Welcome! We are team # 1, Karla, Julio, Ramon, and Marissa worked on this project during the Spring of 2021. The team has worked hard in redesigning a filter system for industrial machining fluids by improving the efficiency and aesthetics. We hope that you enjoy this project as much as we did. Click on the Welcome Video below!

Watch the Welcome Video! SDI T1 MESH Introduction

Title: Video titled: SDI T1 MESH Introduction

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WHAT IS THE PROBLEM WE ARE TRYING TO SOLVE?

In summary, the MESH machine is already a very perfected machine that filtrates dust, metal cuttings, and many other small impurities from the coolant to make it reusable once again. This machine has been the best of its category for forty years consecutively. The whole idea to work on this machine is to give it a set of backup sensors that could foresee or detect when the machine might fail and make it come into a complete stop to where no dust or metal cuttings pass through the filtration system with the water/ coolant. Also, it was requested for the team to come up with some better texturing for the machine to make it more attractive for younger investors or companies that may want to buy this product.

One of the problems we identify in the field of the filtration paper systems is that when the automatic roller stops functioning or derails from its ground position, causing for the filtering paper to not be feed properly and end up clogged with all the debris that will prevent the water/coolant to be filtered properly. This issue could stop the flow of the water/coolant and making it overflow outside the machine wasting precious coolants that are expensive. For instance, if the roller derails from its position it could make the paper filter fall from its position letting all the debris go through and mixing up with the cleaned water/coolant.

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IMPORTANT TO KNOW

To better understand the problem, we conducted background research on relevant topics, from this we learned the following:

· Wire mesh industrial filtration is commonly used in commercial and industrial/OEM applications

· The size of the mesh material depends on what needs to be removed from the water

· Coolants are used to lengthen the devices lifestyle and grant a better finish to machined components

· On average, the coolant consumes 50% of the electrical energy used in traditional metal cutting applications

Mesh fabrics can come in many different sizes and are clearly numbered for understanding. Choosing the required mesh size depends on what needs to be removed from the water. When talking about filtering, there are different terms that define the size of the items to be removed. The equivalent table below shows a comparison between different terms. The equivalence diagram opening is the size of the space between the water and the material through which the particles can pass. The number of openings in a square inch screen is called the mesh size. The micron level is the distance between filter media. A micron is one-millionth of a meter or one twenty-five thousandth of an inch. This is described in more detail in "Water Filter-The Basis of Micron Grade". When using a sediment filter or separator as a pre-filter for other water filtration products, make sure that the mesh size is equal to the larger micron level.

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WHY IS THIS PROBLEM IMPORTANT?

Our main motivation to work on this filter system project to enhance the aesthetics of the filter machine while also improving the reading accuracy of the floating sensor. It highly important to understand who the user is and how they may affect other users. The stakeholder map illustrates potential users for filter systems for industrial machining fluids. As it is shown, the user of the filter system is narrowed down to a machinist technician since they are the ones who understand and utilize the filtering system machine.

Most companies have a designated person who will utilize the machinery which is known as the machinist technician. In addition, there are also people who oversee keeping the machine clean and safe to use which can also be known as maintenance. Furthermore, the filter system machine is in the hands of the manufacturers. These manufacturers are responsible in producing the filtering system machine and distributing it to other companies or customers that have purchased the product. There will be existing companies as well as new companies that may want to purchase the product. In addition, there are various industries that use filtering technology. For this product in particular the industries that use this product are known. These include but are not limited to the wire and cable, tooling machine industry, automotive and supplying industry, and the glass and environmental industry.

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OUR PROPOSED SOLUTION

“We propose the redesign of the filter machine by improving the aesthetics and applying sensors that will facilitate the maintenance of the machine by displaying the process of filtration.”

-KMJR

After understanding the problem in depth, we explored various potential solutions and selected the best concept. Our preliminary idea is to use a combination of different sensors that could foresee when the paper filter roller is about to fail and make it come into a complete stop to prevent spilling or contaminating coolant as mentioned before. Another thing that could be investigated is reinforcing that paper filter roller, so it won't derail from its position, creating a more secure way for the paper to continue being dispensed to trap all the debris and keep the coolants clean as it supposed to be.

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Figure 4: Mesh band filtration machine

This is how our product solution works: the accelerometer microcontroller is able to display and collect live feed data from the mesh using vibrational analysis. We will be using the Arduino UNO microcontroller and a ADXL 335 axis accelerometer to be able to conduct this analysis.

The team has conducted background research on the different colors that may be more convenient when wanting to attract customers. We have understood that colors are very important when it comes to attracting customers. Color preferences do in fact vary between the different age groups. It is to say that infants, teenager, and adults have different color preferences.

However, since our target is based on attracting young engineers our focus is to investigate the color preferences for that specific age group. This has allowed us to decide to use vinyl to improve the aesthetic design of the machine.

