Project Overview

Dr. Ken Semmens with Kentucky State University is working on an experimental, in-pond raceway system which would allow farmers to grow fish in small, pre-existing ponds on their property and sell directly to consumer markets instead of large distributors. One of the drawbacks of the initial system was that it utilized a low efficiency airlift to move water through the raceway, and Dr. Semmens contacted our team to design an improved water movement device.

Design Considerations

1. A minimum flow rate of 690 gallons per minute

2. High reliability, able to run continuously 24 hours a day

3. Power requirement of less than 1 HP, as the current airlift system uses 1 HP

4. Budget of $500

5. Low turbulence to allow solid waste to settle

6. Ease of installation and maintenance by a technically sophisticated non-expert

The system will initially be installed at the Experimental Ag Farm in Frankfort, KY, shown above, in April 2019.
The image above shows the first semester design as a mock-up of assembly implementation.

First Semester Design

Our team designed a six-bladed paddle wheel device to move water at a rate of 700-750 gallons per minute while running off a 1⁄2 horsepower, totally enclosed electric motor. To do this, the paddle wheel assembly at the left will rotate at 45 rpm.

The system currently in place utilized a 1 horsepower blower motor to achieve a flow rate of 643 GPM. Our design increases flow rate while reducing necessary power requirements, while offering ease of access for maintenance and a design that is simple enough to implement in the field, where it may have to be assembled by various non-experts.

Manufacturing

Manufacturing was completed in early April 2019 in the Agricultural Engineering Machine Shop at the University of Kentucky, with assistance by the crew there. Relevant tasks included: cutting and notching components with a CNC Plasma Table, keying shafts, bending sheet metal by means of a brake, and welding assembly components.

Team member Sean Sines assists in the welding process.
Team members Truc Nguyen and Sean Sines perform test to find device RPM.

Testing

Testing began April 15th, 2019 with focus on available torque, wheel velocity and acceleration, and supplied flow of water through the raceway. Results are summarized here.

Finished Design

Our final, manufactured design for the paddle wheel is shown left

Manufactured Paddle-wheel