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P13651: Soluble Wax Melter. Project Team: Rachael Hamilton – Team Leader Michael Blachowicz – Lead Engineer Valentina Mejia – Engineer Jonathan Waldron – Engineer Alex Kibbe – Engineer Sean Sutton - Engineer. Agenda. Project Description Final Design Concept Project Development - PowerPoint PPT Presentation
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P13651: Soluble Wax MelterProject Team:
Rachael Hamilton – Team LeaderMichael Blachowicz – Lead
EngineerValentina Mejia – EngineerJonathan Waldron – EngineerAlex Kibbe – EngineerSean Sutton - Engineer
Agenda• Project Description• Final Design Concept• Project Development• Testing Results• Current state of project• Objective project evaluation• Conclusions• Questions
Project DescriptionProject Goal: Design a device that will
successfully melt and transport soluble and non-soluble wax
Original Design for MPI 55 C-series Wax MelterScaled back project to focus on
wax processingAchieve 5o lbs/hour flow rateDoes not burn, separate waxNo clogging of wax
Design SpecificationsNo. Importance Specifications
ES 6 13.29Operating temperature range(170-220 F mimimum, 100-250 F ideal)
ES 8 10.07Temperature difference across melt surface within operating range (no wax) <=1C
ES 15 7.62 Wax burns or seperates ES 1 7.3 Flow rate of 50lb/hr
ES 13 5.28Weight of wax remaining on melter after melting one hopper (minimize, <current)
ES 5 5.08 Power requirements (240 VAC, low current)
ES 14 4.95Weight of wax remaining on funnel after melting one hopper(minimize<current)
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 4 2.28 Maximum diameter of wax blocks accommodated > 12 inches ES 3 1.27 Width <= 20 inches
Product DevelopmentRealized Schedule: issues with
Finalizing design: Scaled-back project in MSD II Week 3
Construction set-backsMSD I Winter MSD II
Stage 1Concept Development
Stage 2 Detailed Design
Stage 3Feasibility Analysis
Stage 4 Final Design
Stage 5 Construction
Stage 6 Testing
Stage 7Final Review
Final Design Concept
Final Design Concept
Realized machine: A known amount of wax is hand fed into the top of the tank, it is allowed to melt until contents appear completely melted, hand actuated door at base of tank is opened to let out wax to bucket placed under the machine
Testing ResultsTime to steady state with no wax
Issue with PID controller initially, led us to just use on/off control.
Time to steady state was around four minutes from room temperature and with a Tsp of 180°F.
Steady state was about reached here in this test, but the control was not set up properly and began to cause the temperature to fluctuate.
Testing ResultsTested the temperature difference across the surface
around the inside of the tank (melting surface).Tested the difference from the base to the top while
heatingConcluded that there is a temperature difference from
the base of the tank to the top because of heat loss due to convection at the top
Tested radial difference from the base to the topConcluded that there was a minimal temperature
difference along a radial axis in the tank, +-5 °FWith thermocouple variation, the temperature is close
to uniform along a radius
Testing Resultsat Base 3 inches up 3 inches upT Tactual T Tactual T Tactual
269 275.4031 220 224.1295 210 213.6655266 272.2639 225 229.3615 210 213.6655266 272.2639 226 230.4079 216 219.9439268 274.3567 225 229.3615 210 213.6655266 272.2639 221 225.1759
3 inches up 3 inches up(2 from top)T Tactual T Tactual
202 205.2943 173 174.9487200 203.2015 178 180.1807204 207.3871 171 172.8559202 205.2943 174 175.9951
175 177.0415
Z Gradient241 246.1039 base231 235.6399232 236.6863203 206.3407 inch from top
Here you can see the radial test temperatures are all within a reasonable range with each other. The significant difference between the bottom and the top is due to the tests being conducted at different times while heating. The first temperature is the temperature read by the thermocouple and the second is the adjusted temperature from calibration.
