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Sand Bed Turnover Monitor Design Report Team Aqua Tech

1. Black non corrosive finish Mounting Slotted Flex Mount standard additional flex mount options available see Ordering Guide YIR 3 5 oz typical Environmental Operating 0 to 70 C for standard models 40 to 70 C for low temperature option 0 to 100 C for high temperature option 0 to 120 C for extreme temperature option Storage Temp 40 to 100 C Humidily 98 RH non condensing Vibration 10 g 58 to 500 Hz SHOCK ete 50 g 11 ms duration Sealing IP50 IP64 available lt Model 260 With Front Shaft Clamp T Model 260 Rear Clamp R AVAILABLE TO 0 625 BORE SIZE 02 00 REAR CLAMP AVAILABLE TO 0 625 BORE SIZE STYLE SHAFT _ GP ENCODER PRODUCTS COMPANY With 1 811 46 mm BC Slotted Flex SF CABLE LENGTH 18 STANDARD o s 0 15 SLOT WIDTH E s O p LLI 1 811 K MOUNTING as lt gt 0 07 1 00 BLIND w FLEX MOUNT WITH l 30 ROTATIONAL 260CATIF ADJUSTMENT O lt o With 1 811 46 mm BC Slotted Flex SF CABLE LENGTH 18 STANDARD 0 15 SLOT VVIDTH 2 16 1 811 MOUNTING 260 REARC FLEX MOUNT WITH 30 ROTATIONAL ADJUSTMENT Body Mount M12 SMJ SMK All dimensi
2. complete description of DirectSOFT fest z K including features part numbers of programming packages and upgrades External power inputs Discrete input terminals Discrete output terminals Option module slot Hardware features diagrams External power inputs Discrete output terminals Removable Option module slots terminal T mw 26 2 ov Yo 2 ct Ys vz vio vi2 vis vir S Mode status OUTPUT 6 240V 50 60 2 2 0A 6 27V 2 0A PWR 100 240 50 60Hz 40VA indicators YOCU OQO O 66666 D0 06DR x 14 15 16 17 20 21 22 23 00000000000000 9 9 e 12 24V 3 15 Input status indicators Communicat ion status indicators Direct 06 Koyo X0 X2 C1 X5 X7 X10 X12 C3 X15 X17 X20 X22 N C 5594 m C B 5 v4 E lo Discrete input terminals Removable Communication ports Mounting tab A terminal block v vvv automationdirect com dlO5and06 PLC Products 34 2 21 4 Direci v PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field I O Software C more HMIs Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index Product Dimen
3. Load to Yes gt gt Eo Memory V2001 gt Load to Yes x 2 gt B 7 Memory V2002 LS No Yes Is V2010 Is V2001 lt s V2001 s Counter 30 Yes V2002 Yes p Counter V2002 No 6 No Is V2002 lt s V2001 No V2001 Yes gt Counter V2002 No Yes No Yesi v Output Check Filter to LCD Appendix H DFMEA 92 DESIGN FAILURE MODE AND EFFECT ANALYSIS DFMEA Project Sand Bed Turnover Monitor Revision Date Year 2008 2009 Revision Number Team Members Amanda Shannon Jake Yogesh Mark ITEM AND POTENTIAL POTENTIAL POTENTIAL O CURRENT DESIGN RECOMMENDED ACTIONS FUNCTION FAILURE EFFECT S OF CAUSE S OF CONTROLS MODE S FAILURE lt FAILURE C No reading Filter functions fine choose a shape that is well supported and avoids thin 1 3 pieces Too springy to spin Part designed too thin narrow Ensure all pieces are thicker than 1 8 Not enough support in choose a shape that is well Add support bars in supported and avoids thin weak areas 1 3 pieces May not rotate 3D because the Choose a kind of rectangular Printer body is too designed too shape that will build up Part circular No reading 4 circular pressure from the sand VS Could preve
4. BLUE WATER x x May 12 2009 Sand Bed Turnover Monitor Design Report Team Aqua Tech Amanda McGrath Shannon Mitchell Mark Raebel Jacob Meulink Yogesh Bhattarai PO Box 440902 Moscow Idaho 83844 0902 208 885 6579 aquatech uidaho edu May 8 2009 Remy Newcombe Blue Water Technologies 10450 North Airport Drive Hayden Idaho 83835 9742 Dear Dr Newcombe Enclosed is a final report detailing the design process fabrication and validation of the sand bed turnover monitor In this report Aqua Tech has explained a summary of progress throughout the first semester and the selection production and testing of the recommended design The designed monitor will allow Blue Water Technologies to track the rate of sand movement inside the filter bed This will allow detection of bridging at an early stage A prototype has been created and Aqua Tech has validated that the twister shape 1s a viable design A similar report will be delivered to Dr Steve Beyerlein for the University of Idaho s Capstone Senior Design Course and Dr Phil Druker in the University of Idaho s English Department This report contains the design for a sand bed turnover monitor It also includes the test results which show that the monitor is an effective solution to an industrial problem This report explains why the sand bed turnover monitor solves Blue Water Technologies problem with early detection of filter bridging If there are any concerns
5. INPUT X0 X1 X2 X3 X4 X5 X6 X7 5 INPUT X1 X5 XE X7 ise 5 PORT2 oaa 2222 www automationdirect com dl05andO0O6 2 23 3 94 100mm 0 20 5mm Yo YI Y2 Ya Y5 3 34 85mm OUTPUT yo Yi Y2 Y4 Y5 3 74 95mm 0 24 pn tab J 2 68 68mm DIN Rail lt R 2 68 68mm DIN Rail 1 2 56 65mm r O PWR O RUN O CPU O TX1 O RX1 O Tx2 O Rx2 5 00 127mm 4 61 117mm OOOO TERM 181 RUN STOP V Ao Y 0 20 4 5mm 0 43 mounting tab 11mm PLC Products 36 ee Automation Direct PLC Overview DL05 06 PLC DL105 PLC DL205 PLC DL305 PLC DL405 PLC Field 1 0 Software C more 5 Other HMI AC Drives Motors Steppers Servos Motor Controls Proximity Sensors Photo Sensors Limit Switches Encoders Current Sensors Pushbuttons Lights Process Relays Timers Comm TB s amp Wiring Power Circuit Protection Enclosures Appendix Part Index Choosing the I O Type DL105 0106 Base Unit 1 0 Tabl
