Overview of Status of Analysis, Design, Fabrication, Tests, etc.
Prototype 2
Created from metal square mesh coated in some type of polymer attached to an aluminum frame, Lazy Susan Bearing, and twine (to separate and hold the parts onto the square mesh metal).
Testing:
Discovered that with this configuration and bearings, spinning will occur in all washers despite differing water spray patterns and pressure.
Discovered improvements that must be made before the next iteration: a better way to secure the lids (as 2 flew out during testing because of the centripetal force and water pressure).
Accomplishments from Previous Week
Since last week we have decided to make another prototype of the circular basket design (or spool design) using a polymer coated metal material rather than wood due to Ian's concern for the wood's integrity in the washing chambers.
With this new fabricated prototype, our team went to the facility to test the spinning concept as well as gather more dimensional information and blueprints about the three different types of washers.
Further, we are starting our next iteration of prototyping specifically addressing how components will stay in our cart and not fly out.
Goals for Next Week (list names after each item). Use specific and measurable objectives.
Create a solid design and prototype specifically for the arrangement of the components (i.e. spacing and potentially tilt) Annie
Create a solid design and prototype to secure the components in the basket that is simple and will not hinder washing. Kelli
Create a solid design to make each layer of the cart stack and un-stack that will be structurally sound and easy to do. Jonathan
Create a solid design with ergonomics in mind (add handles), will be able to be wrapped (bars going up and down the cart so the machine can wrap it), and loaded into a truck (i.e. square base to carts can be ties together more easily) Yuji
Sponsor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)
Sponsor Comments:
Very good prototype and looking forward to the next iteration (1/18)
Focus next on how easily it is to insert and take out components (1/18)
They really liked the idea of utilizing all washers and being able to separate the tiers if they wanted to (1/18)
Actions Taken:
Assigned each person to one design task. This way we will have progress on our third prototype to test out all main features at once.
Instructor Comments from Last Meeting and Actions Taken to Address these Comments (indicate date of comments and if via email or in person)
Instructor Comments:
Try not to bend steel or buy a bender if we do not have to (1/15)
Asked about our ideas to hold the components in place (1/15)
Suggested we have a support if the cart is going to be rotating together (1/15)
Suggested we use a metal grill surface (via email)
Actions Taken:
Changing our design to be hexagonal instead of circular
Still prototyping various ways to separate components
Looking into different options to support our cart besides a single spine
Comments from Other Students in the Class (indicate date of comments and if via email or in person)
Student's Comments:
How will water be able to hit the top of the components if the wood planks are solid? (1/15)
If the cart is multi-layered won't the dirty water from the top drip down and contaminate the components on the bottom? (1/15)
I don't really understand why y'all chose to use circular wooden planks for the prototype, how will the water be able to penetrate it? (1/17)
Actions Taken:
Reconsidered using wooden planks for our prototype and remade our prototype with a coated metal mesh material
Discussed with sponsors about a multi-layered cart and they have no concern with components not being washed efficiently if it's multi-layered.
Risks and Areas of Concern
The bearings will not be strong enough to spin an entire filled cart.
The bearings will corrode in the washing environment if not encased somehow.
The center structure must be strong enough to handle the torque of a tall cart, so all the weight will be on on one center bearing, such that it will not tip over in the washers.
The cart must be stable when inside the conveyor washer so that it doesn't become off-center and crash into the components inside the washer.
Resources or Information Required but not Available
The amount of RPMs the cart will reach in the wash (attaching a Go-Pro to the prototype may not produce any data because the water obscures visibility).
What forces the cart will experience in the wash.
Schedule
By Friday 1/25, finish our second prototype that will be multi-layered (at least 2) and design a way to hold the components onto the basket without using twine.
On Friday 1/25, update sponsors on our design and bring up questions/concerns we have as well as gather any feedback they have for us.
Budget (list amount spent and amount remaining)
Nothing bought in the during week 2.
60 Dollars spent out of pocket for prototype, not yet reimbursed
Amount remaining in budget: $2000
Progress on Report and Webpage
Finished:
Background
Review of Existing Solutions
Statement of Requirements
Deliverables
Title page
Appendix with Individual Component Reports