MSD I: System Design Review

P13651: MPI WAX MELTER

AGENDA

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

INTRODUCTION

• TeamRachael Hamilton (ChemE) Project ManagerMichael Blachowicz (ME) Lead EngineerSean Sutton (ChemE) Project EngineersAlex Kibbe (EE) Project EngineersValentina Mejia (ME) Project EngineersJonathan Waldron (EE) Edge Expert

• CustomerAaron Phipps, MPI Product Engineer

• SupportMichael Zona, Project GuideSarah Brownell, Faculty Champion

PROJECT INTRODUCTION

• 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

1. Accept wax in multiple forms

2. Hold wax in hopper

3. Melt wax from Hopper

4. Transport melted wax

SYSTEM ARCHITECTURE

FUNCTIONAL DECOMPOSITION

Melt WaxMelt Wax

Built-inBuilt-in

Water soluble: flakesWater soluble: flakes

Store solid wax, prevent passage to subsequent stepStore solid wax, prevent passage to subsequent step

Transport of solid wax to melting zoneTransport of solid wax to melting zone

Provide storage for blocks, pellets or flakes of solid wax

Provide storage for blocks, pellets or flakes of solid waxHold WaxHold Wax

Provide inlet for blocks, pellets, or flakesProvide inlet for blocks, pellets, or flakes

Provide access for manual or vacuum loadingProvide access for manual or vacuum loading

Accept WaxAccept Wax

Regulate/maintain constant temperatureRegulate/maintain constant temperature

Allow temperature adjustments for different waxesAllow temperature adjustments for different waxes

Convert electricity to heatConvert electricity to heat

Condition ElectricityCondition Electricity

Provide ElectricityProvide Electricity

Apply heat to waxApply heat to wax

Generate HeatGenerate Heat

Heat WaxHeat Wax

Based on heat sourceBased on heat source

Wall outletWall outlet

Reduce heat losses?Reduce heat losses?

Prevent re-solidifyingPrevent re-solidifying

Distribute heat evenly to wax in melt zoneDistribute heat evenly to wax in melt zoneMechanisms: Induction/High frequency

Mechanisms: Induction/High frequency

Heat sourceHeat source

Catch and consolidate waxCatch and consolidate wax

Deliver melted wax to reservoirDeliver melted wax to reservoir

Transport liquid wax away from melterTransport liquid wax away from melter

Transport melted waxTransport melted wax

Prevent cloggingPrevent clogging

Reduce residue left behindReduce residue left behind

Prevent cloggingPrevent clogging

Provide electricityProvide electricity

Reduce residue left behindReduce residue left behind

Prevent cloggingPrevent clogging

Maintain flowrateMaintain flowrate

Generate HeatGenerate Heat

Melt WaxMelt Wax

Regulate/maintain temperatureRegulate/maintain temperature

Reduce heat losses?Reduce heat losses?

Distribute heat evenly to wax in transport zoneDistribute heat evenly to wax in transport zone

Allow temperature adjustment for different waxesAllow temperature adjustment for different waxes

Convert electricity to heatConvert electricity to heat

Condition electricityCondition electricity

FUNCTIONAL DECOMPOSITION PT. 2

CUSTOMER NEEDSNo. Need

CN1 Accommodates water soluble wax with or without glass fibers and mica filler.

CN2 Accommodates flakes, pellets, or solid blocks of wax

CN3 Melts wax at a flow rate of at least 50lb/hour

CN4 Prevents clogging during melting

CN5 Prevents clogging during funneling/transport to conditioner

CN6 Prevents wax from separating or burning

CN7Allows a different wax to be loaded and melted without cleaning (little wax residue left on melter)

CN8 Allows loading by hand or vacuum loader

CN9 Mounts to the MPI Series 55 C Frame wax injector

CN10 Works in batches of at least 20 gallons of wax.