6. MIL STD 810C Vibration Resistance Method 5142 Shock Resistance 75 7 Note There is a minimum clearance requirement of 1 5 38 between the panel door any devices mounted Noise Immunity NEMA 1653 304 in the panel door and the nearest DLO6 component CT Atmosphere No corrosive gases 35 2 22 PLC Products 1 800 633 0405 Product Dimensions and Installation Unit dimensions and mounting orientation DLO5 and DLO6 PLCs must be mounted properly to ensure ample airflow for cooling purposes It is important to follow the unit orientation requirements and to verity that the PLC s dimensions are compatible with your application Notice particularly the grounding requirements and the recommended cabinet clear ances mn 9191919196 15181516 mm elele BIB sele Direct 06 sekel airflow 0 39 10mm 8 31 211mm BE OUTPUT 6 240V 50 60 2 2 0A 6 27 2 0 PWR 100 240V 50 60Hz 40VA Y0000000G0000060600 DO 06DR 2 3 4 5 6 7 10 11 12 13 14 15 16 17 20 21 22 2 Direct 06 co xt x3 pos es Der Des NC X2 X7 0 39 10mm Uu 2 holes 0 150 dia clearance for 6 screw
7. 4 16 2009 CAD Application SolidWorks Helix Built on 22 Circle Pitch Rev 0 5 Agua Tech UNIVERSITY OF IDAHO ME DEPARTMENT Part Twister Design Scale 1 2 5 QTY SHEET 2 OF 4 GC 22 00 20 75 19 25 15 68 0 13 22 DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION Material 1 8 Steel Flat DEFAULT TOLERANCES PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART amp 01 OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION XXX 002 OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED ANGULAR 1 At 030 DESCRIPTION Mounting Bracket wasp DRAWN BY Amanda McGrath DATE CAD Application FILE NAME Mounting Bracket SolidWorks Aqua Tech ME DEPARTMENT Part Mounting Bracket QTY Scale 1 5 SHEET 3 OF 4 9c 36 00 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION X XXX 002 DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION 8 E DEFAULT TOLERANCES LINEAR ANGULAR Material PVC DESCRIPTION Shaft DRAWN BY Amanda McGrath DATE Agua Tech UNIVERSITY OF IDAHO ME DEPARTMENT Pa
8. as bridging Bridging will cause the sand flow to become uneven or even stagnant This causes inefficient water filtration and further problems getting the system back to optimal operating condition Currently the only way to monitor sand bed turnover rate 1s to place PVC sticks in the sand and watch to see how quickly they descend with the sand 2 4 Morphological Chart After the preliminary design review Team Aqua Tech and Blue Water Technologies agreed on a preliminary design The design features are described below in the morphological chart shown below in Figure 3 Due to the successful test results over the course of the first semester a general corkscrew shape was selected as the shape of the design To ensure there is enough support to hold the device steady a caster mounting design was chosen As for the data acquisition system a digital optical encoder in conjunction with a PLC was selected to measure analyze and display the rotational rate These choices were agreed on by both Aqua Tech and Blue Water Technologies This ensured that both the team and the company were anticipating the same solution Functions Material Proto Shape Mounting Detection method Transducers Data Conversion Display Software Power Option PVC Corkscrew Caster Rotational Potentometer PLC Microcontroller Computer Matlab Simulink Battery Option2 Fiberglass Auger 2 Bearings Linear Linear Positio
9. Check Filter END NOP 46 Appendix F DivAppendix 47 Chapter 5 Standard RLL Instructions Math Divide DIV Divide isa 16 bit instruction that divides the BCD DS5 Used HPP Used value in the accumulator by a BCD value Aaaa which is either a V memory location or max constant The first part of the guotient resides DIV a 4 digit A aaa in the accumulator and the remainder resides in the first stack location 5 hiiiki r0r 0vviru A ddd NEMOMON in cue ace e V See memory map WU r See memory map e easter pus coses K 0 9999 SP53 On when the value of the operand is larger than the accumulator can work with SP63 On when the result of the instruction causes the value in the accumulator to be zero SP70 On anytime the value in the accumulator is negative SP75 On when a BCD instruction is executed and a NON BCD number was encountered NOTE Status flags are valid only until another instruction uses the same flag In the following example when X1 is on the value in V2000 will be loaded into the accumulator using the Load instruction The value in the accumulator will be divided by the value in V2006 using the Divide instruction The value in the accumulator is copied to V2010 using the Out instruction DirectSOFT 5 V2000 Load t
10. DFMEA evaluation 4 3 Performance Testing The preliminary method used to test the monitor shape was to secure the shape to a long durable plastic rod 1 2 inch diameter A sealed bearing was then secured to the rod using set screws or was press fit to the rod depending on the bearing The monitor was then placed into the sand bed and allowed to submerge until the sealed bearing was the correct height to be secured to a 14 flat steel bar with vise grips which was laid across the top of the filter Markers were used on the rotating shaft and bearing to measure the 1 4 turns A stop watch was used to time the rotation Once the encoder was available for testing it was attached to the top of the rod with set screws and then the encoder was attached to the PLC which displayed counts every 30 seconds The method used to calibrate the radial shaft rotation to linear sand flow rate was to use a multiplier to convert the encoder counts to a sand bed turnover rate The team decided to perform multiple linear tests with a PVC stick to experimentally obtain such a multiplier 2 27 1 Secure device shape on long shaft 2 Secure bearing to mounting device 6 Calibration method Table 4 Step by step pictures of testing methodology 15 1 Acrylic Twister 180 left 2 Acrylic Twister 360 shallow pitch 5 Red Paint Stir right 3 MER e Twister 360 steep pitch 4 Acrylic Twister 90 n DIEI 6 3D printer
