P16486: Test Rig to Characterize Biochar Housing Materials
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

What P16486 wanted to do during this phase:

What P16486 did during this phase:

Test Results Summary

Please click here for an updated Test Plan

Please click here to review the Engineering Requirements

Integration


The following was modified on the ETC:
- Sides of the ETC were drilled and tapped to install drawer slides
- Drawer was drilled to fit the heater and get sandwiched by the flange
- Neoprene was measured to help insulate the previously planned areas
- Water tub and humidifier were installed
- Could get the humidity to 95% - Success!

Aluminum Cylinder, with heater inserted, mounted on drawer for thermal conductivity test

Aluminum Cylinder, with heater inserted, mounted on drawer for thermal conductivity test

Results and Conclusions

Testing the Heater


- The Heater will be sufficient for thermal conductivity tests. It heats the aluminum cylinder uniformly, resulting in 1-dimensional heat transfer along the radial axis to help derive an R-value.

Testing the Sensors


-Temperature Sensors can read the varying temperatures from the heater and will therefore practically assist in deriving a thermal conductivity value.

- 2 humidity sensors bought originally and testing commenced with humidifiers (S4). In doing so, 1 sensor failed during test with humidifier #2, so a 3rd one ordered. During humidifier #2 test (refer to S4 results), 1 humidity sensor read up to a relative humidity of approximately 95% after 5 minutes of running both the humidifier and fan.
- Humidity Sensor Results: humidity sensor ordered (in addition to another one being shipped) should suffice for humidity test.

Testing the Fan and Humidifier(s)


- The fan was tested in combination with S4, the humidifier.
- Fan result: Fan works sufficiently on low speed in moving mist produced from humidifier and will suffice for humidity test.

- Humidifier 1 - (12-LED Water Fountain Pond Atomizer Air Humidifier)- did not mist and did form humidifier as was prescribed by product description; test failed in which the humidifier did not turn on and failed to work.
- Humidifier 2 - (Aluminum Mist Maker Fog Maker for Water Fountain Pond Rockery Fishtank Vase Birdbath) - Humidifier works and mists, causing humidity in ETC
- We incorporated testing of the second humidifier with the fan to see how the subsystems integrate and work together.
- Result: The fan and humidifier integration should suffice for humidity test.
Jim, Prasanna, and Dom testing the humidifier and fan within the test chamber

Jim, Prasanna, and Dom testing the humidifier and fan within the test chamber

The fan connected to the electrical components to demonstrate functionality

The fan connected to the electrical components to demonstrate functionality

Testing the Interface


First code
- Told user to enter K test or Humidity test and then ran the temperature - Input temperature into interface - Utilized fake equation to see if K value could potentially be extracted

New Code
- More sophisticated math library added which allows for double precision floating point values, which will help with accuracy and rounding errors - Further added user input of sample thickness in order to accommodate future expandability by allowing different sample thicknesses -Conclusion: Interface disconnected from ETC works well and user can input all necessary parameters

Micro-controller capability can hold 56 kB of data
- 48K designated for recording samples, which allows for 3000 samples
- For example, if we have a sample taken every 30 seconds, that is 1500 minutes of data (or 25 hours)
- Still have to store code

Overview of electrical components completed for this phase

Overview of electrical components completed for this phase

Risk and Problem Tracking

Problems faced during this phase

1)Tray was too large, and the slides were too thick.
Solution: Use flat screws, and press the slides against the wall of the ETC
2) Heater doesn't fit inside the Aluminum Block, the top of the heater had a bigger diameter than the base. It made the threading of the base to the aluminum block impossible
Solution: Drill a bigger hole in the block, and use a flange to assemble the block to the heater, altogether with the tray.
3) Fasten the sensor to the aluminum block in order to measure heat.
Solution: Use a mouse trap spring to conduct the rotation of the sensor arm.

Risk Management

Risk Management

Risk Management

Please find the updated Risk Management

Here

Plans for next phase

As a team, we want to have almost all of the building phase complete, and begin initial tests to eliminate and fix any issues with the ETC. We also want to have all molds completed so we can begin initial testing.

Prasanna's 3 Week Plan
Lakeishia's 3 Week Plan
James' 3 Week Plan
Domenico's 3 Week Plan
Sari's 3 Week Plan
Kim's 3 Week Plan