p13651: final design. contents revised design subsystem design power requirements bom/budget

P13651: FINAL DESIGN

Contents• Revised Design

• Subsystem design• Power requirements

• BOM/Budget

Hold Wax: Hopper• Designed to hold an entire bag of

wax flakes

• Reduces operator work during operation

• Hopper held within base with springs to reduce affects of vibrations from vibrator

For drawings see attached

Transport Wax: Chute• Goal: Transport 2 gallons of

wax at a time into the tank• Wax flow controlled by a

door operator by a linear actuator

• Ideal chute angle to transport wax flakes: 45°

• Vibrator is attached to the backside of chute to improve transfer

Super-Quiet Low-Impact Electric VibratorNonadjustable Force, 115 VAC,

1.4 Amps, 25 lbs Forcehttp://www.mcmaster.com/#catalog/119/517/=lsgnla

http://www.mcmaster.com/

http://www.mcmaster.com/

Melt Wax: Melting Tank• Goal: Melt 2 gallon batch of wax

within 10 minutes

• Aluminum tank structure• heaters around exterior wall of tank is

sole provider of heat to melt the wax• Aluminum shaft and 2 stirrers induce

flow and increase melt rate• Insulation surrounding tank prevent

heat loss to surroundings

Heat Requirements

Energy Required to Melt 50 lb of Wax

50 lb/hr 100 lb/hr

KC 4088 983 1967

Cerita 28-8 1148 2296

Solucore 1149 1711 3422

Testing Melter Efficiency 39%

• Melted varying quantities of three sample wax in a home wax melting unit

• Determined melter efficiency by comparing results from testing to known material, paraffin

• Used data to determine amount of energy required to achieve customer requirement of 50 lb/hour

Sample CalculationsRaw Data Analyzed Data Power Required

Trial Amt (lbs) Melt Time (min) Time (s) Weight (kg) Melt Rate

(kg/s)Heat of Fusion

(J/kg) 50 lb/hr 100 lb/hr

1 0.6 16.58 995 0.2722 0.00027 213E+3 1341 2682

2 0.6 11.82 709 0.2722 0.00038 152E+3 956 1911

3 0.6 14.98 899 0.2722 0.00030 192E+3 1212 2423

4 0.6 16.83 1010 0.2722 0.00027 216E+3 1361 2723

5 1 26.17 1570 0.4536 0.00029 202E+3 1270 2539

6 1 20.63 1238 0.4536 0.00037 159E+3 1001 2002

7 1 20.38 1223 0.4536 0.00037 157E+3 989 1978

8 1 24.37 1462 0.4536 0.00031 188E+3 1182 2365

9 1.4 35.02 2101 0.6350 0.00030 193E+3 1214 2427

10 1.4 27.50 1650 0.6350 0.00038 151E+3 953 1906

Average 182E+3 1148 2296

Power (W) 58.23

Required Melt Rate (lb/hr) 50 Required Melt

Rate (kg/s) 0.0063

Required Melt Rate (lb/hr) 100 Required Melt

Rate (kg/s) 0.0126

System Heaters• System will require 4

heaters to provide enough energy and cover the tank

• Heaters will come up to 2.25in down from the top of the tank

• Heat density of 100W/in2

Watlow Band/Barrel Heatershttp:/www.watlow.com/downloads/en/catalogs/band-barrel.pdf/

http://www.watlow.com/downloads/en/catalogs/band-barrel.pdf




Melted Wax Transport• Goal: Achieve 50 lb/hour flowrate

• Flow rate out of tank controlled by a door operated by a linear actuator

• Outlet through current baseplate into reservoir

BOM: MetalMetals

Item # Quantity Description Part Vendor Code/Part Number Lead Time Unit Price Total Price

13 1 Cold Roll Mild Steel Sheet A366/1008, 20"x20" 16 Gauge

Chute wall of Hopper

online metals - - $ 24.00 $ 24.00


Hopper bottom wall (3 sides)

online metals - - $ 24.00 $ 24.00

15 2 Cold Roll Mild Steel Sheet A366/1008, 12"x40" 16 Gauge Hopper box online

metals - - $ 19.20 $ 38.40


Heater box walls

online metals - - $ 9.31 $ 37.24

17 1 Cold Roll Mild Steel Sheet A366/1008, 12"x12" 16 Gauge Heater box top online

metals - - $ 4.82 $ 4.82

18 1 Cold Finish Mild Steel Rectangle 1018, 6"x30"x1/8"

Hopper support (Angled)

online metals - - $ 30.30 $ 30.30

19 1 Cold Finish Mild Steel Rectangle 1018 , 1/4"x2"x36"

Hopper support (Horizontal)

online metals - - $ 17.20 $ 17.20

20 4DOM Mild Steel Tube A513 TYPE 5, length 36", OD=3/4", ID=0.53" with wall thickness 0.109 "

