Post on 05-Aug-2020
NicaraguA Bottle Upcycling
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NABU
P18433
Agenda
BackgroundProblem StatementPhase I Follow-up ActionsMarket AnalysisEngineering Requirements
System AnalysisUpdated HOQ DiagramFunctional Decomposition &
sss AnalysisBenchmarking
System Level ProposalSystem Architecture
Concept & Architecture Development
Morphological ChartEngineering Analysis
Environmental AnalysisRisk AssessmentEconomic FeasibilityPhysical Feasibility Research TopicsUpdated Project Plan
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Objective Statement
To upcycle plastic bottles creating a valuable end product, generating employment, and stimulating the economy of
El Sauce, Nicaragua
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Problem Statement● There is lack of proper recycling methods for plastic bottles in El Sauce,
Nicaragua○ Currently trash is being burned or dumped
● Our goal is to design a plastic bottle recycling process that creates jobs and a valuable end product ○ Considering a gutter for water systems, such as irrigation and water
collection○ Connectable, easily expandable
● We aim to design a robust manufacturing process that can accommodate low resource availability and a sparse skilled workforce
● The manufacturing process consists of melting and forming PET plastic chips into a valuable product
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Phase 1 Follow Up Actions
● Based on feedback from our phase 1 problem definition, we have ○ Solidified a product for our molding process○ Updated our engineering and customer requirements so they are quantifiable and relate
directly to each other○ Rebuilt our house of quality to more accurately show the relationships
■ Separated house of quality into final product and process○ Continued benchmarking to include other processes and mechanisms we aim to include in our
process○ Final Product Decision (Gutter) ○ Shredder Status Analysis:
■ Conclusion: Not immediate priority, highly resource intensive
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Engineering Requirements
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HOQ - Product Design
Legend
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HOQ - Equipment
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Phase 2 AchievementsAdam Santagata - Benchmarking, Morphological Chart, Engineering Requirement Values
Vikas Patel - Functional Decomposition, Plastic research, Draft mold design, Risk mitigation
Kyle Appleman - PET Melting feasibility, Concept Generation, Pugh Chart
Ignacio Martos - Set Up Dynamic Tool for Project Management, Economical Analysis, HOQ Equipment Updates, Market Analysis
Pierce Scroggins - Possible solution descriptions, Contributed to Pugh Charts, System architecture, Risk mitigation, Update HOQ’s, Update ER’s & CR’s
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Functional Decomposition
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Functional Decomposition
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Market Analysis
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BenchmarkingPlastic Material Properties
Melting Point Young's Modulus Impact Strength Density Standard
Applications[°F] [GPa] [ft-lbs/in] [lbs/in^3]
Polyethylene
Terephthalate (PET)480-500 2.76 0.7 0.0499 Beverage Bottles
High Density
Polyethylene (HDPE)259-267 1.55 1.3 0.03465
Storage Bins,
Industrial Tubing
Low Density
Polyethylene (LDPE)230 0.29 No Break 0.03321
Plastic Bags &
Bottles
Polyvinyl Chloride
(PVC)320 2.83 0.4-22 0.051 Piping
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BenchmarkingPlastic Melting Machines
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BenchmarkingElectrical Resistance Heating Element
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BenchmarkingCompression Method
Product
AutoCraft 2-Ton Trolley Jack with 2-Ton Jack Stands Combination
Craftsman 2-1/2 Ton Floor Jack, Low Profile
Alltrade Tools 4000LB TRPL LFT JACK
HYDRAULIC SHOP PRESS HSP-10H
Hydraulic Press, 10t, Manual Pump, 36 In
Buffalo Black Bull Fully Automatic Electric Car Jack
Cinva-Ram / Ceta-Ram
Description Car Jack Car Jack Car Jack Hydraulic Press Hydraulic Press Car Jack Custom Press
Max Weight 2 [Tons] 2.5 [Tons] 2 [Tons] 10 [Tons] 10 [Tons] 1 [Tons] ??
