Customer Handoff & Final Project Documentation
Table of Contents
Team Vision for Subsystem Level Build & Test PhaseDuring the Customer Handoff Phase, the group planned to deliver the following items:
- RasPi code related to sensors completed and allows
for accurate sensor readings:
- Indoor Temperature
- Outdoor Temperature
- Integrate relay with the RasPi and finalize testing
of turning on and off.
- User guide to setting this up later.
- All remaining parts will be manufactured and assembled.
- Finish assembly manual document and create a user manual document.
- Work on finishing test plans with conclusions available.
- CAD design will be completed to reflect the desired
deliverables, as confirmed with project stakeholders
- Finish Strengths Analysis
- CAD package generated for handoff/continuation
- Updated documentation related to project
- Budget Maintenance
- Project Plan
- Risk Management
- Problem Tracker
- Finalize the IEEE Grant Paper and project poster.
- Documentation for the above items will be available on the team’s MSD EDGE page.
What We Accomplished:
- Finished manufacturing composter pieces.
- Finished assembling composter.
- Performed or partially performed as many tests as possible.
- Finished coding and integrating temperature and humidity sensors.
- Update project management documents.
- Finial CAD package delivered.
- IEEE paper written.
Shed WiringThe drawing shows the wiring of power being fed to the shed when. This drawing is made under the assumption that a constant feed of 110v Ac is being supplied and the system is being fed from both the infeed and solar panels. Special color coating is used distinguish between the multiple feeds.
Raspberry Pi CodeThe Raspberry Pi code was updated so that the data collection loop would continuously run, once started, until the Pi is turned off. The final time between data collection cycles was set to 5 minutes with the desired climate limits updated from the customer requirements. To update these limits or the collection time, or to learn how to remove the collection file, please review the Electrical User Manual
As stated in the Problem Tracker Section below, a new CO2 sensor was purchased. Upon setup of the sensor, the code was written using the Python Code language. A conversion was attempted as it is possible to run this code in the existing project,which was written in the C code language, however the python language made it difficult to translate and implement in the rest of the code. To solve this, either the rest of the project must be re-written in Python or the new sensor code must be translated to C code.
CADFinal CAD Package During this phase we finalized the CAD and have included the complete CAD package so that future project groups are able to recreate our design.
Larvae Collection BinsIn this phase we had to redesign our larvae collection bins due to them being to small. Instead of a collection bin, we will be adding a bracket to the side of the composter and a plastic bag will be attached and hold the larvae to be collected.
- Making a mount to prop the lid open for operations.
- Sealing the gaps in the composter caused by fast manufacturing and assembly.
- Finding a solution to mount bottom layer tabs since epoxy on plastic is not load bearing (Metal Screw Pattern and Epoxy).
- Redesign of pupae collection bins.
- Design bracket to connect the two halves of the composter.
- Create a drawer stop so researchers know how far to pull out the drawer.
Use the Assembly Manual in order to learn how to assemble this composter from its base pieces.
We also have created a Composter User Manual in order to help operators understand how to operate this system in their day to day research. The test plan section will include a video of bottom layer operation.
In this document we discuss a few changes we would recommend for future projects:
- Broaden Material Usage: HDPE was used for all components of the main structure. It would be better to substitute some of these components (like the lid) with aluminum. This would reduce the weight and cost of the composter, as the plastic is very expensive.
- Tighter Tolerances: The manufacture of many components were completed at the last minute. This meant that many of the connections and pieces were made with loose tolerances. This leaves many open gaps that were not on the original CAD design.
- Bottom Layer Removal: There was not enough time to test and refine the design but it is believed that this system can still be designed to have less top layer disturbance while being easy for the operator to use.
- More Robust Stand: We are unsure of at this point whether the wooden stand will be able to withstand the force and weight of the composter over time. Our alternative is to use the metal cart with a hole cut in it which would not be ideal for operator ergonomics. More thought should have been placed in this area.
- Recruit a CE Researcher: A lot of the programming for this project is beyond the scope of knowledge of a lot of EE's. We recommend you find a CE student next semester to finish up integrating the sensors into the raspberry pi system.
There were several tests that we were able to successfully complete during this project including:
- Size of Composter Within Bounds
- Accuracy of Temperature/Humidity Sensors
- # Larvae Migrated
- Cost of Composter
- Temperature Variability
- Data Collection and Storage Frequency
- Leachate Storage Volume
There were a couple tests that we were not able to successfully meet the requirements:
- Weight of Composter
- Brightness of Composter
There were many tests we were not able to complete at all due to unexpected restrictions of the project including no power being available to the shed, trouble getting the CO2 sensor programmed, and the composter being so behind in assembly. Some of these key tests that should be checked by the researchers before beginning regular operations are:
- CO2, Temperature, and Humidity levels in the shed and how persistence of these levels over time.
- Anaerobic Conditions of Composter
- Moisture Content of Waste
- # Escaped Larvae
- Operator Satisfaction
For more information on the tests that were conducted and the results we found, see the Test Plan Document.
We were able to do a test with leaf compost in order to check the operation of the bottom layer system:
Test Results Document.
Above is a video of the bottom layer test that was conducted towards the end of the semester. Leaf compost was used in the system in order to try and demonstrate how to operate the bottom layer removal. The video shows it took 2 minutes to remove the bottom layer. There was some issues with the compost falling through the slits in the bottom layer but we are unsure if this affect will translate to the actual food waste inputted into the system.
Problem TrackingThe group's problem tracking document has been updated to include the newest happenings related to obstacles in the project's progression. Most notably, problems arose in the manufacture of the composer as well as in the development of code for the CO2 sensor. Despite reasonable efforts to address these problems, the issues presented by these situations have compromised the quality and delivery of the final composting system. New considerations can be seen and expanded upon in the Problem Tracking document.
Risk ManagementThe team reviewed and updated the cumulative risk assessment that was first created in the Problem Definition phase of the project (and has been updated during every project phase thus far). Changes have been witnessed on several fronts but will not be updated until the full impact of these risk changes can be understood by the team administration. The majority of the remaining risks in the below table are associated with the continued operation of the composting system in the future:
Below is a summary of the mitigated risks that have been concluded through their respective efforts (included as a separate column):
BudgetThe Budget Maintenance Document shows the final amount spent on all of the materials along with the breakdown of what budget was used for each item. Blue signifies ISE Budget, White signifies MSD budget, and Green signifies no money spent.
The total amount spent for the entire project was $1,903.33 which is over budget. The total amount spent on materials to build the composter was $989.09 which is also over customer requirements but this is due to vendor restrictions.
The Purchase Plan Document shows that all items have been purchased however we are still waiting for the delivery of the Plug, Enclosure, and Arnold Battery Cables.
Link to our Budget Maintenance document.
The Areas to Cut Cost Document shows the materials and costs that the team has identified that can be changed in future iterations to reduce the cost of the project.