2015 fall- project report (in progress) - il2 (1) (1)

Engineering Service Learning at UC Merced

Project Report

Team: Instructional Lab 2

Project: High-Efficiency Solar Collector

Date: Fall 2015

Project Report Instructional Lab 2, High- Efficiency Solar Collector

1 Design Status Summary.........................................................................................3

2 Project Charter.........................................................................................................42.1 Description of the Community Partner....................................................................................42.2 Stakeholders.............................................................................................................................. 42.3 Project Objectives...................................................................................................................... 42.4 Outcomes/Deliverables.............................................................................................................42.5 Overall Project Timeline............................................................................................................4

3 Overall Project Design............................................................................................63.1 Phase One: Project Identification (Fall 2014)..........................................................................63.2 Phase Two: Specification Development (Fall 2014, Spring 2015)..........................................73.3 Phase Three: Conceptual Design (Fall 2015)...........................................................................93.4 Phase Four: Detailed Design (Fall 2015)................................................................................113.5 Phase Five: Delivery (Fall 2015)..............................................................................................133.6 Phase Six: Service / Maintenance..........................................................................................14

4 Semester Documentation (current semester).....................................................154.1 Team Member............................................................................................................................ 154.2 Current Phase in the Design Process and Location on Overall Project Timeline....................17

4.2.1 Goals for the Semester.............................................................................................................174.2.2 Semester Timeline....................................................................................................................174.2.3 Semester Budget......................................................................................................................184.2.4 Summary of Semester Progress / Comparison of Actual Semester Timeline to Proposed Semester Timeline............................................................................................................................. 19

5 Past Semester Archive..........................................................................................265.1 Spring 2015............................................................................................................................... 26

5.1.1 Spring 2015 Past Team Members......................................................................................265.1.2 Spring 2015 Past Timeline.................................................................................................26

5.2 Fall 2014.................................................................................................................................... 275.2.1 Fall 2014 Past team Members...........................................................................................275.2.2 Fall 2014 Past Timeline......................................................................................................28

Last revised: May 3, 2023 2


1 Design Status SummaryPhase 1: Project Identification Status: Complete

Gate 1: Continue if have identified appropriate Engineering Service Learning project that meets a compelling need for the project partner.

Date of Advisor approval: 11/20/2015

Phase 2: Specification Development Status: Complete

Gate 2: Continue if project partner and advisor agree that you have identified the “right” need, specification document is completed and no existing commercial products meet design specifications.


Phase 3: Conceptual Design Status: Complete

Gate 3: Continue if project partner and advisor agree that solution space has been appropriately explored and the best solution has been chosen.


Phase 4: Detailed Design Status: Complete

Gate 4: Continue if can demonstrate feasibility of solution (is there a working prototype?). Project Partner and advisor approval required.


Phase 5: Delivery Status: Incomplete

Gate 5: Continue if Project Partner, Advisor and Engineering Service Learning Admin agree that project is ready for delivery!

Date of Advisor approval:

Phase 6: Service / Maintenance Status: Not Started

Gate 6: Project Partner and Advisor approve continued fielding of project. If not, retire or redesign.

Date of Advisor approval:



2 Project Charter2.1 Description of the Community Partner

The community partner organization of the Instructional Lab 2 (IL2) Team is the Instructional Laboratory (IL) of UC Merced. The IL has the mission of educating UC Merced students about the properties of the physical world. Instruction is carried out by utilizing a wide variety of apparatuses to demonstrate experiments and physical phenomena.

The product of IL2’s project is a high-efficiency solar collector that will be used in the instructional labs at UC Merced. The project will benefit the students who use the solar collector to study and evaluate heat transfer problems. The lab instructors will also benefit by having a working tool to demonstrate concepts more clearly. The solar collector will be given to the IL at UC Merced.

2.2 StakeholdersThe Engineering Service Learning (ESL) IL2 Team’s stakeholders are the potential customers of

the IL. Those customers will be affected by this project because a more efficient design will be more desirable in the long run with energy savings. This desirability will grow as the price of the apparatus falls with mass production. Unless the customers want a cheaper and less-efficient product, they will invest for better efficiency provided IL2 can deliver a proof of concept. Other stakeholders include students of the UC Merced Heat Transfer course. The curriculum may be modified if IL2’s project’s applications provide more educational opportunities.

