P17433: Plastic Bottle Upcycling
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Systems Design

Table of Contents

Links to all for this section can be found here: Systems Level Design Documents.

Team Vision for System-Level Design Phase

A Link to our Team Vision for this phase can be found here.

Our primary goals were centered around developing our final decisions for our Product/Process that we plan to develop. After meeting with our stakeholders, running several exercises, and evaluating our options, we were able to come to the conclusion that grinding and molding the plastic bottles is the ideal option. We are looking to have a fully developed grinder and a series of product molds prepared by the end of next semester.

Functional Decomposition

Functional Decomposition

Functional Decomposition

A link to the current Functional Decomposition is present here.

Benchmarking

Many Benchmarking steps have already taken place during our systems level design process. You can find all of our Benchmarking here.

Currently, we are benchmarking the primary components of our design mechanism. This includes, the hopper, grinder/blades, and the power source.

Concept Development

Over the course of our concept development we have reviewed many different options and done extensive research on current systems in place which solve similar problems. In order to assess our options we compared many of these process using methods such as the Pugh Chart shown below. Since our primary focus is on the grinding mechanism, we will be showing that Pugh chart here.

Pugh Chart for Grinding

Pugh Chart for Grinding

A link to the current Pugh chart is present here.

Feasibility: Prototyping, Analysis, Simulation

Plastics Testing

Initial chip development was conducted by Afifi and the material was then tested with melting to observe its usability. The below image shows that, with more control applied, molding plastic will be a feasible approach to this problem.

Initial Plastics Molding Tests

Initial Plastics Molding Tests

Another team has developed a grinder with a very similar design to our initial concept. We will be using their design for preliminary testing soon to observe how well it can grind bottles.

The following link: Precious Plastic will take you to an open source project developed to help combat the very issue we face. It was the basis for our concept selection and displays a level of feasibility within a tight budget.

Morphological Chart and Concept Selection

Initial Plastics Molding Tests

Initial Plastics Molding Tests

Concept Selection

The following are the criteria we generated to assess our Concepts:

1. Cost to produce and maintain the system.

2. The Market value of the finished product.

3. The time to produce the finished product.

4. Bottles used per Product.

5. Mobility of system.

6. Societal benefit.

7. Ease of operation and maintenance.

8. Power input to output ratio.

Systems Architecture

Functional Architecture for Grinding

Functional Architecture for Grinding

A link to the current Functional Architecture is present here.

Designs and Flowcharts

While our design advances, we will develop more advanced design sketches. We have several different visual representations of our system here as well.

The following image is a sketch showing the system with a bike powered operation.

Basic System Design

Basic System Design

Risk Assessment

First Iteration of Risk Assessment

First Iteration of Risk Assessment

Design Review Materials

Links to:

Plans for next phase

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.

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