Support Rods online metals - - $ 10.09 $ 40.36

21 1 Cold Finish Alloy Sheet Steel 4130 Annealed, 10"x10"x.19" L Brace online

metals $ 38.00 $ 38.00

22 1 Extruded Aluminum Round 6061 T6511, length 2-1/4", OD=8" Heater base online

metals - - $ 57.89 $ 57.89

23 1 Aluminum 6061-T6 Bare Sheet, 18" x 26", thickness=1/8" Heater tank online

metals - - $ 60.84 $ 60.84

24 1 Extruded Aluminum Round 6061 T6511, length 24", dia 3/4" Stir shaft online

metals - - $ 4.74 $ 4.74

25 1 Extruded Aluminum Round 6061 T6511, length 24" L, dia 1.5" Stir blades online

metals - - $ 18.95 $ 18.95

26 1 Mild Steel BLANCHARD GROUND Plate 1018, 24"x24"x1/2" Base plate online

metals - - $ 284.51 $ 284.51

Metal Sub-Total $ 681.25

BOM: ElectricalElectrical Components


1 12 Logic Gates Electrical Component DigiKey 4 AND, 2 NOR, 2 OR, 4

Inverter packages 5 Days $ 0.42 $ 5.04

2 10 1% resistors for booster circuit Electrical Component Digikey - 3-5 Days $ 0.50 $ 5.00

3 4 MOSFETs for booster circuits Electrical Component Digikey - - $ 0.60 $ 2.40

4 2 120 V Relays Electrical Component Digikey Z774-ND - $ 2.07 $ 4.14

5 1 20 A breaker Electrical Component Lowes Square D Qo 20A

breakerReady to purchase $ 6.44 $ 6.44

6 1 12/2 Wire Electrical Component Lowes 50' of 12 AWG 12-2 Ready to

purchase $ 33.24 $ 33.24

7 1 Light Switch Electrical Component Lowes Single standard 15 A

light switchReady to purchase $ 5.00 $ 5.00

8 1 Primary Drive Motor Electrical Component Grainger Dayton motor 1/3 HP

GP item #5K917 Purchased $ 130.00 $ 130.00

9 2 Linear actuator for valves Electrical Component

Firgelli automation - - $ 160.00 $ 320.00

10 1 Signal wire Electrical Component - 20 gauge signal wire of

various colors, 10ft On hand $ - $ -

11 1 K-A-Watt Electrical Component - - - $ 40.00 $ 40.00

12 4 Heater Electrical Component Watlow ME7L3AP1 Purchased 2

weeks ago $ 130.00 $ 520.00

Electrical Components Sub-Total $ 1,071.26

BOM: AuxilliaryAuxiliary Components


27 2High-Temp Cast Iron Mounted STL Ball Bearing 2-Bolt Flange Mount, for 3/4" Shaft Diameter

Bearing McMaster-Carr 6665K33 2 Weeks $ 112.72 $ 225.44

28 1 Right-Angle Speed Reducer Shaft Input, 30:1 Ratio, 1.33" Center, Left Output

Speed reducer/ Gear box

McMaster-Carr 5887K321 3 Days $ 357.87 $ 357.87

29 2 Steel Machinable-Bore Sprocket for #25 Chain, 1/4" Pitch, 30 Teeth, 3/8" min Bore

Bore sprockets for roller chain

McMaster-Carr 6793K19 In stock $ 10.35 $ 20.70

30 1 Standard ANSI Roller Chain #25, Single Strand, 1/4" Pitch, .13" Dia, 4ft length Chain McMaster-

Carr 6261K171 In stock $ 14.92 $ 14.92

31 1Very HI-Temp Mineral Wool Insulation Wire Mesh One Side, 1" Thick, 24" X 48" Sheet

Insulation McMaster-Carr 9328K21 In stock $ 18.79 $ 18.79

32 10 Reusable SS Harsh-Environment Cable Tie 45" Length, bundle dia 12 1/2"

Insulation holder

McMaster-Carr 1853T64 In stock $ 2.36 $ 23.60

33 1 Tape Made with Kapton® Polyimide High Temperature, 6" W, 5 Yards, .0025" Thk

Electrical Insulator

McMaster-Carr 7648A718 In stock $ 57.94 $ 57.94

34 1 2 oz., highly conductive two part epoxy to 500°F

Thermally Conductive

EpoxiesOmega OB-200-2 In stock $ 17.00 $ 17.00

35 1Super-Quiet Low-Impact Electric Vibrator Nonadjustable Force, 115 VAC, 1.4 Amps, 25 lbs Force

Hopper vibrator McMaster-Carr 5802K13 In stock $ 264.63 $ 264.63

36 8 High Load Plastic Compression Spring 250 in-lbs Energy Cap, 1.11" Overall Diameter Springs McMaster-

Carr 9677K12 In stock $ 8.14 $ 65.12

Auxiliary Sub-Total $ 1,066.01

Manufacturing CostsManufacturing Cost


37 1 CNC Tank Base Brinkman Lab - 2 weeks $

500.00 $

500.00

38 1 Water jet Base Plate Brinkman Lab ` 1 week $

50.00 $ 50.00

39 1 Water jet L-Brace Brinkman Lab ` 1 week $

50.00 $ 50.00

Manufacturing Sub-Total $ 600.00

Budget Breakdown

Budget Breakdown

Project Budget $ 5,000.00

Metal Parts $ 681.25

Electrical Parts $ 1,071.26

Auxilliary Parts $ 1,066.01

Machining Costs $ 600.00

Total $ 3,418.52

Remaining in Budget $ 1,581.48

p13651: final design. contents revised design subsystem design power requirements bom/budget

Documents