Those with vital interest in the completion of this project are the Service Learning IL2 Team’s advisors, IL Manager Sergio Pineda Vargas and Professor Gerardo Diaz. They will be receiving a model for direct use with their respective labs and courses. The conclusions of their testing will decide the viability of this project.

2.3 Project ObjectivesThis project is motivated by the potential of renewable energy. To this end, IL2 is addressing

specific problems such as efficiency, cost, and durability. The mission of this team is to design and create the prototype of a solar collector and subsequently test it. This project fits the mission of the community partner because, once created, the prototype will allow the community partner to use it for demonstration and data collection. Once the solar collector is built, IL2 will test to show if the efficiency of the design is better than the one currently located in the heat transfer lab and possibly the market.

2.4 Outcomes/DeliverablesAfter extensive research and rigorous drafting, the IL2 Team will have constructed the first model

of a high-efficiency solar collector which will deliver a projected increase in efficiency compared to a traditional U-tube solar collector. The entire high-efficiency solar was designed by students with the help of Professor Gerardo Diaz. Once the solar collector is completed, the IL2 team will have contributed a model for future workers to build upon, developing it into a more commercialized machine. In addition to creating being used for commercial use, the high-efficiency solar collector will be used by the upper division Engineering Heat Transfer Lab academic research.



2.5 Overall Project TimelineIn Fall 2014, the IL2 Team reviewed the basics of heat transfer and the concepts of solar energy.

This helped identify and fix issues that came along with the project such as efficiency and cost. The team of Fall 2014 attempted to gain background knowledge on the subject. Building upon that knowledge, the Spring 2015 team was tasked with picking out components for the solar collector and building a prototype. However, the Spring 2015 team dedicated that semester towards more research and were unable to complete a prototype. In Fall 2015, the IL2 Team is taking the general consensus of the previous semesters and attempting to build a test model by the end of the semester.

The members of the Fall 2015 IL2 Team recognized the urgency relayed to them by their faculty advisor and Project Manager. The community partner had created a new deadline for IL2: Finish the project by the end of the Fall 2015 semester. A mutual understanding and many hours of communication brought the team together to accomplish just that. As a result of a combined team effort, milestones were met. Several leaps towards a physical prototype throughout the semester. One milestone was a functional decomposition of the receiver, where two drawings were proposed for approval. After the first drawing, several CAD sketches were made which included proposed dimensions. After dimensions were finalized, parts were ordered. The last step was to fabricate the model, with the help of the machine shop and the UC Merced facilities.

As with the development for any novel technology, the learning experiences are numerous and time-intensive. With this in mind, the project will be be completed by Fall 2015.



3 Overall Project Design 3.1 Phase One: Project Identification (Fall 2014)

Phase 1: Project Identification Status: Complete Evidence can be found:

Goal is to identify a specific, compelling need to be addressed

Conduct needs assessment (if need not already defined)

Completed pg. 5, Project Objectives

Identify stakeholders (customer, users, person maintaining project, etc.)

Completed pg.1, Stakeholders.

Understand the Social Context Completed pg. 5 Outcomes/Deliverables

Define basic stakeholder requirements (objectives or goals of projects and constraints)

Completed pg.1, Stakeholders

Determine time constraints of the project Completed pg.5, Overall Project Timeline

Gate 1: Continue if have identified appropriate Engineering Service Learning project that meets a compelling need for the project partner [This includes a Project Charter]

Decision:

Continue

Rationale summary:

The team was able to identify there was a compelling need from the school for a solar collector. They have identified their time constraints and stakeholder requirements.

Advisor approval: Yes Date: 11/20/2015

The IL2 team identified that there was a need for a solar collector from the school. The collector would serve for instructional and testing purposes in the thermodynamics lab. Since ESL is only in motion every semester during the school year, the time constraint was measured in terms of semesters. The team identified that stakeholders were the school and students. The school required the collector to be made out of micro-channels.

The IL2 team understood in terms of social context that the solar collector would serve the school and could also be used for research purposes. A solar collector with micro channels is predicted to be efficient than those offered on the market. The aim was to create a functional solar collector in three semesters. After the goals and time constraints of the stakeholders were identified, the team moved onto the next phase, specification development phase.


https://ucmerced.app.box.com/files/0/f/4916217773/1/f_40029567321






3.2 Phase Two: Specification Development (Fall 2014, Spring 2015)Phase 2: Specification Development Status: Complete Evidence can be found:

Goal is to understand “what” is needed by understanding the context, stakeholders, requirements of the project, and why current solutions don’t meet need, and to develop measurable criteria in which design concepts can be evaluated.

