1. MSD I: System Design Review

2.  Team Introduction  Project Introduction  System Decomposition  Customer Needs  Concept Generation  Concept Selection  Risk Management  MSD I Work Schedule  Question and Answer Session

3. Team Rachael Hamilton (ChemE)Project Manager Michael Blachowicz (ME)Lead Engineer Sean Sutton(ChemE)Project Engineers Alex Kibbe (EE)Project Engineers Valentina Mejia (ME)Project Engineers Jonathan Waldron (EE)Edge Expert Customer Aaron Phipps, MPI Product Engineer Support Michael Zona, Project Guide Sarah Brownell, Faculty Champion

4. Goal Design a device that will successfully melt, and transport soluble and non- soluble wax Transport rate: 50lb/hr Soluble wax contains a fiberglass matrix Background Investment Casting Soluble and non-soluble wax MPI 55 C-Series Max Injector

5. 1. Accept wax in multiple forms 2. Hold wax in hopper 3. Melt wax from Hopper 4. Transport melted wax

6. Melt Wax Built-in Water soluble: flakes Store solid wax, prevent passage to subsequent step Transport of solid wax to melting zone Provide storage for blocks, pellets or flakes of solid wax Hold Wax Provide inlet for blocks, pellets, or flakes Provide access for manual or vacuum loading Accept Wax Regulate/maintain constant temperature Allow temperature adjustments for different waxes Convert electricity to heat Condition Electricity Provide Electricity Apply heat to wax Generate Heat Heat Wax Based on heat source Wall outlet Reduce heat losses? Prevent re-solidifying Distribute heat evenly to wax in melt zone Mechanisms: Induction/High frequency Heat source

7. Catch and consolidate wax Deliver melted wax to reservoir Transport liquid wax away from melter Transport melted wax Prevent clogging Reduce residue left behind Prevent clogging Provide electricity Reduce residue left behind Prevent clogging Maintain flowrate Generate Heat Melt Wax Regulate/maintain temperature Reduce heat losses? Distribute heat evenly to wax in transport zone Allow temperature adjustment for different waxes Convert electricity to heat Condition electricity

8. No.Need CN1Accommodates water soluble wax with or without glass fibers and mica filler. CN2Accommodates flakes, pellets, or solid blocks of wax CN3Melts wax at a flow rate of at least 50lb/hour CN4Prevents clogging during melting CN5Prevents clogging during funneling/transport to conditioner CN6Prevents wax from separating or burning CN7Allows a different wax to be loaded and melted without cleaning (little wax residue left on melter) CN8Allows loading by hand or vacuum loader CN9Mounts to the MPI Series 55 C Frame wax injector CN10Works in batches of at least 20 gallons of wax. CN11Prevents unmelted pellets or flakes from passing CN12Heats evenly CN13Accommodates non soluble wax

10. No.ImportanceNeed CN 6 9 Prevents wax from separating or burning CN 4 8 Prevents clogging during melting CN 1 7 Accommodates water soluble wax with or without glass fibers and mica filler CN 3 7 Melts wax at a flow rate of at least 50lb/hour CN 5 7 Prevents clogging during funneling/transport to conditioner

11. No.SpecificationsTargets ES 1Flow rate50 lb/hr ES 2Mounts directory to 55 Series C Frameyes/no ES 3Ramp Width<= 20 inches ES 4Maximum diameter of wax blocks accommodated> 12 inches ES 5Power requirements(240 VAC ES 6Operating temperature range100-250 F ES 7Time to reach set temperature from room tempYes/no ES 8Temperature difference across melt surface within operating range (no wax)<= 1 °C ES 9Diameter of critical dimension of flakes/pellets allowed to pass unmelted0 inches ES 10Temperature difference across plate while melting blocks, flakes, pellets<= 1 °C ES 11Volume melted in a batch>= 20 gal ES 12Withstands abrasions from wax with glass fibersyes/no ES 13Weight of wax remaining on melter after melting one hopper0 lbs ES 14Weight of wax remaining on funnel after melting one hopper0 lbs ES 15Wax burns or seperatesyes/no ES 16loads by vacuum loader or by handyes/no

12. RankES 1ES 2ES 3ES 4ES 5ES 6ES 7ES 8ES 9ES 10ES 11ES 12ES 13ES 14ES 15ES 16 CN 179 9 39 31 CN 261 9 11 9131 31 CN 379 3993 33 333 CN 483 39 9111 913 CN 573 39 9191 93 CN 693 39 9 9 31 9 CN 751 1 3 3131 9931 CN 84 1 3 9 CN 94 9919 3 3 1 CN 1031111 9 9 CN 1131 339991 111 CN 1233 9939191 339 CN 131 9 331313331

13. No.Importance Specifications ES 613.29Operating temperature range(170-220 F mimimum, 100-250 F ideal) ES 810.07Temperature difference across melt surface within operating range (no wax) <=1C ES 108.11Temperature difference across plate while melting blocks, flakes, pellets(minimize) ES 157.62Wax burns or seperates ES 17.3Flow rate of 50lb/hr ES 135.28Weight of wax remaining on melter after melting one hopper (minimize, <current) ES 55.08Power requirements( 240 VAC, low current) ES 144.95Weight of wax remaining on funnel after melting one hopper(minimize<current) ES 114.56Volume melted in a batch (>= 20 gallons) ES 93.49Diameter of critical dimension of flakes/pellets allowed to pass unmelted(minimize, ideal 0) ES 73.22Time to reach set temperature from room temp(<= current) ES 123.16Withstands abrasions from wax with glass fibers ES 162.8loads by vacuum loader or by hand ES 42.28Maximum diameter of wax blocks accommodated > 12 inches ES 21.27Mounts directory to 55 Series C Frame ES 31.27Width <= 20 inches