11. No Data Collection No Data Collection No Data Collection No Data Collection The frequency Of reading is too high or too low for plc to detect Vibrational effect may dampen the reading Shorted Wires Unfused input output Unfused input output Unfused input output Dropped Ensure that we choose the right type of encoder Take the encoder as high as possible from the sand Organization of Wires Fuse Inputs Outputs Fuse Inputs Outputs Fuse Inputs Outputs Carefulness Organize Wires Fuse Inputs Outputs Fuse Inputs Outputs Fuse Inputs Outputs Be Careful Figure X Design Failure Mode and Effect Analysis DFMEA Mode of analyzing potential failure modes of the sand bed turnover monitor which also provides recommended actions Appendix I Injection Mold Quote from ProtoMold 26 Protomold Rapid Plastic Injection Molding ProtoQuote protomold Print quote Bk Print PDF 56 RAPID INJECTION MOLDING A Proto Labs Company HOME RESOURCES COMPANY CONTACT US LOCATION PROTOQUOTE ProtoQuote prepared for University of Idaho Quote Number 104928 Quote Date 4 27 2009 Part Name Number Twister rev 1 Extents 2 021 in x 10 in x 2 021 in m Enter Specifications Changes below will reflect automatically in your price Cavities 1 cavity A green side finish PM F1 Lovv cosmetic most toolmarks removed B blue side finish PM FO Non co
12. ensors Number of Commons 4 isolated 0996 9999 Supply olololo olololo olololo olololo olololo Photo Output Voltage Range 12 24VDC Input point wiring Sensors Peak Voltage 30VDC Limit Equivalent input circuit quivatent Input circuit Switches Max Frequency YO High speed inputs X0 X3 Standard inputs X4 X23 ON Voltage Drop 0 3VDC 1A E Encoders Optica 0 5A pt YO Y1 Isolator Optical Maximum Current 1 0A ot y Isolator Curren 5 ensors DC Output Maximum 154 30VDC Specifications Leakage Current i 1 Pushbutons Maximum a 2A for 100ms Inrush Current EE A Process OFF to ON Resp onse 10 Equivalent output circuit Equivalent output circuit lt 20us Y0 Y1 Pulse output 0 1 Standard output Y2 Y17 Relays ON to OFF Response qs 12 117 sas mu REIR External DC Power 20 28VDC Internal module circuitry TUM 5 5 Reguired mA max M Status Indicators Logic side 2 5 TBs amp Fuses None external Tr Wiring recommended Optical Optical Isolator Power When YO Y1 are not used for Derating chart for DC outputs pulse outputs maximum current pis i Circuit output is 1 01 1 r T Protection 0 75A X YO Y17 5 1 0A Enclosures 8 Appendix 0 10 20 30 40 50 55 32 50 68 86 104 122 131 F Part I
13. shipping or providing goods if the buyer appears on a restricted party list or if shipment requires an export license or otherwise becomes restricted by U S law Government Contracts Arms Sales The buyer represents and warrants to Seller that the goods that are the subject of this transaction are not the subject of any government contract and will not be subject to regulations governing international traffic in arms Tooling Due to the proprietary nature of the Seller process all tooling fixturing and software developed by Seller are proprietary and are generally not compatible with or transferable to other equipment Seller retains ownership of the molds Notwithstanding any tooling or engineering charges imposed by Seller all such tooling and software produced by Seller shall be and remain the sole and exclusive property of Seller However Seller shall not use custom tooling or software in the production of goods for any other customer of Seller without buyer s express permission As used in this section custom tooling or software means tooling or software developed specifically for the buyer and for which the buyer is separately charged by Seller Buyer Supplied Materials If Seller agrees to use materials supplied by the buyer then the buyer shall be solely responsible for supplying and delivering such material in a timely manner at no cost or expense to Seller in sufficient quantity and quality including any loss waste or scrap
14. and the clean water leaves the tank 1 cleaned sufficiently to pass EPA standards Other parts to the filter include the drain 4 a sight gauge 8 to calculate total head loss n filter and a splash guard 10 to contain the sand Figure 1 Centra flo Filter www centra flo com 2 2 Acrylic Filter Model To demonstrate this type of filter to future customers a prototype was constructed The prototype is made of acrylic so that the filtration process can be visualized The acrylic prototype has all the features of the full scale filters but at a fraction of the size This model has been valuable to Team Aqua Tech First it helped the team to understand the filter design process and limitations to the project and second it provided a device to perform preliminary testing for further project learning The model was also the instrument of the project s final product evaluation Figure 2 Miniature working model of a Centra flo filter 2 3 Problem Definition The sand flow in the Centra flo gravity sand filtration system needs to be monitored when a large number of systems are in use This type of tertiary filtration is common both in municipal and industrial operations Currently the sand flow is monitored manually on a scheduled basis Proper movement of the sand bed within the filters 1s imperative to the proper function of the filter If the filter 1s not functioning properly the sand in the filter may clump up this is known
15. encoder Next the two rates obtained from the two encoders are compared against each other within the program of PLC When one rate 15 larger than another a counter is activated When counter reaches six the message Check Filter 1s sent to the LCD In order for the counter to reach six the rates must be unequal for six cycles in a row Since the rates are obtained every 30 seconds this requires the device rates to be imbalanced for three minutes in order for a Check 11 Filter message to display on the LCD Below 15 a table that shows the memory addresses used by the PLC program Timer 0 Conversion Table 2 Memory addresses of device functions in the PLC 3 5 Display Methods The PLC has an external display that is used to display the rotational rate found by the PLC and encoders The LCD has a data monitor menu that will allow the operator to monitor any memory address located in the PLC The program has conveniently placed any information that could be helpful in troubleshooting problems in concurrent memory addresses so that problems can be easily accessed 4 Product Evaluation 4 1 Specification Evaluation Comparing the actual performance of the sand bed turnover monitor to the specifications outlined at the beginning of the project the majority of the acceptable performance categories were met Below is a breakdown of each category and each specification 1s marked with a yes or no