Testing ResultsTest melt 1 was melting exactly one gallon of
KC-4088D. This was 8 pounds 6 pounces in weight
Tsp was set at 180°FTook temperature readings every 10 secondsTemperature saw an increase when the wax
transitioned from solid to mostly liquidTime to melt 1 gallon was 10 minutes
Testing Results
Testing ResultsTest melt 2 involved adding 1 gallon of wax to
the melter and adding a second gallon of wax on top once the first batch was mostly liquid.8 pounds 6 ounces was added both times
Tsp was set to 200°FTotal time to melt 16 pounds and 12 ounces
was 27 minutes. This translates to 37.22 pounds per hour
Testing Results
Testing ResultsThe goal of Test melt 3 was to see how long it
took to melt 25 pounds of wax8 pounds 9 ounces added initially, then 8
pounds 6 ounces followed by another 8 pounds 6 ounces
Tsp was set to 205°FThe total time to melt 3 gallons of wax
(25.4167 lbs) was 45 minutes. This translates to a melt rate of 33.889 pounds per hour.
Testing Results
Issues While TestingPhysically holds 1 gallon of solid wax at a timeTorque from the motor caused the sprocket on the
shaft to start spinning and stop mixing in the systemCaused by motor torque and binding of the sprocket
and shaftFixed by dropping a pin through the sprocket to keep
it from slipping on the shaftMelted wax leaving the system would come in
contact with chainA chain guard or some sort of protection should be
used to prevent this
Objective Analysis of ProjectNo. Specifications Targets Achieved Characteristics
ES 1 Flow rate 50 lb/hr 30-35 lbs/hr
ES 2 Mounts directory to 55 Series C Frame yes/no No
ES 3 Ramp Width <= 20 inches N/A
ES 4 Maximum diameter of wax blocks accommodated > 12 inches Processes Flakes only
ES 5 Power requirements( 240 VAC 240 VAC
ES 6 Operating temperature range 100-250 F 180-205 °F
ES 7 Time to reach set temperature from room temp Minimize ~ 4 minutes w/o wax
ES 8 Temperature difference across melt surface within operating range (no wax) <= 1 °C >= 1°C
ES 9 Diameter of critical dimension of flakes/pellets allowed to pass unmelted 0 inches Minimized
ES 10 Temperature difference across plate while melting blocks, flakes, pellets <= 1 °C N/A
ES 11 Volume melted in a batch >= 20 gal No hopper for batch testing
ES 12 Withstands abrasions from wax with glass fibers yes/no Yes
ES 13 Weight of wax remaining on melter after melting one hopper 0 lbs > 0 lbs
ES 14 Weight of wax remaining on funnel after melting one hopper 0 lbs > 0 lbs
ES 15 Wax burns or separates yes/no No
ES 16 Loads by vacuum loader or by hand yes/no No
Current State of ProjectCurrent machine capable of melting soluble wax
with fibersNo issues with cloggingWax does not separate or burnStirring mechanism succeeds in inducing flow
during operationTemperature variation above spec, but even heating
to produce a thoroughly melted batchInsignificant testing to determine hourly outputTesting procedure did not achieve 50 lbs/hourCleaning an issue if testing different waxes
Further WorkOptimize tank loading to achieve maximum flow rate
1 gallon achieved average hourly flow rate of 51 lbs/hour
Higher loading: ~ 34 lbs/hourOptimize placement and shape of stirring bladesImprove PID control of heaterModify design to improve ease of cleaning
Make water-tight for cleaning processAllow testing with other waxes
Incorporate a novel aspect to the designHeat stir rods and/or stirring shaft
ConclusionsDesign does not meet all customer specs and
is not a novel designSystem is capable of processing water-
soluble wax, has potential to meet desired flow rate
Things to do differentlyBetter communication amongst group and with
customerUse acquired experience to better develop and
utilize risk assessment
Questions?