Understand and describe context (current situation and environment)

Complete Fall 2014 Semester Report “Introduction”

Create stakeholder profiles Complete Semester Proposals from 2014-2015 “Stakeholders”

Create mock-ups and simple prototypes: quick, low-cost, multiple cycles incorporating feedback

Complete Image of Cardboard Mock-up

Materials List for Prototype/ “Mockup”

Develop a task analysis and define how users will interact with project (user scenarios)

Complete Possible User Scenario

Identify other solutions to similar needs and identify benchmark products (prior art)

Complete Other Solutions

Define customer requirements in more detail; get project partner approval

Complete Fall 2014 Project Report “Description of the Community Partner” (pg. 5)

Project Partner Approval Email

Design Status Summary

Develop specifications document Complete Solar Collector Research

Establish evaluation criteria Complete Evaluation Criteria

Gate 2: Continue if project partner and advisor agree that you have identified the “right” need, specification document is completed and no existing commercial products meet design specifications. [This includes their agreeing that you have captured and documented the critical requirements and specifications for this project]

Decision:

Continue

Rationale summary:

Current commercial solar collector models use copper pipes in their designs. This method is not as efficient as the mini-channels that will be used in this prototype, which provide the fluid with more contact area to the heated



















metal. This mini-channel model will fulfil the community partner organization which has commissioned us because it will have greater efficiency than commercial products.


The community partner organization, Instructional Labs, headed by Sergio Pineda and advisor Gerardo Diaz commissioned IL2 to build a more efficient solar collector. Current solar collector products use copper pipes which lower efficiency. In order to fix this problem, this project will utilize micro-channels, also called mini-channels, in conjunction with a vacuum sealed glass tube, which should increase efficiency. For the purposes of this project, success will be considered the construction of a functional prototype which is stable and can be altered or added onto later, as well as the integrity of the vacuum seal.



3.3 Phase Three: Conceptual Design (Fall 2015)Phase 3: Conceptual Design

Status: Complete

Evidence can be found:

Goal is to expand the design space to include as many solutions as possible. Evaluate different approaches and selecting “best” one to move forward. Exploring “how”.

Complete functional decomposition

Complete

Functional Decomposition 1 Functional Decomposition 2

Brainstorm several possible solutions

Complete

Concept Sketches

Prior Artifacts Research

Complete

Instructional Lab 2 Project Report Spring 2015 Instructional Lab 2 Project Report Fall 2014

Create prototypes of multiple concepts, get feedback from users, refine specifications

Complete

Solar Collector Cardboard Model CAD Drawings Instructional Lab 2 Project Report Spring 2015 , Page 7

Evaluate feasibility of potential solutions (proof-of-concept prototypes)

Complete

Instructional Lab 2 Project Report Spring 2015 , Page 7

Choose "best" solution

Complete List of tentative parts chosen Spring 2015 , page 26

Gate 3: Continue if project partner and

Decision:

Complete

Rationale summary:

Finalized designs have been chosen and initial goals have been modified. Out of the various models discussed, we have chosen a vacuumed tube that will incorporate minichannels into the design. A reflector will be





https://ucmerced.app.box.com/files/0/f/5126460402/CAD_DRAWINGS




https://ucmerced.app.box.com/files/0/f/4515351518/Concept_Sketches




advisor agree that solution space has been appropriately explored and the best solution has been chosen.

Complete

added for additional efficiency. Aluminum minichannels will be chosen for its availability.

Advisor approval:

Yes Date: 11/20/2015

IL2 finished Semester 1 by providing a range of specifications that needed to be addressed. Under guidance from Advisor Professor Diaz, the team sought to create a device that would meet specifications as well as be cost-effective.

Several models have been discussed, some of which were incorporated into the Spring 2015 Project Report. This include the options of two minichannel configurations in the vacuum tube. Twin-layer tube design was considered an option before settling for a pump system and/or getter system.

Options for a reflector and similar solar components were restricted due to the lack of market availability. American markets did not provide candidates that would meet project requirements. A reflector would likely come from China, as with other solar parts due to the country’s current solar industrial capacity.

As a result of the conceptual design, IL2 has modified specifications to address current resource and time constraints.