16. or questions with the information presented in this report please contact us through the e mail address provided Thank you for your support on this project Sincerely Team Aqua Tech Enclosure Final Design Report Table of Contents 1 Executive Summary ___ 2 Introduction 2 1 Background 2 2 Acrylic Filter Model 2 3 Problem Definition 2 4 Morphological Chart 2 5 Specifications 3 Design Solution 3 1 Shape 3 2 Mounting 3 3 Mechanical to Electrical Interfacing 3 4 Data Analysis with the PLC 3 5 Display Methods 4 Product Evaluation 4 1 Specification Evaluation 4 2 DFMEA Evaluation 4 3 Performance Testing 4 4 Economic Evaluation 5 Conclusions and Recommendations 6 References Figures Figure 1 Centra flo Filter Figure 2 Acrylic Model Figure 3 Morphological Chart Figure 4 Design Solution Figure 5 Flow Chart of Design Solution Figure 6 Twister Shape Figure 7 Mounting System Figure 8 Encoder Figure 9 PLC Program Flow Chart for Encoder VO AO Nn d QU QU N NO t NO o oo BR t t NM Qo WB W N 10 Tables Table 1 Specification Table 2 Memory Addresses Table 3 Specification Evaluation Table 4 Methodology Table 5 Tested Devices Table 6 Testing Results Table 7 Cost for Injection Molding Table 8 Implementation Costs Eguations Eguation 1 Calibration Eguation Appendices Appendix A Drawing Package Appendix B Pr
17. other document of the buyer and no such different or additional terms shall be effective or binding upon Seller unless agreed to in writing and signed by an officer of Seller If the buyer issues a purchase order or other writing addressing the subject matter of this transaction that writing shall be for the buyer s internal purposes only and 62 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote the terms and conditions contained therein shall have no force or effect Quotations A quote is valid only for the 3D CAD model on which it was based Any change to the 3D CAD model requires an updated quote Quotes are valid for 30 days after which pricing may change without notice Delivery Title Risk of Loss Premium delivery options are subject to review at the time of order All parts are shipped i for deliveries within the United States F O B at Seller s facilities in Maple Plain Minnesota and ii in all other cases FCA Incoterms 2000 at Seller s facilities in Maple Plain Minnesota Title passes to the buyer at the time and place of delivery to the carrier Taxes Duties Etc The buyer shall pay all duties and sales excise use or other taxes arising in connection with this transaction other than taxes based solely on Seller s taxable income Warranties Seller assumes no responsibility for the design of the goods that are the subject of this transac
18. that may occur for any reason as Seller deems necessary to complete the order The buyer hereby acknowledges that Seller shall not be liable for and the buyer shall continue to be obligated to pay any previously negotiated delivery premiums despite any failure or delay in delivering any goods to be provided hereunder if such failure or delay is caused by the buyer s failure to supply and deliver such materials in a timely manner or in sufficient quantity and quality as Seller deems necessary Governing Law Jurisdiction The rights and obligations of Seller and the buyer under this contract shall be governed by the laws of the State of Minnesota without regard to principles of conflict of law including the Minnesota Uniform Commercial Code The United Nations Convention on Contracts for the International Sale of Goods shall not apply to this transaction Any suit action or other legal proceeding arising out of or relating to this transaction shall be brought in a court of record in Hennepin County Minnesota or in the courts of the United States located in such county Seller and the buyer each consent to the jurisdiction of each such court in any suit action or proceeding and waive any objection which it may have to the laying of venue of any such suit action or proceeding in any such courts and any claim that any such suit action or proceeding has been brought in an inconvenient forum English Language All documents notices and legal proceedin
19. CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND WHETHER FOR BREACH OF ANY WARRANTY FOR BREACH OR REPUDIATION OF ANY OTHER TERM OR CONDITION FOR NEGLIGENCE ON THE BASIS OF STRICT LIABILITY OR OTHERWISE Indemnification The buyer shall defend indemnify and hold harmless Seller and its employees representatives and agents from and against all claims liabilities losses damages penalties fines and sanctions of any kind including without limitation interest attorneys fees and expenses customs duties fines taxes penalties or any other governmental sanctions of any kind i resulting from or arising out of any breach of any representation warranty or covenant of the buyer or its affiliates hereunder ii if the buyer has supplied Seller with drawings designs or other specifications for the goods or services arising out of any assertion that any goods manufactured by Seller or the act of manufacturing such goods according to those drawings designs or other specifications infringe or misappropriate any patent copyright trade secret or other proprietary right iii otherwise arising out of or related to this transaction or It is specifically understood that the buyer shall indemnify and defend Seller and hold Seller harmless from claims that Seller was itself negligent or otherwise at fault If any action suit or proceeding is commenced or any claim demand or assessment asserted against Seller or its employees representatives or a
