P18416: Belasenp Arborloo Base Manufacturing Process
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase


Our team accomplished the following:

Progress Report

Updated Percent Completed By Subsystem

Updated Percent Completed By Subsystem

Drawings, Schematics, Flow Charts, Simulations

Simulation in Simio based on Functional Decomposition

Simulation in Simio based on Functional Decomposition

Concrete Sample Production

Materials Used in Mix
Biochar

Biochar

Gravel

Gravel

Sand

Sand

Concrete

Concrete

Material Mixing
Mixing of the Concrete Samples

Mixing of the Concrete Samples

Weighing Out Ingredients for Each Sample

Weighing Out Ingredients for Each Sample

Poured Samples

Poured Samples

Samples
Three Samples Created

Three Samples Created

Detail of Sample 1

Detail of Sample 1

Detail of Sample 2

Detail of Sample 2

Detail of Sample 3

Detail of Sample 3

Mixes for Each Sample

All percentages by weight.

Sample 1

Density = 0.0545 lbm/in^3

Sample 2

Density = 0.0470 lbm/in^3

Sample 3

Density = 0.0532 lbm/in^3

Biochar: Kathleen Visit

Kathleen's Kon-Tiki Kiln
Kathleen's Kon-Tiki Kiln

Kathleen's Kon-Tiki Kiln

Starting the Fire

Starting the Fire

Fire Started

Fire Started

Fire Towards the End of the Burn

Fire Towards the End of the Burn

Biochar Possibilities
Examples of Things Kathleen Has Charred

Examples of Things Kathleen Has Charred

Examples of Things Kathleen Has Charred

Examples of Things Kathleen Has Charred

Examples of Things Kathleen Has Charred

Examples of Things Kathleen Has Charred

TLUD Concept
Example of a TLUD

Example of a TLUD

TLUD With Okara

TLUD With Okara

TLUD Fire

TLUD Fire

Finished Biochar From Okara

Finished Biochar From Okara

Notes From The "Burn and Learn":

Master Mold Fabrication

Plywood Molding Attempts
Master Mold Being Machined

Master Mold Being Machined

Master Mold Being Machined

Master Mold Being Machined

Foam Geometry Base

Foam Geometry Base

Foam Coating Options
Resin Coating

Resin Coating

Plaster Coating

Plaster Coating

Fiberglass Coating

Fiberglass Coating

1 gal for $64 25 lb bag for $16 $54.95 for 4"x80yds
Enough for a .05" coat Enough for 0.15" coat Enough for several glass layers
Purchase Link Purchase Link Purchase Link

Mold Material Assessment

Simulation Setup

Simulation Setup

Mold Displacements

Mold Displacements

Mold Stresses

Mold Stresses

Bottle Stringing Update

Stringer Prototyping Update
Changes to Bottle Stringing Device

Changes to Bottle Stringing Device

Newly Purchased Shears

Newly Purchased Shears

Sifter Prototyping

Sifter Prototype Construction
Sifter

Sifter

Sifter

Sifter

Top Sifter

Top Sifter

Bottom Sifter

Bottom Sifter

Sifter Assembly

Sifter Assembly

Bill of Material (BOM)

Updated BOM

Updated BOM

BOM document.

Feasibility Test Plans

Formal feasibility test plans can be found here. The initial concrete testing report can be found here. Basic test plan templates are shown below for all subsystems. For reference, Engineering Requirements can be found on our Problem Definition page.

Concrete Mixtures

This test plan is intended to determine the ideal concrete mixture for our required use.

Results of these tests will have direct impact on ER's 1, 5, 8, & 9

Biochar Production

This test is intended to determine two separate factors. Which kiln process is most effective for use in Haiti, and how well agricultural waste works as material for biochar.

Preliminary steps have been made at conducting these steps, via the visit to Kathleen's

Bottle Stringing/Chopping

This plan is intended to test the viability of different chopping and sizing methods.

Initial prototyping has undergone two levels, with the current design the rod in bucket for chopping with a stringer attached to the outside. Keeps bottle strings contained while chopping.

Aggregate Sorting

This test is intended to determine the efficiency of our proposed sifting system.

Sifter has been prototyped, awaiting formal testing

Molding Process

These tests will be performed during MSD II, as they are dependent upon components currently under development. The tests are intended to determine how well our system meets ER15 & ER16.


At this moment, none of our subsystems require external power, exceeding the ideal value for ER7. A direct test must be developed to test ER6. All subsystems are currently under the size limit defined by ER15.

Test Plans

Formal test plans for each ER need to be developed, and are scheduled for the very beginning of MSD II. Initial comments on how the ER's are to be tested have been added to the ER document, and can be found on our Problem Definition page.

Drawing Packages

The current subsystem drawing packages can be found here. Currently included are the drawings for the master mold development, the sifting table, and bottle cutting operations. Formal drawing packages are still required for biochar production and bottle stringing integration. These are on the plan to be generated at the very beginning of MSD II.

Risk Assessment

Updated Risk Assessment

Updated Risk Assessment

Risk Assessment document.

Design Review Materials

Plans for next phase

Team vision for next phase located on the associated phase page.

Individual Three-Week Plans located here.


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