3.4 Phase Four: Detailed Design (Fall 2015)Phase 4: Detailed Design

Status: Complete

Evidence can be found:

Goal is to design working prototype which meets functional specifications.

Bottom-Up Development of component designs

Complete Component Evaluation

Develop Design Specification for components

Complete Concept Sketches (1)

Concept Sketches (2)

Design/analysis/evaluation of project, sub-modules and/or components (freeze interfaces)

Complete Component Sketches and Assembly Manuals

Design for Failure Mode Analysis (DFMEA)

In Progress Assembly Instructions

Prototyping of project, sub-modules and/or components

Complete Finalized CAD Designs (Labeled F)

Field test prototype/usability testing

In Progress First Vacuum Test (Leaks)

Gate 4: Continue if can demonstrate feasibility of solution (is there a working prototype?). Project Partner and advisor approval required.

Decision:

Continue

Rationale summary:

Community partner has approved the progress of the team, and will be satisfied if the solar collector receiver is completed. Testing and the overall system components such as the pump can be completed at a future time.


With advising from Professor Diaz and resources from previous semester, the team is projected to complete a solar collector prototype by the end of the fall 2015 semester. Previous semesters have identified the overall components of the solar collector, but have not acquired these parts. In order to complete a proof of concept, the team focused on the solar collector receiver. The main components




https://ucmerced.app.box.com/files/0/f/5368720849/Assembly_and_Operation_Instructions

https://ucmerced.app.box.com/files/0/f/4655457254/Assembly_Manual


https://ucmerced.app.box.com/files/0/f/4515351518/Concept_Sketches



include; aluminum mini-channels, aluminum pipes, glass envelope, and aluminum cap. For the prototype to be considered a success, it has to maintain a vacuum.

The team went through several designs such as a bell-jar model, which was designed to make the vacuum component easy. However this design was too wide, and would lose efficiency, it was also difficult to obtain a tall enough bell jar (Concept Sketch 1). With advising from Dr. Diaz, the team decided with a similar design to u-tube collectors, revolving around the shape and size of the micro-channels (Concept Sketch 2). This design allowed us to find a suitable glass envelope as well as a cap that can be fabricated. After these sketches were finalized, the team was able to move onto obtaining the materials and dimensions for the design.

The mini-channels were the most difficult to obtain, but the team was able to get a few samples from Professor Diaz. Once the team had the mini-channels, the next task was to design the manifolds they will connect to. In order to minimize heat loss, these manifolds will have to be separated at the inlets and outlets, this was done by having two separate tubes at these ports. These manifolds were machined by Ed Silva and welded by Justin McConnel. The manufacturing methods will be later discussed in section 4.2.4.

The most difficult aspect of the receiver design was maintaining the vacuum. The first component needed to achieve this was a strong enough glass envelope. The team found a glass company that could make a custom sized glass. After consulting with the company, the team was advised to order a glass that had a wall thickness of 3/16’’. The dimension of the glass envelope is 5’’ x 50’’. After acquiring the glass, the next step was to make a lid that can maintain this vacuum. For this component Ed Silva from the machine shop was willing to work with the team. The cap has to be custom fitted to fit the wall thickness of the glass, and have an O-ring groove that will maintain the vacuum. The cap design can be found under the prototype phase link.

As of 12/9/15, the receiver is 95% completed, with just the outside tubing waiting to be welded to complete the seal. The lid fits very well and can simply be placed over the opening of the glass envelope.






3.5 Phase Five: Delivery (Fall 2015)Phase 5: Delivery Status:

IncompleteEvidence can be found: Phase 5 Delivery

Goal is to refine detailed design so as to produce a product that is ready to be delivered! In addition, the goal is to develop user manuals and training materials.

Complete deliverable version of project including Bill of Materials

Incomplete Phase 5 folder

Complete usability and reliability testing

Complete user manuals/training material

Complete delivery review

Project Partner, Advisor, and Engineering Service Learning Admin Approval

Gate 5: Continue if Project Partner, Advisor and Engineering Service Learning Admin agree that project is ready for delivery!