20. DL06 With tour donun module slots HO ECOM100 Ethernet Communications Module 10 100 Mbit and optional LCD display if is Enclosures DO DEVNETS DeviceNET Slave Module necessary to verity that sufficient power H CTRIO High Speed Counter I O Module is available for all optional devices Appendix HO PSCM Profibus Slave Communications Module Power budgeting is described in detail DO DCM Serial Communications Module on page 2 29 and in the DLO User Pam Index 0 128 ASCII CoProcessor Module Manual www automationdirect com dl05andO6 PLC Products 37 2 25 Appendix C Wiring Diagrams 38 Field Device PLC DC Input BEH Output input sinking sourcing ON s A Ground 1 Common uz s d zs x s xu d 4 Figure 1 Encoder PLC Diagram N 110 220 VAC Power Input use j amp db D QD X GO uw 621621 ov vo v2 YS v7 Y6 OUTPUT 17 240V 50 60Hz 0 5 PWR 100 240V 50 6 Y 6 6 6 6 6 6 6 6 9 9 O 0000000000 INPUT 90 120V 7 Tit Figure 2 Input Power to PLC Diagram 39 Appendix D Mathcad 40 Distance in between encoder steps d 0 51 C md ANN steps 1270 C d 1 237x 10 in steps d step Multiplying Constant D d 10 10 1 237 x 10 in pstep Calculating the rate of the encoder t 30s C d step R
21. O or additional communication options PLC Products DLO5 CPU Specifications System capacity Total memory available words Ladder memory WOrdS 2 048 V memory Wwords 4 096 User 3 968 Non volatile user V memory Battery backup Total built in 1 0 Performance Contact execution Boolean 0 715 Typical scan K Boolean 1 5 3ms Instructions and diagnostics RLL ladder style RLLPLUS flowchart style Stages Run time editing Number of Instructions Types of Instructions Control relays Counters Immediate 1 0 Subroutines For next loops Timed interrupt Integer math Floating point math Drum sequencers Bit of word ASCII print Real time clock calendar Internal diagnostics Password security System and user error log Communications Built in ports Protocols supported K sequence proprietary protocol DirectNet master slave Modbus RTU master slave ASCII out Baud rate tees 9 600 baud fixed selectable 300 38 400 baud default 9 600 Specialty Features Filtered inputs Interrupt input High speed counter Pulse output Pulse catch input 1 These features are available with use of certain option modules Option module specifica tions are located later in this section 2 Our 1K program includes contacts coils and scan overhead If you compare our products t
22. SS OR IMPLIED OF ANY KIND WHATSOEVER WITH RESPECT TO ANY GOODS OR SERVICES INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT Without limiting the generality of the foregoing Seller assumes no responsibility or liability for the selection of any materials for the goods that are the subject of this transaction The buyer is solely responsible for ensuring that materials selected for goods to be manufactured by Seller meet any regulatory requirements or specifications including but not limited to Directive 2002 95 EC on the restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS Directive together with any national legislation implementing such Directive ISO FDA UL CSA CE TUV FCC NSF and USP Any statements made by Seller personnel or specifications provided by Seller regarding materials should be verified by the buyer with the manufacturer of that material LIMITATION OF DAMAGES IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL CONSEQUENTIAL OR PUNITIVE DAMAGES OF ANY KIND WHETHER FOR BREACH OF ANY WARRANTY FOR BREACH OR REPUDIATION OF ANY OTHER TERM OR CONDITION FOR NEGLIGENCE ON THE BASIS OF STRICT LIABILITY OR OTHERWISE Indemnification The buyer shall defend indemnify and hold harmless Seller and its employees representatives and agents from and against all claims liabilities losses damages penalties fines and s
23. anctions of any kind including without limitation interest attorneys fees and expenses customs duties fines taxes penalties or any other governmental sanctions of any kind i resulting from or arising out of any breach of any representation warranty or covenant of the buyer or its affiliates hereunder ii if the buyer has supplied Seller with drawings designs or other specifications for the goods or services arising out of any assertion that any goods manufactured by Seller or the act of manufacturing such goods according to those drawings designs or other specifications infringe or misappropriate any patent copyright trade secret or other proprietary right iii otherwise arising out of or related to this transaction or It is specifically understood that the buyer shall indemnify and defend Seller and hold Seller harmless from claims that Seller was itself negligent or otherwise at fault If any action suit or proceeding is commenced or any claim demand or assessment asserted against Seller or its employees representatives or agents which may result in liability with respect to which a party seeks indemnification then the party shall notify the buyer promptly and the buyer shall have the right at its own expense to assume the entire control of the defense compromise or settlement Upon the buyer s request and at the buyer s expense Seller shall cooperate fully in such defense and make available to the buyer all relevant info
