p13651: mpi wax melter
DESCRIPTION
MSD I: System Design Review. P13651: MPI Wax Melter. Team Introduction Project Introduction System Decomposition Customer Needs Concept Generation Concept Selection Risk Management MSD I Work Schedule Question and Answer Session. Agenda. Team - PowerPoint PPT PresentationTRANSCRIPT
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• Team
Rachael 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 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 waxHold 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 zoneMechanisms: Induction/High frequency
Heat source
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
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
CN7 Allows 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 NEEDSNo. 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/noES 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 °CES 9 Diameter of critical dimension of flakes/pellets allowed to pass unmelted 0 inchesES 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 lbsES 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 SpecificationsES 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) <=1CES 10 8.11 Temperature difference across plate while melting blocks, flakes, pellets(minimize)ES 15 7.62 Wax burns or seperatesES 1 7.3 Flow rate of 50lb/hrES 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 fibersES 16 2.8 loads by vacuum loader or by handES 4 2.28 Maximum diameter of wax blocks accommodated > 12 inchesES 2 1.27 Mounts directory to 55 Series C FrameES 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 -1Handles 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
happen3 - Impact Severe - Project will likely fail to deliver a functional product on
time and in budget
NEXT STEPS – MSD I SCHEDULEWeek 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10
Tasks 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?