CN11 Prevents unmelted pellets or flakes from passing

CN12 Heats evenly

CN13 Accommodates non soluble wax

PRIORITIZING CUSTOMER NEEDS

TOP CUSTOMER NEEDS

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

ENGINEERING SPECIFICATIONSNo. Specifications Targets

ES 1 Flow rate 50 lb/hr

ES 2 Mounts directory to 55 Series C Frame yes/no

ES 3 Ramp Width <= 20 inches

ES 4 Maximum diameter of wax blocks accommodated > 12 inches

ES 5 Power requirements( 240 VAC

ES 6 Operating temperature range 100-250 F

ES 7 Time to reach set temperature from room temp Yes/no

ES 8 Temperature difference across melt surface within operating range (no wax) <= 1 °C

ES 9 Diameter of critical dimension of flakes/pellets allowed to pass unmelted 0 inches

ES 10 Temperature difference across plate while melting blocks, flakes, pellets <= 1 °C

ES 11 Volume melted in a batch >= 20 gal

ES 12 Withstands abrasions from wax with glass fibers yes/no

ES 13 Weight of wax remaining on melter after melting one hopper 0 lbs

ES 14 Weight of wax remaining on funnel after melting one hopper 0 lbs

ES 15 Wax burns or seperates yes/no

ES 16 loads by vacuum loader or by hand yes/no

HOUSE OF QUALITY

Rank ES 1 ES 2 ES 3 ES 4 ES 5 ES 6 ES 7 ES 8 ES 9 ES 10 ES 11 ES 12 ES 13 ES 14 ES 15 ES 16

CN 1 7 9 9 3 9 3 1

CN 2 6 1 9 1 1 9 1 3 1 3 1

CN 3 7 9 3 9 9 3 3 3 3 3 3

CN 4 8 3 3 9 9 1 1 1 9 1 3

CN 5 7 3 3 9 9 1 9 1 9 3

CN 6 9 3 3 9 9 9 3 1 9

CN 7 5 1 1 3 3 1 3 1 9 9 3 1

CN 8 4 1 3 9

CN 9 4 9 9 1 9 3 3 1

CN 10 3 1 1 1 1 9 9

CN 11 3 1 3 3 9 9 9 1 1 1 1

CN 12 3 3 9 9 3 9 1 9 1 3 3 9

CN 13 1 9 3 3 1 3 1 3 3 3 1

ENGINEERING SPECS No. Importance Specifications

ES 6 13.29 Operating temperature range(170-220 F mimimum, 100-250 F ideal)

ES 8 10.07 Temperature difference across melt surface within operating range (no wax) <=1C

ES 10 8.11 Temperature difference across plate while melting blocks, flakes, pellets(minimize)

ES 15 7.62 Wax burns or seperates

ES 1 7.3 Flow rate of 50lb/hr

ES 13 5.28 Weight of wax remaining on melter after melting one hopper (minimize, <current)

ES 5 5.08 Power requirements( 240 VAC, low current)

ES 14 4.95 Weight of wax remaining on funnel after melting one hopper(minimize<current)

ES 11 4.56 Volume melted in a batch (>= 20 gallons)

ES 9 3.49Diameter of critical dimension of flakes/pellets allowed to pass unmelted(minimize, ideal 0)

ES 7 3.22 Time to reach set temperature from room temp(<= current)

ES 12 3.16 Withstands abrasions from wax with glass fibers

ES 16 2.8 loads by vacuum loader or by hand

ES 4 2.28 Maximum diameter of wax blocks accommodated > 12 inches

ES 2 1.27 Mounts directory to 55 Series C Frame

ES 3 1.27 Width <= 20 inches

CONCEPT SELECTION

Key system component: Melt wax Two main concepts:

• Modified waffle heater wax melter• Heated, stirred tank process

Determines choice of other components

PUGH SELECTION – MELT WAX

Selection Criteria Rank (1-3)

Current

Honeycomb

Parabolic

Ramps

Coated Waffle

Spiked Waffle

Heated Stir tank

Waffle with diff holes

Multi stage heater

MeshPressurized Waffle Plate Heating

Survival of wax fibers 3 0 3 0 3 0 -3 -3 3 3 0 0

Temperature control 3 0 0 0 0 0 0 3 0 0 -3 0

Melt rate 3 0 -3 -3 -3 0 0 3 -3 0 -3 0

Risk of burning wax 3 0 -3 -3 -3 0 0 3 0 0 0 3

Sensitivity to viscosity 3 0 3 -3 -3 0 0 3 3 0 3 3

Power consumption 2 0 2 -2 -2 0 -2 -2 0 -2 0 -2

Possibility of unmelted wax passing through system 2 0 -2 -2 -2 0 0 2 -2 0 0 0

Cleaning 2 0 3 2 2 2 -2 2 2 0 2 2

Cost 1 0 0 1 -1 -1 -1 -1 -1 -1 1 -1

Complexity 1 0 0 1 1 0 -1 -1 -1 -1 1 -1

Abrasion resistance 1 0 -1 0 0 1 0 -1 0 -1 -1 -1Total 0 2 -9 -8 2 -9 8 1 -2 0 3

PUGH SELECTION – ACCEPT WAX

Selection Criteria Rank (1-3)

