P18433: Nicaragua Bottle Upcycling Product Design and Manufacturing
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Integrated System Build & Test

Table of Contents

Team Vision for Integrated System Build & Test Phase

During this phase, the team aimed to complete building the structural frame and mold to begin integrating the heating and electrical systems. In addition, finalized design packages for the mold, heating, and electrical systems.

We were able to tack weld the structural frame so that we could verify all components were in the correct position and properly aligned. We found that the alignment for attaching the car jack and mold frame were off. The tubes to attach the car jack only needed to be repositioned but additional holes need to be drilled for the mold attachment. For our heating system, the heaters and insulation were purchased and received. The electrical system has begun to be assembled, however we realized we do not have all the necessary components. Additional wiring, connectors, and thermal paste are needed to finish assembly. We have receive most of the electrical components and begun assembly of the system. We plan to meet with professor Indovina to ensure that everything is connected properly and the electrical system will function as planned.

System Build

The product manufacturing time can be found here.

Welded Frame

Initial Tack Weld of Structural Frame

Initial Tack Weld of Structural Frame

Bottom Plate Alignment

Bottom Plate Alignment

Wheel Attachment

Wheel Attachment

Machined Mold

Top Plate Machining

Top Plate Machining

Top Plate Finish

Top Plate Finish

Top Plate Finish

Top Plate Finish

1st Iteration

Disassembling of Initial Tack Weld

Disassembling of Initial Tack Weld

Insulation

Insulation is needed on the system due to safety and heating efficiency. For insulating the system, we have chosen to wrap and tape ceramic fiber insulation around some of the vertical square tubing and use flat sheets on the top and bottom of the mold. The insulation benchmarking can be found here.
Insulation Concept

Insulation Concept

Insulation Drawing

Insulation Drawing

The complete drawings for preparation of the insulation can be found here.

Insulation Preparation

Insulation Preparation

Test Results Summary

Test Plan Results

The majority of our tests for the engineering requirements cannot be completed until more of the system is built and the heating, electrical, and insulation subsystems are integrated.

The engineering requirements that could be tested sufficiently at this point include:

Test Plan Chart

Test Plan Chart

Working Test Plans & Results can be found here.

Risk and Problem Tracking

Risk Assessment

Risk Assessment Screenshot

Risk Assessment Screenshot

A working Risk Assessment file can be found here.

Risk Chart

Risk Chart

Problem Tracking

Problem Tracking Screenshot

Problem Tracking Screenshot

A working Problem Tracking file can be found here.

Functional Demo Materials

Plans for next phase

Individual 3-week plans


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