14.  Key system component: Melt wax  Two main concepts: Modified waffle heater wax melter Heated, stirred tank process  Determines choice of other components

15. Selection CriteriaRank (1-3) Current Honeycomb Parabolic Ramps Coated Waffle Spiked Waffle Heated Stir tank Waffle with diff holes Multi stage heater Mesh Pressurized Waffle Plate Heating Survival of wax fibers303030-3 3300 Temperature control3000000300-30 Melt rate30-3 003 0 0 Risk of burning wax30-3 0030003 Sensitivity to viscosity303-3 0033033 Power consumption202-2 0 0 0 Possibility of unmelted wax passing through system20-2 002 000 Cleaning203222-222022 Cost1001 1 Complexity100110 1 Abrasion resistance100010 0 Total02-9-82-981-203

16. Selection CriteriaRank (1-3) Current (hand fed hole) Current (Vacuum fed)Funnel Rotating SeederTrap door Rotating feeder w/ vacuum Survival of Wax fibers300000-3 Power Requirements20-20 Handles flakes, pellets, block10 0 Staffing requirements101001 Cost10 Complexity100 Total0-4-2-5 -7

17. Selection CriteriaRank (1-3)HopperVatCylinder hopperTank with feeding wheel Survival of Wax Fibers3000 Volume/capacity20000 Power requirements2000 Handles flakes, pellets, blocks1000 Abrasion resisitance10000 Cost100 Complexity1000 Total00-5

18. Selection CriteriaRank (1-3)CurrentRamp w/ guidesConePumpConveyor belt Survival of fibers in wax300000 Temperature control30333-3 Ability to keep melted303330 Melt rate303330 Risk of burning wax3000-30 Sensititivity to viscosity3000-3 Power consumption2000-2 Cleaning2022-2 Cost1000 Complexity1000 Abrasion resistance10000 Total011 -4-12

19. Accept wax: Hand-fed hole Hold wax: Cylindrical vat Melt wax: Heating and stirring mechanism Transport wax: Cone

21. IDRisk ItemCauseEffect Likelihood Severity Importance Action to minimize riskOwner Technical Risks AWax gets damagedExcessive temperatures Room fills with dangerous levels of CO2236 Ensure adaquate temperature controls and safety systemsMike BParts don't arrive on timeParts are ordered too late Machine cannot be assembled in time122 Order parts before winter quarterRachael COur fabrication skill set Parts required for design are beyond our ability to make Machine cannot be assembled in time122Limit part complexityMike DLab space cannot be secured Fume hoods and 240 V outlets tend not to go togetherMachine cannot be tested339 Ask everyone on campusTeam EDesign is too complex Team overcomplicates the designs Machine is very expensive, large, and hard to maintain122 Rule out overly elaborate schemes like lasersMike FInvalid assumptions Insufficient knowledge of non-Newtonian fluid with fibers Design decisions based on false assumptions236 Consult experts when neededTeam

22. IDRisk ItemCauseEffect Likelihood Severity Importance Action to minimize riskOwner Project risks ATeam member has to drop out Sickness or family issuesMore work for less people122Drink orange juiceTeam BProject runs over budget High cost of fabricationProject cannot be completed122 Get quotes for parts and select items within our budgetRachael C Team members fail to accomplish assigned tasks Laziness or lack of time The rest of the team has to pick up the slack224 Time management and team motivationTeam D Lack of skill in group to accomplish goal Insufficient knowledge and experience Poor design decisions236 Consult experts when needed Team LikelihoodSeverity Scale 1 - This cause is unlikely to happen1 - Minimal Impact - This will have little to no effect on the outcome of the project 2 - This cause is somewhat likely to happen2 - Impact Noticable - Machine functions but may not meet all specifications 3 - This cause is very likely to happen3 - Impact Severe - Project will likely fail to deliver a functional product on time and in budget

23. Week 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9Week 10 TasksMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSSMTWRFSS 1. Meet group members and guide- Team 2. Familiarize with project - Team 3. Conduct customer interview - Team 4. Document customer specifications - Team 5. Identify team roles -Team 6. Develop quality function deployment chart - Team 7. Develop house of quality – Jon and Sean 8. Develop functional decomposition - Mike 9. Concept generation - Team 10. Complete Pugh diagrams - Team 11. Concept selection - Team 12. Prepare for System Design Review - Team 13. Revise concepts based on feedback from review - Team 14. Develop concepts for detailed design – Valentina and Mike 15. Draw-up system schematics – Valentina and Mike 16. Create bill of materials – Rachael and Mike 17. Prepare for Detailed Design Review - Team 18. Revise detailed design based on feedback from review - Team 19. Order parts - Rachael 20. Prepare for MSD II – Team 21. Develop schedule for MSD II - Rachael