Fabrication

Fabrication of the prototype was broken up and done by individually assembling each subsystem - including an enclosure designed to hold specific components to ensure safety and practicality. (note - fabrication of the system not completed due to COVD-19 pandemic of 2020)

Gas Inlet Subsystem

Fabrication for this subsystem primarily consisted of machining and assembling the CO₂tank with the sparger and the immersion heater openings. Polycarbonate plates with half-inch thickness were first marked and drilled. Threads were added to holes that needed screws and a small chamfer was given to these holes to ensure a snug fit. Next, larger holes for various components such as the pressure transducer, two thermocouple probes, two spargers, the gas outlet, drain port, immersion heater, and fill port were created and threaded. Some larger holes required use of a milling machine for accuracy of hole placement. This was done with a drill attachment. The sparger plate on the tank was also drilled and then threaded. The tank was then assembled to ensure all components would fit together and that threads were accurate. The final stage of fabrication for the CO₂ humidifying tank would be to use a polycarbonate glue to seal all edges, however Discovery Park closed before the team could finish this step. Figure 23 shows the CO₂ humidifying tank without polycarbonate glue.

Gas Outlet Subsystem

The gas outlet subsystem comprised mostly of assembly, and not as much fabrication. It consisted of assembling and attaching various Teflon tubing, a variety of sensors, and a rope heater to be able to measure output and make sure the exit conditions were proper. The team never got to assemble and fabricate this subsystem.

Housing

The enclosure's fabrication consisted of cutting, and then assembling aluminum t-slot material, aluminum plates, and poly carbonate plates to act as windows for clear visibility. The frame was constructed out of 1 inch t-slotted aluminum, that were marked to their appropriate lengths, cut using a horizontal band saw, and attached together using fasteners. To make the system more mobile, wheels were placed on the bottom of all four supports. An aluminum plate was used as a base to support the gas inlet subsystem shown above - which was cut to fit using a vertical bandsaw. A door was created using t-slots of smaller length, fastened and connected using two door hinges on one side, with two bolt locks to allow for opening/closing.

Separator Loop System

Fabrication of the separator loop system never occurred due to cancellations and closures from the COVID-19 pandemic. The main separator body was to be machined and milled out of a cylindrical poly carbonate piece by the University of North Texas's machine shop laboratory manager Bobby Grimes. The nozzles of the system were to be machined out of stainless steel by Mr. Grimes as well. A mock-up prototype - separator and nozzles - was printed using PLA for display and sizing purposes.

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