Fabrication
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The Fabrication team develops fabrication methods that are useful at AguaClara construction sites, while being feasible and economical. We research the requirements for our tasks, select appropriate design criteria, and come to recommendations for plant parts and construction techniques. We integrate our ideas into the overall plant and help future plants be built more easily and at less cost, with several beneficial features.
Introduction and Objectives
The Fabrication Team was created in the Spring 2011 semester to solve some of the problems of constructing plant parts on-site in Honduras. One goal of AguaClara is to empower Hondurans to be able to build the plant, and the Fabrication team works to make that easier. We work on better methods for drilling, cutting, and fitting parts, as well as improving designs to make fabrication simpler. We also work on several entrance tank problems, such as deigning a trash rack for large debris and an overflow weir so that water can bypass the plant without turning off the transmission line. We also look into connections between PVC pipes for the inlet manifold. Our approach to these tasks has been to brainstorm and come up with many possible solutions, then evaluate which ideas are feasible for the Hondurans. Then we build prototypes to test our solutions and make recommendations for future plants.
Task 1 : Rapid Mix Pipe and Orifice Plate
Goal:
a. To create an air release vent through the piping after the rapid mix pipe.
b. To attach an orifice plate to the pipe stub to lower water level 10cm.
Material Possibilities
a. PVC, clear plastic
b. Stainless Steel, PVC, (Coffee Can / Paint Bucket etc.)
Brainstorming:
a. "Candy Cane" idea
Double Fitting for 180 degree turn
Slits to diffuse water in different directions
Mesh to allow air out but not water up?
b. Use flat PVC as an end stop and screwing into the stop and the pipe parallel with piping.
Create flat PVC end stop that fits into the pipe and secure with perpendicular bolts to the piping.
Monroe: Use Worm-drive hose connector and tighten to fit
Monroe: Use metal twine and clamp both sides
"Coffee Can Idea" or Bucket
Restrictions
Ability to tap holes into end of pipe
Potentially cut gasket
Mold Pipe
Questions for APP:
*How are you cutting the piping? Would it be a straight cut if we want to place a flat piece of pvc on the end of the pipe?
*Could you make a 6inch diameter gasket of sorts? Wouldn't have to be air tight, just to adjust for
Task 2: Inlet Manifold for Sedimentation Tanks
Question: is the end of the manifold tight against the sed tank or will there be room to slide pieces together?
Goal:
Create a way to connect two larger diameter manifold pipes with diffuser constraints.
Design 1: Puzzle fit + Clamp
Could be 2.5 inch thick alternating cut sections.
*Can we bore out this area? It would be very strong but can we cut it out? How much machining?
Design 2: Parallel pins to pipe + Clamp
Cut holes parallel into manifold edge for support then include clamp.
Design 3: Clamp and Sheet metal constricting design
Use the duct repair thing?
Sheet metal overlaps on itself and tightens
very water tight
Design 4: Modify Coupling
Task 3: Drain and Jet Reverser System for Sedimentation Tanks
*Can We heat Large Diameter Pipes to Mold them?
Task 4: Pipe Stub Valves
Problems: Bulky so heavy, Pipe gets Jammed
Suggestions: Use hot water or oil to move it (How feasible is this - to heat it enough to bend)
O-rings are ginormous, maybe could make our own.
Task 5: Large Diameter Valves
50 cm