = 250 psi = 1.724 MPa Supplier will give us free gaskets upon completion of detailed design drawings, cut to our specification.

31. Seal Considerations: Test Plan Use standard gasket “sealability” test: ASTM F37 -06 Testing capabilities available through Garlock

32. Component Feasibility Other Key Components

33. Fasteners Fastener Choice is dependent on the design requirements and the environment in which the fastener will be used. Threaded vs. Non-Threaded o Non-threaded is not ideal for continuous dis and reassembly o Threaded fasteners provide ease of assembly and reusability without much wear. Two main threaded fasteners: o Nuts & Bolts o Screws *** Although this may not be necessary if captive or welded nuts can be used. Fastener Materials with high resistance to weather and/or corrosion: Stainless Steel Titanium Brass Bronze Of these four materials, Titanium is the most lightweight. But considering the costs of each, stainless steel is the most feasible material to use in our Filter. Summary: We should use stainless steel bolts with wing nuts. The wing nuts allow for tool-less dis and re-assembly, which is a great convenience in our application.

34. Water Usage Average of 2.6 liters / day / person needed Therefore a family of 5 needs 13 liters or 3.4 gallons / day

35. Lifting Task Used NIOSH Lifting Equation to evaluate the feasibility of the task Assumption made on height of media Recommended Weight Limit: 33.5 lbs 3.4 Gallons of Water ~ 28.4 lbs 5 Gallons of Water ~ 41.7 lbs* *Lifting Index: 1.25, slight risk for low-back pain or injury

36. Preliminary Bill of Materials

37. Engineering Requirements: Test Plan (On Edge)On Edge

38. Risk Assessment (On Edge)On Edge IDRisk ItemImportanceAction to Minimize RiskOwnerDate OpenedDate Closed (or expected) Describe the risk brieflyL*S What actions will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occuring Who will ensure that this risk is fully mitigated? 1Cleaning is difficult9 Supply cleaning instruction, minimize number of parts, minimize disassembly/assembly time, mistake proof up/down directionsTom9/17/20132/14/2014 2Costs more than $25/unit9Design to be low costKelly9/17/201311/28/2013 3Stress concentration6Spread load out around edge of filterPerry9/17/201311/21/2013 4 6Calculate necessary force ratingPerry9/17/201311/21/2013 5Flow rate is too slow6 Increase surface area of filter, find more porous materials, define minimum flow rate to test against (use scenario) Test PlanPerry10/1/201311/7/2013 6Sand may corrode steel6Pack sand tightly, select different material for mediumKarina10/22/201310/31/2013 7Filter fails "warm-up" time test6Introduce an additional mesh screenTom10/24/20134/7/2014 8User not detecting tear in filter4No hidden filter, instruct user to inspect both sides of "sandwich"Dan10/1/201310/8/2013 9Bacteria may build up in filter4 Chemically treat sand to prevent material build up. Select different material for mediumKarina10/10/201310/31/2013 10Corrosion3 Use materials which won't corrode, provided clear cleaning instructionKarina9/17/201310/16/2013 11Weight is too much3Ergonomic study, design to allow women and children to useKelly9/17/201310/21/2013 12 Incorrect usage, sandwich inserted upside-down3Use visuals whenever possible, minimize text, poka-yokeDan10/3/201312/5/2013 13Stability issues with bucket2 Design proper attachments, make sure surface is level prior to use, worse case - will the bucket withstand that?Dan9/17/201311/26/2013 14 Filter introduces bad taste to water2Use non corrosive materialsPerry10/24/20133/7/2014 15Leakage1Use rubber gasket, clamped down tightlyPerry9/17/201311/19/2013 16Filter may be too tall1Calculate necessary height ASAP, test for fill amountKelly9/17/201310/1/2013

39. Risk Growth

40. Project Plan

41. Detailed Design: Diagram of Activities Component Selection Make/Buy Decisions Part Drawings Assembly Drawings Complete Bill of Materials Risk Assessment (Detailed Design) Engineering Analysis Simulation Models Input from Eng. Analysis & Research. Demonstrate the more experimental and/or derived metrics and specs. Proof of Concept Test Plan Develop Assembly Process Detail test procedures to be executed in MSD 2: Build & Test. Hardware Design Complete Drawing Package Assembly Process Bill of Materials Budget Overview Risk Assessment Testing Plan (for MSD 2) Hardware Design Complete Drawing Package Assembly Process Bill of Materials Budget Overview Risk Assessment Testing Plan (for MSD 2) Budget Review of BOM Detailed Design Demonstrate feasibility and meeting specifications Design for manufacturability, cost, & repeatability (assembler perspective). Ensure the proposed design can be completed with the Budget constraint.

42. Questions