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Prototype Doser Frame

Abstract

A full scale proto-type is being created.  This model will allow us to run full flow/ full scale accuracy tests in the lab. Additionally, this model will be taken to the EP3 conference this spring.  With this proto-type we will be able to demonstrate the functionality and flexibility of our chemical doser.

Proto-type Design

The proto-type is made up of two main components: the structural frame work and the moving lever-arm.  The frame components are constructed using a modular aluminum framing system manufactured by a company called 80/20. Affectionately called "The Industrial Erector Set," this company offers a wide variety of components along with an Auto-cad plug-in of each of their components. With these tools, we have been able to design and evaluate multiple proto-types. Additionally, their T-bar design will allow us to mount extra components that can be mounted with any standard "National Course" thread.  All accessories are readily available components purchased through McMaster-Carr.

The dimensions of the structural framework is based on the actual dimensions of the entrance tank of the Agalteca plant.  We have reduced the width to 1/2 meter as a space/material-cost saving measure but otherwise accurately reflect the entrance tank dimensions. 

Entrance tank dimensions and elevation are a critical criteria in plant operations.  All headloss throughout the plant must be accounted for in the entrance tank.  Furthermore, the addition of the rapid-mix tube has added to the depth of the entrance tank.  Full analysis of these parameters can be found on the Agalteca Page

Additionaly, the the frame work includes a table to hold a small stock tank and another table to hold the constant-flow device. As determined in the design of the constant head device, there should be ideally 30 cm between the orifice and the low water lever of the stock tank. This dimension has been taken into account in our design. **Find and link this page

Fig 1.0 Isometric View

Fig 1.1 Top View

Fig 1.2 Side View

Components

Lever Arm
The lever arm is a 1" x 1" aluminum bar classified by the 80/20 Inc. as 1010. The length of the lever arm was decided to be 0.80 meters to account for the variation in the water level of the entrance tank from the overall head loss in the plant. The lever arm is attached on the top with components from McMaster Carr. The bar is attached to the lever arm with a clamp, while the sides of the bar are attached by bearings so that it can rotate. The lever is positioned in a way so that the slide can slide to zero and have a manual shutoff.

Slide
The slide is a component from 80/20 Inc. (Part # 6730) that we attach the orifices to. There is also a hand brake that is attached.

Brake
 

Fig 1.3 Slide and Brake

The brake keeps the slide in place, also a component from 80/20 Inc. The brake naturally keeps the slide in place, while pushing on the area shown on the diagram relieves the pressure and allows for the movement of the slide

Float and Counter-Weight Connectors
The connectors are eyebolts that are screwed into the ends of the lever arm. The float and counter-weight are attached to these eyebolts by fishing line.

Stock Tank
The stock tank will sit on the triangular table that is pictured. The table for the stock tank was decided to be 24.13 cm (9.5 inches) tall to provide enough head to demonstrate how our system works.

Constant Head Tank
The constant head tank is maintained on this makeshift platform that will place the tank at the same level as the lever arm.

The AutoCad Drawing can be viewed Here

 Useful 80/20 information

 80/20 Inc. is a manufacturer of modular aluminum framing system.  80/20 components are used extensively throughout our lab and specifically in this project.  This section provides some details to assist getting started with these components and using them in design. 

http://www.8020.net/  This is the main web page for this company.  Available is a complete on-line catalog, price catalog and design ideas.  Design is made easier using their "Auto-cad Plug-In."  All components and frames are available with this Plug-In making requiring only limited Auto-cad knowledge for a professional looking design. 

This Plug-In, called Auto-Quoter, is used by the distributors to generate their price-quote.  Auto-Quoter can be downloaded on to any computer that is running Auto-cad and is free.  This program leads to greater accuracy when ordering and less chance of error as the Bill of Materials is generated directly from the Auto-cad drawing.

 Two local distributors are: Ralph W. Earl Inc.

5930 E.Molloy Rd.

Syracuse NY 13220

315-454-4431

rwearl@rwearl.com

Specifically- Bob Prosher:bproscher@rwearl.com.  Competent and helpful salesman.
Hughes Industrial

9685 Main St.

Clarence NY 14031

800-759-8374

www.hughesind.com

 Ordering Information

 The Bill of Material as generated by the AutoQuoter program and is attached.  Bob Proscher from Ralph W. Earl Inc was able to procure a 40% discount for us on materials.  The order for these components was submitted to Christene Day on November 17,2009.  We are currently waiting on receipt of the materials to continue on the project.

**Attach the BOM here

Bibliography

Deliverables

By the end of the semester we intend to have a functional, full scale non-linear chemical doser.In order to accomplish this, this sub-group needs to complete the following:

  • Complete final changes to Autocad drawing to represent changes in the bracketing.
  • Talk to Paul Charles about fabrication of the bushing and drilling of the lever-arm
  • Update Material's List
  • Contact 80/20 distributor about pricing. Plan to discuss the possibility of having them sponsor our frame
  • Order and receive components. Assemble according to Autocad Dwg.
  • Install hydraulic components
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