Decision: Rationale summary:

Advisor approval: Yes / No Date:

The team has accomplished the goal of making the proof of design concept model in the fall of 2015. The team has identified and designed the components of the solar collector receiver, which includes micro-channels, aluminum manifolds, glass envelope, aluminum cap, solar coating, parabolic reflectors, and a vacuum fitting. All of these parts are documented and the metal components were dimensioned and modeled using a CAD software. The team will include a Phase 5 folder that will include everything else that will be needed to complete the system, and some suggestions and calculations done by the team.


https://ucmerced.app.box.com/files/0/f/5712748781/Phase_5%3A_Delivery




3.6 Phase Six: Service / Maintenance Phase 6: Service / Maintenance Status: Not

StartedEvidence can be found:

Evaluate performance of fielded project Not Started

Determine what resources are necessary to support and maintain the project

Not Started

Gate 6: Project Partner and Advisor approve continued fielding of project. If not, retire or redesign.

Decision: Rationale summary:

Advisor approval: No Date:



4 Semester Documentation (current semester)4.1 Team MemberJoseph Camaddo – Project Manager

Supervises overall progress of project. In charge of procuring micro-channels, leads the preliminary and final design review team, meets weekly with community partners. Assisted with the micro-channel assembly manual and made CAD drawings.

Greg Mellos – Assistant Project Manager

Assists in supervising project progress. Responsible for overseeing machining of micro-channels and pipes, participates in the preliminary and final design review team, meets weekly with community partners. Assisted with the micro-channel assembly manual.

Kelly Zaldana – Intellectual Property Officer

In charge of Box organization. Oversees in selection and application of solar coating for micro-channels. Managed and oversaw the creation and approval of the Project Report by community partner. Assisted with thermal spray assembly manual.

Elissa Espinoza – Procurement and Finance Officer

Wrote and submitted work orders for project parts. Managed project storage and semester budget. Assisted in design and research for vacuum sealable cap, rubber seals, and bulkheads. Assisted with O-ring assembly manual.

Salvador Padilla – Communications Officer

Oversaw the design and selection of vacuum sealable tube. Researched the parameters of failure of pressurizing glass envelopes. Worked on project report, scheduled the preliminary design review. Assisted in researching and selecting vacuum pump and tubing, assisted with the vacuum and seal assembly manual.

Zack Baskin – Web Master

Managed the project website. Worked on project report, reviewed part compatibility for shape/length relative to pipe and tube receivers. Assisted in base assembly manual.

Arjun Kohli

Responsible for finding local part vendors and part vendors related to the campus. Modelled preliminary design in CAD, part of the presenting team in the preliminary design review. Assisted with the micro-channel assembly manual.

Christian Tran

Oversaw research and selection of sheet reflector concentrator. Assisted in researching vendors for parts, and in designing the base assembly. Assisted with the base assembly manual.



Raymond Vang

Designed preliminary pump and fluid flow design. Assisted in designing vacuum seal assembly, assisted with vacuum seal assembly manual.

Mark Armstrong

Worked on the design of the parabolic solar concentrator. Measured and designed the tube suspension and foci of the double parabola. Researched vendors for the part and base assembly. Assisted with the base assembly manual.

Kevin Tien

Designed the tube and tee caps. Assisted in CAD and dimensional design of the microchannel and pipes. Assisted with the inside bracing assembly manual.

Edward Ngheim

Assisted in researching, selecting, and designing several tubes and caps for vacuum sealing certain parts of the module. Managed the project timeline, was a part of the preliminary design review creation and presentation team. Part of the final design review presentation team. Assisted in the O ring assembly manual.

Mark Radgowski

Worked on researching how to create and maintain a vacuum. Assisted in the research and selection of the vacuum pump and collaborated with the glass envelope and vacuum seal teams. Assisted in researching available vendors, and in writing the base assembly manual.

Roberto Nava

Assisted in designing the micro-channel and tube assembly, and in the machining process required to weld and cut the apparatus. Assisted in CAD designs for the parts and in writing the thermal spray assembly/application manual

Jason Gutierrez

Oversaw and designed maintaining tube connections under vacuums, and from the glass envelope to the outer environment. Helped design the preliminary design review presentation, and in writing the inside bracers assembly manual.



4.2 Current Phase in the Design Process and Location on Overall Project TimelineThe team, with the prototype completed, can begin the delivery phase. The team finalized the

design for the solar collector and created the functional decomposition of the solar collector. Just like the project charter specifies, the team was able to finalize and acquire the components needed to create a functioning prototype. The functional decomposition is one of the milestones this semester that served as the blueprint for the final solar collector. From the decided blueprint, the team acquired all the major parts in the first batch of work orders.

