P16371: Controlled Oscillating Meniscus Test Fixture
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Detailed Design

Table of Contents

The Deliverable of P16371 MSD Team

It's expected that this MSD team designs and constructs a device that is capable of meeting the customer requirements as outlined in the problem definition. Specifically, this means that the device must create a stable liquid meniscus, oscillate the meniscus at a frequency of approximately 100 Hz, be capable of utilizing multiple different working fluids, be able to interface with the other subsystems, and it must be reliable. In order to fulfill the customer requirements, it's also expected that the MSD team designs a computer program that allows for adequate control of the device. Therefore, upon completion of MSD II the customer will receive a device that meets his requirements along with a program that is capable of supplying the necessary controls. It's the customer's desire that the device which is being designed and constructed by this MSD team will enable him to conduct his doctoral research.

Team Vision for Detailed Design Phase

Anticipated Tasks

For the detailed design phase, our team expected to accomplish the following tasks:

Accomplished Tasks

The following tasks were actually accomplished during the detailed design phase:

Feedback from Preliminary Detailed Design Presentation

The following bullets list the major points of feedback provided from the preliminary detailed design presentation:

To view a detailed description of all the feedback given during the preliminary detailed design presentation click here.

Customer and Engineering Requirements

Customer Requirements

Customer requirements

Customer requirements

An Excel Worksheet containing the updated customer requirements can be accessed by clicking here.

Engineering Requirements

Engineering requirements

Engineering requirements

An Excel Worksheet containing the updated engineering requirements can be accessed by clicking here.

Drawings & Schematics

Small Speaker Enclosure Design

Final design of small speaker enclosure

Final design of small speaker enclosure

Exploded veiw of final design of small speaker enclosure

Exploded veiw of final design of small speaker enclosure

Drawing of small speaker enclosure with 15 degree internal cone angle

Drawing of small speaker enclosure with 15 degree internal cone angle

Drawing of small speaker enclosure with 30 degree internal cone angle

Drawing of small speaker enclosure with 30 degree internal cone angle

Drawing of small speaker enclosure with 45 degree internal cone angle

Drawing of small speaker enclosure with 45 degree internal cone angle

Small speaker design drawing Link to PDF document
15 degree angle Click here.
30 degree angle Click here.
45 degree angle Click here.

Large Speaker Enclosure Design

Initial design of large speaker enclosure

Initial design of large speaker enclosure

Final design of large speaker enclosure

Final design of large speaker enclosure

Final design of large speaker enclosure

Final design of large speaker enclosure

Drawing of large speaker enclosure with 15 degree internal cone angle

Drawing of large speaker enclosure with 15 degree internal cone angle

Drawing of large speaker enclosure with 30 degree internal cone angle

Drawing of large speaker enclosure with 30 degree internal cone angle

Drawing of large speaker enclosure with 45 degree internal cone angle

Drawing of large speaker enclosure with 45 degree internal cone angle

Large speaker design drawing Link to PDF document
15 degree angle Click here.
30 degree angle Click here.
45 degree angle Click here.

System schematic

Updated system schematic

Updated system schematic

Feasibility plan

Feasibility testing plan.

Feasibility testing plan.

A PDF of the feasibility testing plan can be viewed by clicking here.

Liquid Oscillations Induced by Speaker

To view a video demonstrating proof of concept for inducing oscillations via a speaker click on one of the videos in the table shown below. The images shown below display the setup that was used to capture the first video clip of oscillations being induced in a glass beaker. The successful demonstration seen in the videos implies a speaker will be utilized in the fabrication of the final system. However, in order to view oscillations at a higher frequency, a camera with a higher frame rate will be required.

Description Link to video
Oscillations in glass beaker click here.
Oscillating a meniscus click here.
Setup used to demonstrate proof of concept of inducing liquid oscillations via a speaker.

Setup used to demonstrate proof of concept of inducing liquid oscillations via a speaker.

Schematic of the setup used to demonstrate proof of concept of inducing liquid oscillations via a speaker.

Schematic of the setup used to demonstrate proof of concept of inducing liquid oscillations via a speaker.

Glass beaker used to hold liquid volume while observing oscillations.

Glass beaker used to hold liquid volume while observing oscillations.

Glass beaker with submerged needle used to observe liquid oscillations.

Glass beaker with submerged needle used to observe liquid oscillations.

Completed small speaker enclosure.

Completed small speaker enclosure.

Completed small speaker enclosure.

Completed small speaker enclosure.

Completed small speaker enclosure.

Completed small speaker enclosure.

Image captured from video clip of oscillating liquid.

Image captured from video clip of oscillating liquid.

Bill of Materials

Current bill of materials

Presently, we have spent $356.62 of our $5,000 budget.

