Alpha Prototype Presentation Nov 4, 2008. Today’s Presentation: System Schematic Review Materials...
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Transcript of Alpha Prototype Presentation Nov 4, 2008. Today’s Presentation: System Schematic Review Materials...
Alpha Prototype PresentationNov 4, 2008
Today’s Presentation:• System Schematic Review• Materials Analysis• Materials Processing • Tube Fabrication• Joints and Filter Designs• Tank Specifications• Alpha Prototype• Cost Analysis• Project Concerns/Plans for Beta Prototype
Schematic of Drip Pipe Irrigation System
1 m
(not to scale)
6 m
20 cm spacing between plants
Large Particle Filter
Water Tank
Materials Analysis• HDPE cheap & environmentally friendly.• HDPE bags widely available in Ethiopia.• HDPE bags Too light to be fed into grinding
machine.
Material Processing
• Two ways of making pellets out of plastic bags:
1. Heat (320 F) + Pressure (1000 Pounds) 20 bags to get thick solid sheets; Cut the sheet into smaller rectangular pieces to fed into grinding machine
Carver Press
2. Roll 6 plastic bags in a cylindrical shape and feed.
Shredded Plastic bags Grinding Machine
Tube Fabrication
• 75% LDPE pellets + 25% HDPE shredded bags by weight.
• Used Blown Film Processor
Blown Film Processor
Blown Film Processing
Fabrication Steps
1. Pour in the pellets into hopper
2. Blown film coming out from the circular die
Fabrication Steps (Continued)
3. The HDPE tube growing in length
4. Pulling at a constant rate to make long tubes
Initial SolidWorks Models:
Elbow Joint Y Joint
Prototype made with simpler joint designs made of HDPE
Initial Joints Designs
Alpha Prototype Joint Design
• Solid HDPE tubes with holes drilled in them.• Tube is affixed onto opening:– Superglue (bad seal)– Soldering iron (decent watertight seal)– Shrink wrap? (possible future consideration)
Filter Design
Alpha Prototype does not include the designed filter
Tank Specifications
• Original Plan: A 110 Liter Tank (3 water refills/day)– Sorghum Plants in 6m X 6m Plot– 230 Sorghum requires a maximum of 3-4 Inch of water/10
days (during its highest growth phase)– At the flow rate of 51 L/hour the plants needs to be
irrigated for 6.25 hours per day• The plot will require 320 L/day of water
• Prototype Tank: 2.5 Liter water jug (Smaller scale)
Alpha Prototype
• Tubes are inserted into the T and elbow joints.• Superglue, soldering iron is used in the
attachment of some tubes to ensure stability.• Smaller scale Drip Irrigation System• 2.5 Liter Water Tank
Cost Analysis• Total Cost = $ 2.69 per system• Materials Cost
– $0.85 for injection molded water tap– $0.80 for 48 feet of tubing (including 5% rejection rate)– $0.70 for joints, elbows
• Utilities Cost– $0.03 per system based on current costs of electricity
• Other Costs (Rent, Machinery, Delivery) – Not included– Rent = $14 per system– Sunk
• $77 per system after 1 years• $15 per system after 5 years• Problems include high costs of machinery
• Labor Costs – would have to be $0 to make this reasonable without much funding
Project Concerns
• Leaking of water from the joints• Some tube/ joints attachments less stable (use
of superglue)• Not 100% recyclable material• Tubes not straight (tend to curve)• Tube diameter not even throughout
Plans for Beta Prototype
• Better T and elbow joints• Better/more stable attachments of tubes to
the joints• Tube of uniform diameter • Greater number of tubes (a larger drip
irrigation system)• Fabrication of filter for grey water
Working Prototype is
Outside
Any Questions?
Initial Output Valve Design
3-D Printing currently presenting problems with assessing design.
2nd Generation Output Valve Design
Filter Material
•36in X 100 ft Charcoal Aluminum Screen for $82.00 a roll •Required filter area
would be 32 in2
•Allows for 1,375 filters at 6 cents a piece.
www.homedepot.com
Pressure Flow Calculations
efunda.com
3rd Generation Output Valve
3D Print of 2nd Generation Design