INTRODUCTION

Introduction

This report describes the automated trash rack prototype in detail. A common problem in water channels or power plant reservoirs is debris floating on the water. Debris get trapped in the intake of turbines reducing their water flow or even damaging the system. If the solution is applied in a real scenario, it can save money and improve workers' ergonomics.

The project was a success. Throughout 3 months the CGR Solutions team worked on the project and was able to build a functional prototype that delivers what was defined in the project scope. The automated trash rack mixes electrical commands and mechanical features to clean the intake of water in either automatic or manual modes.

The project was organized into six phases. Details about planning documentation, electrical and mechanical design, procurement of materials, machining process, integration of electrical and mechanical systems, and final test are described in the methodology section of this report.

At the project`s closing, the SPI was at 1.29 and CPI was at 1.06. The project was finished 2 weeks ahead of time due to a team decision to focus a week straight in the final phase. The CPI is under budget due to the designing phase being performed close to excellence. The details in the drawing and schematics allowed the team to save time in assembly phases and troubleshooting.

Although the project was finished under budget and ahead of schedule, the team learned some lessons that can improve the efficiency of future projects. Buying materials in bulk and avoiding all team members working on the same task can save money. Checking material and space availability before starting tasks can save time and avoid project delays. Adding a contingency budget proved to be the right decision. The project indeed used the contingency to finish the design and assembly phase.

Project Description

The project`s purpose is to build an automated trash rack prototype that can collect debris floating in the water of a hydropower plant reservoir or water channel operated automatically or manually. The project aims to solve a common problem in any water channel in an agricultural area or hydropower plant, which is the obstruction of the water supply. Figure 2 shows an overview of the project.

The electrical circuit was assembled on a 25 x 13.8 x 1.8 cm breadboard, with precise color coding utilized to simplify wiring and minimize confusion during troubleshooting. Two power supplies were integrated. One provided 12 VDC for motor supply and sensor operations, while another supplied 5 VDC for the logic circuit. Four "AND" gates, one "NOT" gate, and one "OR" gate were utilized to execute the logic operations and allow the circuit functionalities to be operated in both automatic and manual mode. The electrical panel and breadboard holder were 3D printed for better fittings and appearance.

The mechanical design consisted of a motor connected to a shaft by a coupling. The driver sprockets are installed in the shaft. Whenever the motor rotates, it will move the sprockets and consequently the roller chain. The roller chain is equipped with a set of pushers. The pusher`s design combined with the rotational speed creates a movement to grab the debris or any trash that flows on the water. For prototype purposes, the trash rack frame has 3 screens, and its overall size is about 12” (length) x 6” (width) x 8” (height).

The project was a success. The deliverables were met. The trash rack chain automatically moves and collects garbage if the sensor is energized or manually operated by the operator. At the end of the project, the CPI was slightly above one, indicating that the project was under budget. However, the SPI was above the high limits, indicating that the team finished the project two weeks ahead of schedule.

Figure 2 - Prototype overview.

Page updated

Google Sites

Report abuse