24. as through heating and twisting thin pieces of acrylic Preliminary testing proved that this was a viable design shape and multiple variations were modeled using SolidWorks This allowed the team to test the effects of different details of the design and the computer model created a reproducible design After the designs were finalized models were created using the 3D printer on campus The 3D printer was the best option for creating these prototypes because it was the least expensive option for Aqua Tech s low volume production and it was readily available Multiple variations of the model were tested and through this testing Aqua Tech was able to observe the effects of different design details such as amount of twist model width and thickness The optimal design was chosen through this testing process Figure 6 The Twister is the optimal shape that Aqua Tech is recommending to Blue Water Technologies The optimal design is built on a two by one half inch rectangle It has one half revolution 180 and then tapers from the rectangle to a circular shape as shown in Figure 6 The overall height is ten inches A drawing package 1s provided in Appendix A The twister has a hollow PVC pipe mounted to the top cylinder The hollow shaft is three feet long and has a coupling that reduces the outside diameter from 0 84 to 0 5 at the top of the shaft The roller bearing is mounted on the hollow shaft before the coupling After the c
25. cated in such county Seller and the buyer each consent to the jurisdiction of each such court in any suit action or proceeding and waive any objection which it may have to the laying of venue of any such suit action or proceeding in any such courts and any claim that any such suit action or proceeding has been brought in an inconvenient forum English Language All documents notices and legal proceedings executed given or instituted pursuant to or relating 63 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote directly hereto shall be in the English language and the meaning of all words and phrases of this offer shall be defined construed and interpreted in the English language March 25 2009 Refresh data Copyright Protomold 1999 2009 Terms and Conditions Privacy Policy 64 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009
26. compliance with U S Export Laws and that it will comply with these laws including not selling or distributing the goods to prohibited parties or end users as described in the U S Export Laws and obtaining all necessary export licenses or approvals that may be required if the buyer sells or exports the goods to parties or countries for which a license or approval is required Seller reserves the right to stop shipping or providing goods if the buyer appears on a restricted party list or if shipment requires an export license or otherwise becomes restricted by U S law Government Contracts Arms Sales The buyer represents and warrants to Seller that the goods that are the subject of this transaction are not the subject of any government contract and will not be subject to regulations governing international traffic in arms Tooling Due to the proprietary nature of the Seller process all tooling fixturing and software developed by Seller are proprietary and are generally not compatible with or transferable to other equipment Seller retains ownership of the molds Notwithstanding any tooling or engineering charges imposed by Seller all such tooling and software produced by Seller shall be and remain the sole and exclusive property of Seller However Seller shall not use custom tooling or software in the production of goods for any other customer of Seller without buyer s express permission As used in this section custom tooling or software m
27. corkscrew 7 3D printer twister Table 5 Pictures of devices tested in the acrylic model Numbers for devices correspond to Table 6 16 Description of shape tested Results 3 Acrylic Twister 360 steep pitch 00 5 Red Paint Stirrer 9 minutes 40 seconds for a 4 turn 6 3D printer corkscrew Plastic layers sheared failed 7 3D printer twister 9 minutes 30 seconds for a 1 4 turn Y inch PVC tube 0 237 inches minute Table 6 Testing results obtained for multiple devices Numbers for devices correspond to Table 5 The twister and paint stirrer have comparable results The 180 and 360 steep pitch twisters have comparable results The 3D printer design must be above a certain thickness The linear rate at which all testing occurred was 0 237 inches minute and an average count was 24 counts 30 seconds The rotational rate must be multiplied by 0 00246875 to obtain the sand bed turnover rate The environment that testing was performed in was a constant and unvarying sand slurry at a constant air lift speed Further testing needs to be performed by varying the air lift speed to confirm that the radial monitor of the monitoring device varies linearly with the sand bed rate At this point the radial rotating monitor 1s assumed to be turning linearly with sand bed turnover The result of the PVC stick calibration resulted 1n an average rate of 0 237 inches per minute for the sand bed turnover rate For th
28. d be used to measure all four guadrants of one filter Figure 4 Design solution for two quadrants The design solution consists of a 3D Printer shape connected to a shaft The mounting consist of steel flat bar with two welded horizontal flat bar pieces to form double storied mounting The shaft is secured to the mounting using a sealed ball bearing and the encoder The sealed ball bearing is located on the bottom flat bar of the mounting device The encoder is located on the top of the mounting bars This allows both the encoder and bearing to rotate as the shaft rotates The rotating signal form the optical encoder is sent to the PLC for processing Ladder logic was used to program the PLC and its display screen was used to display the rotation rate of the encoder in two quadrants Any difference in rotation between the two quadrants for a time period of three minutes alarms the PLC and displays Check Filter on the LCD screen Figure 5 Flow Chart of Design Solution 3 1 Shape Over the course of last semester Aqua Tech experimented with several shape designs n the acrylic model Through this testing Aqua Tech was able to determine an optimal shape to develop in more detail throughout the second semester The focus of the detailed shape design and fabrication was the twisted acrylic design from the first semester named the Twister This twisted shape is a rectangular extrusion on a helix Initial testing of the design w