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FROM IDEA TO REALITY

Once we defined a clear solution idea (i.e. concept), we applied our engineering knowledge to transform it into a real product. These were some of the important design challenges and how we approached each one of them:

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Progression of embidement design fall 2021

STRATEGIES AND PRIORITIES

FMEA

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Table 1: fmea

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testing and validation

TEST 1: TESTING VIBRATION SENSOR CODE

This is the testing protocol, the team started by uploading the code to the microcontroller, until indication light on the microcontroller said it was ready. After that the team opened a data plotter on the software to see the reading the sensor is capturing. Then the team began exciting the accelerometer to see if it picked up the excitations that were done to it. Since the vibration sensor did pick up and display the excitations shown below, the team decided to test it with a greater excitations force.

SDI T1 MESH ARDUINO PROTOTYPE

TEST 2: TESTING VIBRATION SENSOR WITH A GREATER FORCE

The team decided to test the vibration sensor with something that would give it a larger amplitude of excitation. So, the team decided to use the base sound system from one of our cars which is stronger than most normal cars have. The vibration sensor succeeded in detecting and plotting these excitations as can be seen below. Now in future the team plans to test it on the actual machine.

Arduino Vibration Trial with speakers

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Description automatically generated IMPROVEMENTS: VIBATION SENSOR WITH LED LIGHT AND BUZZER

The team went ahead and took one step further on improving the vibration sensor with the addition of an LED light and a buzzer to set off an alarm with a flashing light to signal when the vibration sensor is getting high excitations and let the user know when the machine requires maintenance.

The team was also able to wire and turn on the filtration machine but have found that we need to reverse the polarization of the motor. Once we fix the polarization on the filtration machine, it allowed us to both find the most efficient placement of the vibration sensor and determine what frequencies are made when machine needs maintenance.

Development of Vibration Sensor

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TEST 3: LOAD CELL SENSOR

The team was able to work with a 100kg load cell sensor and did some research on how it works to be able to understand its functionality and get data from the machine. The team successfully developed a code on the Arduino micro controller to help display information from the load cell sensor to display whenever the load sensor is either in tension or compression. This data will also help the user know when the MESH tensioner is either well under tension or in compression.

Development of Load cell & Screen

TEST 4: SLIDING PLEXIGLASS WINDOW AND LED SCREEN

The team implemented an LED Screen on the filter machine to allow the user to view the information and data generated from the vibration and load sensors. The user is also able to adjust the height of the LED screen by using the housing to make it easier to use. In addition, the plexiglass is to be placed at the front end of the machine. The user will be able to slide the plexiglass upwards to facilitate maintenance and be able to view the filtering process.

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PROTOTYPE EARLY AND OFTEN

We found that physical prototyping was very helpful to increase our understanding of the problem and the feasibility of our solutions. Our first prototypes were simple but useful and we continued evolving into more complex ones.

This was our first prototype, it may be simple but it helped us understand ….

SDI T1 MESH Arduino Demonstration

Title: Video titled: SDI T1 MESH Arduino Demonstration

Arduino Vibration Trial with speakers

Title: Video titled: Arduino Vibration Trial with speakers

Development of Load Cell

As one of the methods needed to size the linear actuator, which is finding working capacity of the MESH band. Our team determined that the best solution to finding the load capacity was incorporating a linear load cell between the pneumatic gas spring and base of the machine. The team was able to design and machine the thread cross overs from 6mm threads to 12mm threads in the machine shop. And again, this load cell will show the user the current working capacity while the machine is operating.

Development of Plexiglass Window

The team was not 100% satisfied with just adding a plexiglass window. Instead, the team decided to take a step further and find a solution to have a sliding mechanism that will allow the customer to open and close the plexiglass window when needed. The team also design a housing to hold the plexiglass that is sturdy enough to mount to the sliding rails. As a team it was decided to 3D print the plexiglass glass housing using PLA filament.

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FUTURE WORK

This section is to inform and update of current and possible future application on the filtration machine.

LINEAR ACTUATOR

The team investigated the possibility of sizing a linear actuator which can potentially replace the current pneumatic gas. The replacement of the pneumatic gas spring will help in preventative maintenance. The methods which can be used to size the actuator are the following.

1. Finding working capacity (load/tension) that is being applied to the MESH belt

2. Travel (linear distance/stroke)

Aesthetic Design |F.W.

For our aesthetic design we will show our final product with our color palette and electrical and mechanical components incorporated into the machine.

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REFERENCES

1. Forsta Filters. “Automatic Self-Cleaning Water Filters.” Forsta Filters, 5 Aug. 2020, www.forstafilters.com/.

2. “Shelco Industrial Products.” Shelco Filters, shelco.com/products/shelco-industrial-products/.

3. TEKLEEN. “Self-Cleaning, Automatic Water Filters for Industrial and Irrigation Water Filtration.” TEKLEEN Industrial Water Filter and Irrigation Filter - Self-Cleaning Water Filtration - Automatic Filters Inc., 2021, www.tekleen.com/.

