P17433: Plastic Bottle Upcycling
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Detailed Design

Table of Contents

All documents and files used for this phase can be accessed through the following Directory: Detailed Design Documents.

Team Vision for Detailed Design Phase

During the Detailed Design phase, our team wanted to get as close as we possibly could to a finalized design package, detailed BOM, and Specific Plan for MSD II. We wanted to finalize materials and begin gathering quotes and estimates from material suppliers. This phase is a very iterative process that includes several steps of justification and modification to designs as well as consultation of subject matter experts regarding the design. We made significant progress on designs as well as the BOM and have begun receiving part cost quotes. We have received useful feedback from the machine shop and begun preparation for production of our parts. Overall, this was a very successful phase and we feel comfortable and prepared for MSD II.

The following Table outlines the items that we are working on and their approximate percent completion as a result of this phase. A link to the file can be found here.

 Percent Completion Table

Percent Completion Table

Our overall Takeaway was that we made strong progress, but due to the delayed start we are slightly behind where we would like to be. We will be slightly delayed into MSD II, however we believe we can still complete the project successfully.

Progress Report

In the next phase we want to finalize our designs and refurbish them based on the feedback received from our review. We will continue to iterate and adjust our designs and our BOM will gain detail and will refine as we progress on our designs. One of our main priorities is to consult subject matter experts on both the blade machining and the plastic recycling. Refining the designs will be very important for our progress especially for power systems as they will be some of the more complex parts. Afifi will be working with us on the designs of the touch points in the power system to ensure functionality as well as aesthetics. .

Progress:

Planned:

Drawings, Schematics, Flow Charts, Simulations

Our current CAD model for our shredder can be accessed and observed through the following link: http://a360.co/2fPvntd

The Drawing package can be found at the following file path: Drawing Package. This is a comprehensive set of part drawings which contain all necessary dimensions and specifications required for complete development of our Shredder.

Some of the latest drawings are shown below:

Full Shredder Assembly.

Full Shredder Assembly.

Shredder Blades.

Shredder Blades.

Blade Drawing.

Blade Drawing.

Side Panel.

Side Panel.

Front Panel.

Front Panel.

Blade Spacer.

Blade Spacer.

Sieve.

Sieve.

Sieve Mount.

Sieve Mount.

Even under these extreme conditions, there is very little deformation of the blades and this indicates that, provided we have a proper shear pin fail safe, we should see no issues related to blade damage from normal use.

1500 Newton Load Engineering Analysis.

1500 Newton Load Engineering Analysis.

Our designs are among the strongest portions of our project to this point. We have very high detailed models and we are pleased with our progress here. Our main takeaway from the design was focusing on the interaction of the subsystems involved in the shredder. The design should allow for a fluid modular shredder that allows for easy breakdown and maintenance as well as efficient transport. The consultation regarding the materials was incredibly beneficial.

Bill of Material (BOM)

The current Bill of Materials is seen below and a link to the live document can be found here: Bill of Materials.

Current Bill of Materials.

Current Bill of Materials.

Results of Consultation:

After consulting Professor John Bonzo regarding the machining of our blades, we received the following information:

The main takeaway from our BOM is that the cost is significantly more than we initially anticipated. We want to reevaluate our material selection, as we may be able to replace the casing with a cheaper material. The blades are fixed at SS304 as we believe that is the ideal material, but other smaller components can be changed. We also want to shop around other material providers to see if we can get any competitive pricing to our benefit. We also may be able to edit our designs to reduce the material needed.

Test Plans

In order to conduct appropriate testing of our system once we begin prototyping, we have developed a set of test plans to ensure we meet our predetermined engineering metrics. Each test plan has its own document to outline the objective, procedure, ownership, and other significant details necessary to complete the test.

A link to the directory containing all of our testing plans can be found here: Testing Plans.

The tests we plan to run consist of the following:

  1. Chip size and sieve effectiveness analysis
  2. Shredding force and shear pin testing
  3. Shredding Apparatus testing
  4. Stand stability testing
  5. Shredded Bottles per hour
  6. Ergonomic fatigue testing
  7. Mean time between failures
  8. Lock Out, Tag Out

We believe these tests will be thorough enough to vet any concerns the shredder may bring about and should help us validate our business case.

Process Steps and Flow

The following folder includes documents related to the flow of our process: Process Flow.

Systems Breakdown.

Systems Breakdown.

Functional Decomposition.

Functional Decomposition.

A list of justification for our designs and our procedures are documented in the following Directory: Process Justification.

Some of the justifications can be seen below.

Component Justification.

Component Justification.

Systems Justification.

Systems Justification.

Justifying each step of our process was essential to ensuring the success of our design. Following the flow process for the design phase was very useful and these images show our though process throughout the phase.

Risk Assessment

The following is an up to date image of our Risk Assessment:
Risk Assessment.

Risk Assessment.

The following link will direct you to the current version: Risk Assessment.

We have also updated our Customer and Engineering Requirements which can be found in the following document: Customer and Engineering Requirements.

From this exercise our main takeaway was that there are more variables than we initially identified and we have more risk to plan for. We feel comfortable, but we are also cautious of potential issues arising. Most of our contingency is adequate, but there are some gaps.

Industrial Design Progress

Afifi is a key component of the success of this project and he has been doing extensive research and work on various products and cultural solutions we can provide to the nations we are helping. His progress book and all of his research, sketches, and plans can be found in the following directory.

Industrial Design Work

Nicaragua Trip Progress

We are currently in the process of planning and coordinating a funded trip to Nicaragua to perform some target market research and gather feedback. All of the current progress is in the directory linked below.

Trip Information

Plans for next phase

The early phase of MSD II will be focused on design finalization, material purchasing and Beginning production of our system. We will also be focused on polishing the details of our trip and our product line. The following is a high level breakdown by month for the next phase. When we meet in the early weeks of next semester we will develop a more specific schedule on a weekly basis. A current copy of our MSD II plan can be found here: Project Plan

public/Detailed Design Documents/Pictures/Project Plan.PNG

public/Detailed Design Documents/Pictures/Project Plan.PNG

Value Expectations
January/Intercession
  • Finalize Project Plan
  • Finalize Designs
  • Purchase Known Materials
February
  • Finalize BOM
  • Purchase remaining stock materials
  • Begin Machining of materials received
  • Begin Assembly
March
  • Continue Building
  • Troubleshoot Building
  • Travel to Nicaragua to pitch products and consult locals
April
  • Finalize Assembly
  • Test Shredder
  • Finalize Documents for Imagine RIT
May
  • Present at Imagine RIT
  • Last Minute Modifications

The team developed a Team Vision and Individual visions for next semester. They are outlined here.

The following are links to our individual three week plans :
David Swerzenski Three Week Plan.
Evan Oslakovich Three Week Plan.
Michael Kist Three Week Plan.

Additionally, you can observe our team's meeting notes at the following link: Meeting Notes

Design Review Materials

All materials used and provided for this design review can be found in the following directory.

Review Materials


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