29. e 02 3 8 0 375 See CPR Options below PP Push Pull S 18 Cables CE CE Marked6 10 1 2 0 500 Price adder gt 1999 HV Line Driver J00 18 Cable with 11 5 8 0 625 5 M127 06 5mm NUMBER OF 54 K00 18 Cable Mn SEALING COMMUTATION 04 6mm Channel A Leads B m E 1 1 50 for Thru Bore N No Commutation 14 8 mm Q OuadratureA amp B apa M 2 1 64 for Thru Bore C4 4 Pole 05 10mm R Quadrature A amp B with Index 7 3 64 for Hollow Bore C6 6 Pole n Channel B Leads A m s 4 P50 for Hollow Bore everse Quadrature 7 E D Reverse Quadrature A amp B MAXIMUM MOUNTING C12 12 Pole ap pin FREQUENCY SD 1 575 40 mm BC Flex Mount See http www encoder com 1 Standard SF 1 811 46 mm BC Flex Mount literature index phasing pdf for 2 Extended XF 2 250 BC 3 point Flex Mount HOUSING STYLE additional options and waveforms See Specifications NF 2 375 BC 3 point Flex Mount B Hollow Bore Blind For Explanation FA Flex Arm T Front Clamp Thru Bore OPERATING FB Flex Arm R Rear Clamp Thru Bore TEMPERATURE En L 40 to 70 C For specification S 0 to70 C assistance call e V 0 to 120 C Customer Service at 1 800 366 5412 NOTES 1 Contact Customer Service for additional options not shown 2 Notavailable in all configurations Contact Customer Service for availability 3 51016 VDC supply only for H option 5 VDC supply only for V option Contact Customer Service for availability and additional information 4 Co
30. e Analog PLC Inputs Outputs By using option modules you can add DL205 PLC Part Number 0 Type Sink or Voltage 1 0 Type Sink or Voltage Current analog inputs or outputs to your DLO5 ommons source Ranges Commons Source Ratings or DLO6 PLC The table below shows 5 an 17 240VAC 0 5A the input and output types at a glance PLC 5 50 60 Hz Detailed specitications are provided DO 06AR ACI N A 90 120VAC Relay 4 NA 5 later in this section rm DO 06DA 00 5 Sink or 12 24 0 AC A E Analog 1 0 Option Modules Field O Sink or 45 16 27VDC 0 5A 0 1 Inputs Outputs Price 00 06001 05 source 12 24 0 SK 6 7VDC 1 0A Y2 Y17 Part Number S D0 06DD2 065 Sink or 422406 DOM ue ee No Input Type No source 12 24VDC 1 0A Y2 Y17 yp em sink or 6 2 VDC 2 00mA D0 06DR M2 24VDC Relay 4 F0 04AD 1 5 NA Sink or 45 6 27VDC Y0 Y1 DEN 00 06001 0 02 5 source 12 24000 DUA 6 27VDU 1 0A Y2 Y17 F 04AD 2 77 N A Sink Or 49 12 24VDC 0 5A Y0 Y1 D0 06DD2 D 5 source 12 24 0 DC 4 Source 45 5 1 08 Y2 Y17 e w m 00 0608 0 00 5 Sink or 12 24 0 Relay 4 hm _ 0 5VDC or Motors ese outputs must be derated to 0 6A for EN61131 2 compliance Discrete 1 0 Option Moduless F0 04DAH 1 N A 4 20mA 50 Apps Mns FO 08DAH 1 NA 4 20mA Part Number s Sink or Voltage FS Sink or Voltage Current Controls Commons Source Ran
31. e encoder counts are each 30 seconds so the linear sand rate for 30 seconds would be half of what it 1s from the inches per minute rate 4 4 Economic Analysis In order for Blue Water Technologies to implement a monitoring device in each quadrant the devices will need to be mass produced Aqua Tech asked ProtoMold for a quote on plastic injection molding A summary of the cost is shown below in Table 7 For the initial 100 Twister pieces it will cost approximately 13 000 For every 500 devices afterward it will cost just over 18 4 000 A more detailed cost breakdown and design suggestions from ProtoMold are provided in Appendix I Additional Initial Setup Production Tooling Setup Cost 12 645 750 Prototypes ea 6 92 6 92 Total Initial Cost Table 7 Cost of plastic injection molding of recommended twister Quote from ProtoMold Along with the cost of plastic injection molding creating the rest of the monitoring device has additional costs It is recommended that Blue Water charge an estimated ten dollars per injection molded device to make up the setup and tooling costs In some of Blue Water Technologies Centra flo filters a PLC is already required for proper operation With the monitoring device that Aqua Tech has created a PLC will need to be included with every filter Shown below in Table 8 is an implementation cost analysis This analysis shows the cost for filters that already have a PLC as well as
32. eans tooling or software developed specifically for the buyer and for which the buyer is separately charged by Seller Buyer Supplied Materials If Seller agrees to use materials supplied by the buyer then the buyer shall be solely responsible for supplying and delivering such material in a timely manner at no cost or expense to Seller in sufficient quantity and quality including any loss waste or scrap that may occur for any reason as Seller deems necessary to complete the order The buyer hereby acknowledges that Seller shall not be liable for and the buyer shall continue to be obligated to pay any previously negotiated delivery premiums despite any failure or delay in delivering any goods to be provided hereunder if such failure or delay is caused by the buyer s failure to supply and deliver such materials in a timely manner or in sufficient quantity and quality as Seller deems necessary Governing Law Jurisdiction The rights and obligations of Seller and the buyer under this contract shall be governed by the laws of the State of Minnesota without regard to principles of conflict of law including the Minnesota Uniform Commercial Code The United Nations Convention on Contracts for the International Sale of Goods shall not apply to this transaction Any suit action or other legal proceeding arising out of or relating to this transaction shall be brought in a court of record in Hennepin County Minnesota or in the courts of the United States lo