Lift Range 5.5 - 13.375 [inches]
14 [inches] 5.5 - 17.5 [inches] 4.33 - 14.33 [inches] 10 [inches] 5 - 14 [inches] 8 [inches]
Power Manual Manual Manual Manual Manual Electric Manual
Price $40 $60 $150 $300 $337.50 $60 Home Made 16
Morphological Chart
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Morphological Chart-Analysis of Components
Green = Practical Solution Components
Orange = Low Budget Solution Components
Red = Impractical / Non-beneficial Components
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First DesignCons: Complexity of molten plastic transfer into mold
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Concept - Previous vs CurrentPrevious Design:
● Two part system with heating and molding accomplished with different mechanisms
● Mold would be contained within an oven and compressed to melt and shape plastic
Current Design:
● Integrated heating and molding into a single unit
● Mold is heated internally and pressured
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Reasoning for Changing Design
After meeting with HARBEC we decided to update our design based on the following criteria
● Lower energy use- don’t have to heat an entire oven● Lower heat loss- mold doesn’t have to cool completely to be re-used● Increased production rate- with multiple molds in use in a series, there will be no down time where
workers are waiting for an oven to heat the mold or to cool down● Decreased materials needed to build system- Aluminum block and resistance heaters● Decreased size of total system- a single mold should only be as large as a shoe box
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System Level Proposal● Plastic is compressed and heated within the mold to increase energy● Plastic has to exceed glass transition temperature to be shaped into the mold (approximately 67 -
81°C)● Force requirement depends on mold shape and temperature and must be determined through
testing● Includes ejector pins to easily remove molded part
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System Level Proposal Schematic
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Draft of Gutter Mold Design (System Level Proposal)
● Current design for gutter mold
● 12” x 6” x 3” (LxWxH) outside gutter dimensions and ⅛’’ thickness
● Resistant heating elements will run through bottom of mold
● Conductive grout will secure the rods and assist heat transfer
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System ArchitectureSystem Inputs:● Energy input● Human input
Failure Modes:● Melting plastic timing● Melting temperature regulation● Applying insufficient compression forces● Product damage during extraction● Product deformation from insufficient
cooling time● Personal injury from operation● Equipment wear from regular use
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Pugh Chart
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Screening Matrix
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Engineering Analysis
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Environmental Analysis● Effects of sun exposure on PET
○ Little to no change in water quality during short exposure periods
○ High temperatures and CO2 presence increased release of formaldehyde and acetaldehyde during long exposure periods
● Recommend not to consume water collected by gutters until further studies are conducted
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Economic FeasibilityObjective:
Payment processed by production: $x for one gutter, quality standards would be important
Desired payback period: 3 ← → 6 months at 0% profit
Desired machine cost: < $500
Average salary range in El Sauce, Nicaragua:
● $0/month, some percentage of the population● $100/month, high percentage of the population● $200/month, some percentage of the population● $400/month, very low percentage● $500+/month, extremely low
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Economic Feasibility Cont.
Hypothesised production scenarios:
● Number of workers: 2 ← → 6● Number of work hours: 8 ← →16● Number of products per mold: 1 ← → 5● Number of molds per batch: 1 ← → 3● Time per batch: < 1hr
○ Length of a single gutter: 1 foot○ Weight of a single gutter (quality): tbd grams (g)
● Price of each foot of gutter: $0.30 ← → $1.00 ● Number of workdays: 25 ← → 30● Monthly salary for operators: <= $100● Cost of plastic chips per liter: $ 0.05 ← → 0.08 (Team 18434 suggestion)
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Physical Feasibility Research Topics● Plastic mold design and methods of molding● Liquid plastic flow mechanics● Required pressure to form plastic at different temperature ranges ● Plastic cooling (rate and how to)● PET & HTP plastic qualities● Liquid plastic feed systems, dripping, injecting, etc● Plastic cooling rate and cooling systems● Handling of hot plastic molds (Leather, can we get it?)● Gas emissions of molten plastics, rate, toxicity, and ppm● Mold clogging scenarios
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Risk AssessmentHigh Importance (9)
● R2: The heater could break down and malfunction○ Mitigation ➜ repeatedly testing the heating element prior to installation
● R3: Inconsistent temperature regulation in the plastic melter○ Mitigation ➜ measuring temperature gradients in different regions of melter
● R8: Insufficient funds to purchase all the required design materials○ Mitigation ➜ research multiple vendors and compare prices
A full list of current project risks can be found on our team edge page
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Risk Assessment Cont.Medium Importance (6)
● R5: We are unable to fill the mold using the plastic melting process○ Mitigation ➜Plastic melted inside the mold, eliminates molten plastic transfer
● R7: System inconsistently produced the plastic product○ Mitigation ➜Measure dimensional variation, adjust molds
● R10: No facilities for us to safely test a moderately large furnace○ Mitigation ➜Locate usable lab with ventilation
● R13: Initial benchmarking machines require salvaged items that may be difficult to acquire○ Mitigation ➜Salvage parts from old, free, or cheap appliances
A full list of current project risks can be found on our team edge page 34
Project Plan - Phase 3
● Finalize mold design including connectability and strength of product● Acquire materials for building mold and product (aluminum, plastic chips,
heating coil, electronics, controls, insulation, compression method)● Create a test plan for initial molding prototype● Risk mitigation analysis
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Management Platform: Dapulse
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Current Direction
● Finish research and designing of mold
● Analyze benchmarked solutions for most viable option
● Start acquiring materials to build prototype
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Questions
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