P14417: B9 Particle FilterCycle 3: System Integration and Testing

Dan AndersonThomas HeberlePerry HosmerKarina RoundtreeKelly Stover

Agenda• Final Design• System Integration Issues• Requirements Update• Testing Update• Risks• Project Plan• Action Items• Purchasing & Cost Summary• Documentation• Problem Management Review

Final Design

System Integration

Two problems occurred during building:1. Bolts were too short- easily fixed by getting longer bolts. Issue

occurred due to a measurement assumption.2. Placed mesh on wrong side of lid assembly

• Was not possible to fix but was able to use it for taste testingSo far no problems have occurred that will prevent the collection of data.

Engineering Requirements and Test Plans

Test Plans: Here

Turbidity & Flow Rate Testing Update

• Testing performed on water from pond near Global Village• Genesee River was frozen over• Three prototypes have been used to test how well the assembly works• Testing has been successful!• We plan to continue flow and turbidity tests through the first week in April.

– Genesee River water– Custom water (varying levels of sand and soil added to tap water)

Turbidity & Flow Rate Testing Update

TurbidityTest Source Prototype Initial Turbidity (NTU) Final turbidity (NTU) % Reduction

1 pond 1 322 11 0.965838509

2 pond 2 240 7 0.970833333

3 pond 1 47 16 0.659574468

4 pond 3 42 11 0.738095238

5 pond 1 74 9 0.878378378

6 pond 2 64 4 0.9375

7 pond 3 84 6 0.928571429

FlowrateTest Source Prototyp

eInitial Turbidity (NTU) Filter time (min) Flow Rate (l/min)

1 pond 1 322 90 0.105150556

2 pond 2 240 90 0.105150556

3 pond 1 47 100 0.1324897

4 pond 3 42 64 0.266162344

5 pond 1 74 77 0.098322597

6 pond 2 64 77 0.122903247

7 pond 3 84 85 0.155870235

Taste Testing

Durability Testing● Brush

○ Procedure○ Ordering

● Bucket Assembly○ Procedure○ Location

RisksID Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Risk Status

1 Cleaning is difficult

Users may not clean properly or often enough

Difficult to take apart, reassemble 3 3 9

Supply cleaning instruction, minimize number of parts, minimize disassembly/assembly time, visual cues to indicate which side of filter is up Closed

2Costs more that $25/unit

Product may not be used

Materials selection, construction 3 3 9 Design to be low cost Closed

3 Stress concentration

Damage to filter within 2 year lifespan

Repeated use of filter 2 3 6 Spread load out around edge of filter Open

     Stress on clamp/fastener 3 2 6 Calculate necessary force rating Open

4Flow rate does not meet requirement

Not meeting customer needs

Insufficient area of filter/diffuser, filter isn't porous enough 2 3 6

Increase surface area of filter, find more porous materials Open

5User not detecting tear in filter

Particles escape into clean water undetected

Filter is hidden from view 2 2 4

No hidden filter, instruct user to inspect both sides of "sandwich" Open

6 CorrosionWater tastes bad, equipment fails

Improper cleaning, interaction of materials with water 1 3 3

Use materials which won't corrode, provided clear cleaning instruction Open

7 Weight is too muchToo heavy for women and children Materials selection 1 3 3

Ergonomic study, design to allow women and children to use Closed

8 Incorrect usageFilter could break, water not cleaned

Not intuitive, poor instructions 1 3 3

Use visuals whenever possible, minimize text, poka-yoke Open

9Stability issues with bucket

bucket tips, breaks, etc

poor structural design, unlevel surface 2 1 2

Design proper attachments, make sure surface is level prior to use Open

10 Leakage

UV Absorbing particles reach "cleaned" water Not a tight seal 1 1 1

Use rubber gasket, clamped down tightly Closed

11 Filter may be too tallNot enough room for "clean" water

Planning issues, imprecise calculations 1 1 1

Calculate necessary height ASAP, test for fill amount Open

JanuaryFebruary March April May0

2

4

6

8

10

12Risk Curve

Active RisksWorst Case

Month

Unre

solv

ed R

isks

Project Plan

Action Items12 Turbidity & TSS Testing (Data Gathering Phase) 15-Feb In-Progress Perry13 Build Prototype 18-Feb Completed Thomas14 Begin Testing on Prototype 21-Feb Completed Perry15 Record Final Prototype Weight: S3 28-Feb Completed Thomas16 Finalize Shipping Costs Estimate: S4 28-Feb Behind Schedule Dan17 Finalize Cost Summary 3-Mar Completed Thomas18 Determine method of attaching brush (cleaning) 6-Mar Behind Schedule Karina19 Outline Final Paper 7-Mar Completed Kelly20 Finalize Cleaning Materials & Procedures 10-Mar Behind Schedule Karina21 Outline Final Poster 13-Mar Completed Karina22 Build 2nd Prototype 13-Mar Completed Thomas23 Statistical Analysis for Specs: S1,S5,S10,S13 26-Mar Not Complete Dan24 Build 3rd Prototype 27-Mar Completed Thomas25 1st Draft Paper 1-Apr In-Progress Kelly26 Statistical Analysis for Durability Spec.: S8 2-Apr Not Complete Kelly27 Complete Final Paper 16-Apr Not Complete Team28 Finalize Documentation & EDGE Site 16-Apr Not Complete Dan & Kelly29 Final Poster Designed 17-Apr Not Complete Karina30 Imagine RIT 3-May Not Complete Team31 Project Completion 6-May Not Complete Team

Purchased Parts

• 4 Prototypes– Mesh– Buckets– Lids– Bolts/Nuts

• Testing Supplies– Cups– Spring Water

• Brushes for durability testing• Sand and topsoil for additional

cleaning and flow testing

Already Purchased Upcoming Purchases

Cost Summaries

Product Cost Summary (BOM)No. Item Vendor Vendor item

number/description Qty Price per item/Sq ft

price per unit

1 Bottomless bucket The Cary Company 57WCU5 1.00 2.97 2.972 Lid The Cary Company 57WCUP 1.00 1.47 1.47

3 5 Micron Mesh Macro Specialty Steel 200x1400 Twill Dutch Weave 316ss 1.00 11.75 6.32

4 Bucket The Cary Company 57WCU5 1.00 2.97 2.975 Hex nut 1/4"-20 thread McMaster Carr 91845A029 6.00 0.05 0.27

6 Cap Screw 1/4"-20 thread, 2"long McMaster Carr 92240A550 6.00 0.28 1.71

7 Nylon Brush Home Depot Quickie Original Iron Handle Curved Plastic Scrub Brush 1.00 2.19 2.19

9 Rods N/A Made from cut out portion of bottomless bucket 20.00 0.00 0.00

total 17.90

Project Budget Starting Budget: $500.00 Previously Purchased: Prototyping & Testing $(222.49)To be Purchased: Brushes $(7.00) Sand $(5.00) End of Term Balance: $265.51

Documentation• Imagine RIT• Poster - Outline created started filling in information• Paper• Outside Submission

Problem Management Review• Schedule

– Flow Rate Testing Pushed Back– Durability Testing Pushed Back

• Brush Durability– Setting up Testing

• Incorrect Assembly for one prototype– Taste Testing– Brush Durability