As a consequence of an overall plan change, we were unable to achieve all of the objectives set out by project charter. Due to time constraints, the IL2’s advisor – Professor Diaz – recommended that the overall focus of the project be shifted from having a system to just producing the solar collector itself as it is the most important part. The next major shift came from two sources, both of which influenced each other. The initial design was predicated on specific dimensions, but it soon became apparent the market did not carry these specialized parts. Therefore, we had to acquire parts that would approximately meet the requirements of the design at the cost of compatibility issues. The team had to alter the dimensions of the initial design to meet what the market had. As a result the team was only able to construct a prototype, and strayed from the initial expectations made by the project charter.

4.2.1 Goals for the SemesterProfessor Diaz, the team’s main advisor, had tasked the team to complete a functioning prototype of a micro-channeled solar collector by the end of the semester. In order for the semester to be considered a success, the receiver part of this solar collector had to be built and able to maintain a proper vacuum. Testing and outside components could be added at a later date, but the team was advised to focus on the receiver first. After two semesters of design and component analysis, the team finally had a physical product to deliver to the community partners. This design will be approved and built for future use by the community partner. Several milestones have already been met, and the team is projected to fulfill the community partner’s task.

4.2.2 Semester Timeline

Figure 1 Proposed Semester Timeline



4.2.3 Semester Budget

Figure 2 Proposed Semester Budget



Figure 3 Actual Semester Budget

The reason for the difference between the budgets proposed during the semester, versus the actual budget of items purchased by the end of the semester was due to the shift of focus from the whole system to just the solar collector receiver. Therefore, we didn’t need to purchase all of the parts that we had anticipated. However, the team underestimated the price of the glass envelope, which needed to be a custom order that was 50 inches long. Two of these glass tubes were also purchased as a safety.

4.2.4 Summary of Semester Progress / Comparison of Actual Semester Timeline to Proposed Semester TimelineCompared to the semester timeline, the team has made several adjustments in order to complete a physical prototype. A major adjustment that was made was the shift of focus from the building the entire solar collector system to just the receiver instead, which does not include a pump system. This adjustment allowed the team to create a functional design that can be modified and tested in the future. While previous semesters had focused on the overall components, the receiver is the most important and needed the most attention.

Figure 4 Actual Semester Timeline



The progress of the Fall 2015 team was a tremendous leap from previous semesters. Huge efforts were made in creating designs and functional decompositions of the receiver. Such designs can be found here. This process took many weeks, and the team constantly revised dimensions, especially for the insides.

Figure 5 Functional Decomposition - Jason Gutierrez

The team identified and ordered parts based on these designs. A major problem the team struggled with was acquiring the micro channels, which were not sold individually by companies. However during the team’s search for micro-channels, they learned the many applications of this innovation. Many members were calling radiator shops and HVAC companies that used micro-channels for their high-efficiency fluid systems. Eventually, Professor Diaz was able to acquire a couple of samples for the team, which made the process a lot easier.


https://ucmerced.app.box.com/files/0/f/4655457254/Assembly_Manual


After the micro-channels were acquired, the team faced the challenge of dimensioning the manifolds. These manifolds need to be able to transport the liquid, while maintaining high efficiency. A way to ensure that cold water and hot water do not mix, was separating the inlet and outlet manifolds. This separation however, will mean that the micro-channels will have a distance apart, which will allow for heat loss. Nevertheless, the team worked to optimize this design.

Figure 6 Preliminary Dimension - Kevin Tien

Figure 7 CAD Dimension - Joseph Camaddo



The biggest achievements of the team came from utilizing resources available inside and outside the campus. Ed Silva from the machine shop, Justin McConnel from facilities, Dr. Diaz, and even a few manufacturing companies and local shops all contributed to the final design of this solar collector. The team learned greatly by dealing with professionals in the field and this process of inquiry and research greatly contributed to the team’s understanding of engineering practices. One example of this is the collaborative efforts between Ed Silva and the team. The project manager would meet with Ed several times a week for advising on dimensions and request parts to be made. Each week the receiver would get closer to completion, as new problems are addressed and suggestions are taken to the advisor and the team.