Item Price
2.5" round speaker from Jameco Electronics $6.09
6.5" round speaker from MCM Audio $33.68
6061 Aluminum round rods $249.37
Brake hose $15.97
Teflon PTFE 0.01" gasket material $17.76
Carbide turning inserts $33.75
TOTAL $356.62

Anticipated purchases for MSD II

It's anticipated that we will spend approximately $3,000 of our $5,000 budget with the following purchases.
Item Approximate cost
Stainless steel syringe $900
Flexible brake line $40
Additional speakers $50
150W Amflifier $150
LED light source $75
Electronic stage $1,200
Swagelok components $120
Hot plate $250
PCB for capacitance sensor $100
MSD 1 purchases $356.62
TOTAL $2,991.62

Test Plans

Oscillation feasibility

Purpose: To demonsrate that the speaker can induce oscillations at a given frequency.
Equipment:
1. Camera
2. Light source
3. Speaker with enclosure
4. Amplifier
5. Appropriate swagelok connections
6. Copper chip
Steps:
(1) Connect speaker and enclosure to needle
(2) Focus camera and light source on needle
(3) Fill speaker enclosure and needle with water
(4) Connect amplifier to speaker
(5) Operate speaker at lowest possible frequency
(6) Record oscillations with camera
(7) Verify oscillation frequency by reviewing captured video
(8) Repeat for both speakers and with different pitch angles

Oscillations with capacitance sensor

Purpose: To ensure that the capacitance sensor functions as expected with the addition of oscillations.
Equipment:
1. Camera
2. Light source
3. Speaker with enclosure
4. Amplifier
5. Appropriate swagelok connections
6. Copper chip
7. Capacitance sensor with appropriate wired connections
Steps:
(1) Connect speaker and enclosure to needle
(2) Focus camera and light source on needle
(3) Fill speaker enclosure and needle with water
(4) Connect amplifier to speaker
(5) Connect capacitance sensor to needle and copper chip
(6) Operate speaker at various frequencies
(7) Observe the functionality of the capacitance sensor

Oscillations and capacitance sensor with heat source

Purpose: To ensure that the syringe pump can provide adequate fluid in the presence of heat generation and the capacitance sensor, and also to ensure that oscillations can be seen with an evaporating meniscus.
Equipment:
1. Camera
2. Light source
3. Speaker with enclosure
4. Amplifier
5. Appropriate swagelok connections
6. Copper chip
7. Capacitance sensor with appropriate wired connections
8. Heater
9. Syringe
10. Syringe pump
Steps:
(1) Connect speaker and enclosure to needle
(2) Focus camera and light source on needle
(3) Fill speaker enclosure and needle with water
(4) Connect amplifier to speaker
(5) Place copper chip on the hot plate
(6) Connect capacitance sensor to needle and copper chip
(7) Adjust the temperature of the hot plate to 110 Celsius
(8) Operate speaker at a given frequency
(9) Observe the functionality of the capacitance sensor
(10) Verify oscillation frequency by reviewing captured video

Height adjustment

Purpose: To ensure proper functionality of the height adjustment subsystem.
Equipment:
1. Height adjustment stage
2. Copper chip
3. Syringe
4. Syringe pump
5. Appropriate swagelok connections
6. Computer with LabVIEW program
Steps:
(1) Ensure height adjustment stage is properly connected to LabVIEW
(2) Create stable meniscus with water
(3) Adjust height in LabVIEW
(4) Observe height changes

PID & LabVIEW controls

Purpose: To ensure proper operation of the PID controller and other LabVIEW controls
Equipment:
1. Speaker with enclosure
2. Amplifier
3. Appropriate swagelok connections
4. Copper chip
5. Capacitance sensor with appropriate wired connections
6. Heater
7. Syringe
8. Syringe pump
9. Height adjustment stage
10. Computer with LabVIEW program
11. Camera
12. Light source
Steps:
(1) Completely assemble system with all appropriate connections
(2) Verify oscillations can be seen with camera
(3) Adjust oscillation frequency via LabVIEW and verify with video
(4) Adjust height between the needle and copper plate via LabVIEW
(5) Adjust the heat generation of the heater via LabVIEW and verify response
(6) Record time that it takes the PID controller to reach steady state
(7) For a multitude of heat generation values, verify that the mensiscus remains stable over a period of 30 minutes

Operation of all subsystems

Purpose: To verify proper operation of all subsystems combined
Equipment:
1. Speaker with enclosure
2. Amplifier
3. Appropriate swagelok connections
4. Copper chip
5. Capacitance sensor with appropriate wired connections
6. Heater
7. Syringe
8. Syringe pump
9. Height adjustment stage
10. Computer with LabVIEW program
11. Camera
12. Light source
Steps:
(1) Assemble all subsystems
(2) Fill assembled system with desired working fluid
(3) Focus camera and light source on the meniscus
(4) Oscillate the liquid meniscus for a desired time period
(5) Record video footage
(6) Review video footage

Design Review Materials

Item Link to document
Project readiness package Click here.
Team norms Click here.
Preliminary detailed design presentation feedback Click here.
Detailed design presentation Click here.
Detailed design presentation audio Click here.
Detailed design presentation feedback Click here.

Plans for Transitioning to MSD II

In order to prepare for MSD II, our team anticipates that the following tasks need to be completed:

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