Current (hand fed

hole)Current

(Vacuum fed) FunnelRotating Seeder Trap door

Rotating feeder w/ vacuum

Survival of Wax fibers 3 0 0 0 0 0 -3

Power Requirements 2 0 -2 0 -2 -2 -2

Handles flakes, pellets, block 1 0 -1 -1 -1 0 -1

Staffing requirements 1 0 1 0 0 -1 1

Cost 1 0 -1 -1 -1 -1 -1

Complexity 1 0 -1 0 -1 -1 -1

Total 0 -4 -2 -5 -5 -7

PUGH SELECTION – HOLD WAX

Selection Criteria Rank (1-3) Hopper Vat Cylinder hopperTank with feeding

wheel

Survival of Wax Fibers 3 0 0 0 -1

Volume/capacity 2 0 0 0 0

Power requirements 2 0 0 0 -1

Handles flakes, pellets, blocks 1 0 0 0 -1

Abrasion resisitance 1 0 0 0 0

Cost 1 0 0 -1 -1

Complexity 1 0 0 0 -1

Total 0 0 -1 -5

PUGH SELECTION – TRANSPORT WAX

Selection Criteria Rank (1-3) Current Ramp w/ guides Cone Pump Conveyor belt

Survival of fibers in wax 3 0 0 0 0 0

Temperature control 3 0 3 3 3 -3

Ability to keep melted 3 0 3 3 3 0

Melt rate 3 0 3 3 3 0

Risk of burning wax 3 0 0 0 -3 0

Sensititivity to viscosity 3 0 0 0 -3 -3

Power consumption 2 0 0 0 -2 -2

Cleaning 2 0 2 2 -2 -2

Cost 1 0 0 0 -1 -1

Complexity 1 0 0 0 -1 -1

Abrasion resistance 1 0 0 0 -1 0

Total 0 11 11 -4 -12

PROPOSE CONCEPT

• Accept wax: Hand-fed hole• Hold wax: Cylindrical vat• Melt wax: Heating and

stirring mechanism• Transport wax: Cone

MODELED FLUID FLOW IN HEATED STIR TANK

RISK MANAGEMENT: TECHNICAL RISKS

ID Risk Item Cause Effect

Likelihood

Severity

Importance

Action tominimize risk Owner

  Technical Risks              

A Wax gets damaged Excessive temperaturesRoom fills with dangerous levels of CO2 2 3 6

Ensure adaquate temperature controls and safety systems Mike

B Parts don't arrive on timeParts are ordered too late

Machine cannot be assembled in time 1 2 2

Order parts before winter quarter Rachael

C Our fabrication skill set

Parts required for design are beyond our ability to make

Machine cannot be assembled in time 1 2 2

Limit part complexity Mike

D Lab space cannot be secured

Fume hoods and 240 V outlets tend not to go together Machine cannot be tested 3 3 9

Ask everyone on campus Team

E Design is too complexTeam overcomplicates the designs

Machine is very expensive, large, and hard to maintain 1 2 2

Rule out overly elaborate schemes like lasers Mike

F Invalid assumptions

Insufficient knowledge of non-Newtonian fluid with fibers

Design decisions based on false assumptions 2 3 6

Consult experts when needed Team

RISK MANAGEMENT: PROJECT RISKS

ID Risk Item Cause Effect

Likelihood

Severity

Importance

Action tominimize risk Owner

  Project risks              

ATeam member has to drop out

Sickness or family issues More work for less people 1 2 2 Drink orange juice Team

B Project runs over budgetHigh cost of fabrication Project cannot be completed 1 2 2

Get quotes for parts and select items within our budget Rachael

CTeam members fail to accomplish assigned tasks

Laziness or lack of time

The rest of the team has to pick up the slack 2 2 4

Time management and team motivation Team

DLack of skill in group to accomplish goal

Insufficient knowledge and experience Poor design decisions 2 3 6

Consult experts when needed Team

Likelihood Severity 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 happen 2 - Impact Noticable - Machine functions but may not meet all specifications  

3 - This cause is very likely to happen

3 - Impact Severe - Project will likely fail to deliver a functional product on time and in budget  

NEXT STEPS – MSD I SCHEDULE

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10Tasks M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S M T W R F S S1. 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

QUESTIONS?