Figure 8 First Part Machined

The inside assembly took a short amount of time, as the design was straight-forward. The next step was to assemble a cap that will maintain a vacuum. The design of this cap actually took a very long time. During the early stages of the project, the team was unsure on how to maintain the vacuum seal. Previous semesters have suggested the idea of Mason jar sealing, but go no further than that. There was also the problem of finding such a mason jar cap that will fit on our glass envelope, which at the minimum needed to be 4 inches in diameter. In order to have a feasible seal, the team recognized the need for a custom-built cap, which luckily, Ed was willing to make for the team. With this in mind, a cap design was drawn up, which needed to include an O-ring groove to maintain the seal, holes for the inlet and outlet tubing, and a vacuum connector. The hardest part of this lid was finding the correct O-ring and dimension for the groove to perfectly have the lid sit on the lip of the glass and have the O-ring be at a desired diameter and compression. Several versions of this component can be found here, all parts labeled F are the final components.




Figure 9 Dimensions of Glass and Custom Lid

After several variations of the design and after finding a suitable O-ring, the lid was finally machined. After this was done, all that was left was to weld the micro-channel assembly. This was done by Justin McConnel from facilities, who used Tig welding for aluminum. Currently as of 12/10/15 the outside tubing still needs to be welded to the cap.

Figure 10 Final Machined Lid by Ed Silva



During this entire project, the team practiced suitable design processes and learned how to work with professionals. An example of this is with the ordering of the glass tube. Salvador inquired many times with the glass manufacturer Greatglas about their borosilicate tubes before consulting with team for purchase. This company gave the team several key information about their glass such as the recommended wall thickness for vacuum applications (3/16’’) and durability of round the bottom finish. The main appeal of this company for the team was the option to custom make the glass. Since the micro-channels that were provided to us were 1.2 meters long, our glass tube needed to be long. Our outside diameter also had to be big enough for the inside assembly.

Figure 11 Sample Email Before Work Order is Done



With the completion of the first prototype, the team can deliver a physical product to the community partner instead of a conceptual design. The project outline predicted the prototype to be completed last semester, and testing to be done this semester. However this was not the case, and the team started from the start of detailed design phase this semester. With this in mind, the team put their best effort to make this prototype a reality. Many hiccups were encountered along the way and mistakes were made throughout the project, but they were all part of the team’s learning process. With this great achievement, the team can happily move on to phase five, which is delivery.

Figure 12 Tu Ngheim Operating the Vacuum while the team runs their first vacuum test

As for future teams that may work on this project or a similar project, the team advises them to learn how to ask the right questions and utilize all available resources. Part of this project was learning how to work in a professional setting, no progress can be made if they are scared to ask questions.



5 Past Semester Archive5.1 Spring 2015

5.1.1 Spring 2015 Past Team Members Juan Hernandez – Project Manager

Joseph Camaddo – Assistant Project Manager

Fatima Shah – IPO

Joshua Reynoso – IFO

Hang Liang – Communication Officer

Majok Ring – Webmaster

Jacob Clark – SAC Officer

Raymond Yang – Team Leader

5.1.2 Spring 2015 Past Timeline

Weeks 1-7: Research/Lab Experience/CAD Design The semester started with familiarizing everyone with solar collectors, getting lab experience, and creating CAD drawings of the design. The first few weeks included presentations by individual members on an aspect of the solar collector. The presentations began with professor Diaz and his powerpoint on solar collectors.

Weeks 8-12: Ordering Parts One of the challenges with ordering parts for the solar collector is that most of the components are hard to find on the market. One example of this are the copper microchannels, which have to be especially made by a professor out of state. There are aluminum microchannels available for purchase, but only in bulk and exceed reasonable budget. The evacuated tubes were also



hard to find, as there are wide varieties to choose from. The only parabolic concentrator we found was sold by a manufacturer in China which the team decided was too risky to buy. Here is a list of the parts we considered.

5.2 Fall 2014

5.2.1 Fall 2014 Past team Members Karen Turcios – Team Leader

Neekole Acorda – Sub Team Leader

Ladejah Dillard – Sub Team Leader

Juan Hernandez – Deputy Leader

Hang Liang – IPO

Joshua Reynoso – IFO

Francisco Diaz – Communication Officer

Jovana Salado – SAC Officer

Huimin Zhang – Webmaster

Raymond Yang

Jose Medina

Arjun Kohli

Noel Duenas

Kyle Garozzo

Craig Berger



5.2.2 Fall 2014 Past Timeline


2015 fall- project report (in progress) - il2 (1) (1)

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