4. U-Tech. “Compacto Compact Band Filter.” U-TECH, 2021, www.u-techindia.com/product/compact-band-filter/.

5. Bedard, Risa. “Choosing a Proper Water Mesh Filter Element.” BoshartU - Free Plumbing Blogs, Articles and Education, blog.boshart.com/choosing-a-proper-water-filter-mesh-element.

6. “Mesh Fabric - History and Applications: Canvas ETC .” Canvas ETC, 19 Feb. 2019, www.canvasetc.com/mesh-fabric-history-and-applications/.

7. “Top Industrial Water Filter Companies and Manufacturers in the USA.” Thomasnet® - Product Sourcing and Supplier Discovery Platform - Find North American Manufacturers, Suppliers and Industrial Companies, Thomas, www.thomasnet.com/articles/top-suppliers/industrial-water-filter-manufacturers-suppliers/.

8. Cannon, D., & Cannon, P. (2019, October 16). Centrifugal separators: Working PRINCIPLE, benefits, and APPLICATIONS Discussed. Retrieved February 28, 2021, from https://cannonwater.com/blog/centrifugal-separators-working-principle-and-applications/

9. What is the difference between vacuum filtration and gravity filtration? (2020, January 18). Retrieved February 28, 2021, from https://www.labrotovap.com/what-is-the-difference-between-vacuum-filtration-and-gravity-filtration/

10. HydroGroup®. (n.d.). Sand filter, DEPTH filter, filter GRAVEL, FILTER SAND, jurassic lime, MARBLE, DOLOMITE, river water FILTRATION, well water filtration, Filtrate, Flocculant, Water flushing, air Flushing, MagnoDol, HydroCalcit, hydrogroup, HYDRO-ELEKTRIK, rwt gmbh. Retrieved March 01, 2021, from https://www.hydrogroup.biz/areas-of-use/water-treatment/filtration.html

11. Onur, A., Ng, A., Batchelor, W., & Garnier, G. (2018, September 12). Multi-Layer filters: Adsorption and Filtration mechanisms for Improved separation. Retrieved March 01, 2021, from https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6143674/

12. Saha, U. (2020, October 01). Corrosive or scaling water. Retrieved March 02, 2021, from https://extension.uga.edu/publications/detail.html?number=B1523&title=Household+Water+Treatment%3A+Mechanical+Filtration+Methods+and+Devices

13. Rahäuser R., Klemm P., Verl A., Kircher C. (2013) Increasing the Energy Efficiency in Metal Cutting Manufacturing through a Demand Based Coolant Filtration. In: Nee A., Song B., Ong SK. (eds) Re-engineering Manufacturing for Sustainability. Springer, Singapore. https://doi.org/10.1007/978-981-4451-48-2_38

14. “The History of Water Filtration.” Pelican Water, 9 Sept. 2014, www.pelicanwater.com/blog/history-water-filtration/.

15. The principle of vacuum filtration. (2018, September 06). Retrieved March 20, 2021, from https://www.vacuumfiltrations.com/the-principle-of-vacuum-filtration/

16. Mein, S. (n.d.). The importance of Coolants in machining. Retrieved March 20, 2021, from https://www.firetrace.com/fire-protection-blog/importance-of-coolants

17. Fuchs, J. (2020, February 18). Liquid level sensors - floats. Retrieved March 26, 2021, from https://techblog.ctgclean.com/2020/02/liquid-level-sensors-floats/

18. Microcontroller. (2021, February 10). Retrieved March 26, 2021, from https://en.wikipedia.org/wiki/Microcontroller

19. What is an Arduino? (n.d.). Retrieved March 26, 2021, from https://learn.sparkfun.com/tutorials/what-is-an-arduino/all

20. Plantservices.com. (n.d.). Retrieved March 26, 2021, from https://www.plantservices.com/articles/2006/154/

21. Martínez-Rego D., Fontenla-Romero O., Pérez-Sánchez B., Alonso-Betanzos A. (2010) Fault Prognosis of Mechanical Components Using On-Line Learning Neural Networks. In: Diamantaras K., Duch W., Iliadis L.S. (eds) Artificial Neural Networks – ICANN 2010. ICANN 2010. Lecture Notes in Computer Science, vol 6352. Springer, Berlin, Heidelberg. https://doi.org/10.1007/978-3-642-15819-3_9

LEARN MORE ABOUT OUR DESIGN PROCESS

We went through a meticulous design process to arrive to the final solution. The information in this page is a summary intended for the general public. To learn about the project details, visit the DESIGN PROCESS page. To obtain access contact the course instructor.

ACKNOWLEDGEMENTS

The team received help from various persons, their help was critical to our success, we would like to acknowledge our faculty advisors Martin Johansson and Mostafa Malki for their endless support.

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