33. exture requires at least 3 degrees of draft and PM T2 medium bead blast texture requires at least 5 degrees of draft Faces colored red have a draft of less than 3 degrees and faces colored yellow have a draft of 3 5 degrees Additional draft will need to be added to these faces in order to accommodate your texture choice Notes Customers are responsible for ensuring that the properties and performance of the resin selected meet the requirements of their application There is no provision within the Protomold process to make the tool steel safe Since dimensional tolerances are highly dependent on the material selected and on the part design we are not able to guarantee that a specific tolerance will be met e A side shown in green B side ejection side shown in blue The expected tolerance in a well designed part in ABS Black Lustran 433 904000 is 0 003 in 0 002 in in Upload a new model for a quote If you would like to upload a revised model of this part click here Terms and Conditions ProtoQuote Seller As used herein Seller means Proto Labs Inc including both its First Cut Prototype Division and its Protomold Division a Minnesota corporation Offer and Acceptance This document from Seller contains the entire terms and conditions associated with this transaction Seller objects to any different or additional terms or conditions contained in any request for quotation purchase order or
34. filter models that will need to add a PLC Each Quadrant Cost Table 8 Implementation cost for entire filter Cost analysis shown both with and without a PLC which is already included in some filters 19 Overall the cost benefit to Blue Water Technologies has been positive It has provided a monitoring device that meets all requirements originally is an improvement to acquire a monitoring device that meets all requirements of Blue Water Technologies 5 Conclusions and Recommendations The project proved to be overall very effective and Aqua Tech was able to measure the sand flow rate with a fair amount of precision After two semesters of vigorous design and testing Aqua Tech found that a twisted plastic piece attached to an encoder and PLC via a sealed ball bearing worked most effectively The design calculations were based on the acrylic water tank that Blue Water Technologies provided on the first visit to Hayden Idaho Therefore in order to implement the design solution in an industrial filter some design modification will be necessary It is estimated that the total cost for the device in all four quadrants would be approximately 1100 Aqua Tech found that successful designs gave consistent results It is recommend that Blue Water work with future senior design teams or senior lab teams to conduct further testing on a multiplier before this design is implemented into an industrial system This would give an observer direct mea
35. gents which may result in liability with respect to which a party seeks indemnification then the party shall notify the buyer promptly and the buyer shall have the right at its own expense to assume the entire control of the defense compromise or settlement Upon the buyer s request and at the buyer s expense Seller shall cooperate fully in such defense and make available to the buyer all relevant information under its control Force Majeure Seller shall not be liable for any failure to manufacture deliver or provide or for any delay in the manufacture delivery or provision of any goods to be provided hereunder if such failure or delay is caused by acts of God fire storm strikes blackouts labor difficulties riots inability to obtain materials equipment labor or transportation governmental restrictions serious public health nuisance or any similar cause over which Seller is unable to exercise control U S Export Laws The goods that are the subject of this transaction may be subject to U S laws restricting the export and reexport of certain sensitive products and technology These laws include export regulations administered by the U S Department of Commerce and the U S Department of State as well as economic and trade sanctions programs administered by the U S Department of Treasury collectively U S Export Laws By receiving these goods the buyer agrees it is legally responsible for using or distributing these goods in
36. ges commons Source Ratings F0 04DAH N A 0 10VDC Proximity Sink 6 27VDC 1A D0 07CDR DCA 12 24VDC Relay 3 1 N A 1A F0 08DAH 2 N A 0 10VDC m Sink S D0 08CDD1 4 2 12 24 V06 00 4 2 6 27 VDC 0 3A FO 4AD2DA 1 0 20mA or 0204 aoe D0 08TR NA NA N A Relayliz 7 420mA Limit 6 240VAC 1 050 Switches Sink or FO 2AD2DA 2 2 2 0 DO 10ND3 122400 NA li UNDE Sink or i 3 0 5VDC or D0 10ND3F 00 10 20 Source 12 2AVDC N A N A F0 4AD2DA 2 o 10v00 2 Current D0 10TD1 NA NA NA DC 10 2 Sink 6 27VDC 0 3 F0 04RTD RTD N A D0 10TD2 N A NA NA DC O 2 Source 12 24VDC Nei Tremo DO 16ND3 Dc 6ja 20 26V06 N A N A 7 NE See module specifications page for thermocouple D0 16TD1 N A N A N A DC 16 2 Sink 6 27VDC 0 1A types and voltage input ranges supported Relays D0 16TD2 N A N A N A DC 16 2 Source 12 24VDC 0 1A Power budgeting 04 5 N A N A N A Relay 4 4 N A DALA No power budgeting is necessary for the DL05 The built i ly i FU 08NA 1 b b h A for e e base ps ns iring F0 08SIM 68 01 Input simulator any of the option modules the hand held programmer and even a Power Communications and Specialty Option Modules DV1000 operator interface Part Number Description i Povver budgefing is necessory for the Ethernet Communications Module 10 Mbit
37. gs executed given or instituted pursuant to or relating directly hereto shall be in the English language and the meaning of all words and phrases of this offer shall be defined construed and interpreted in the English language March 25 2009 Refresh data 99 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote 1 Dark blue color coding indicates areas where part thickness is significantly greater than nominal Sink marks are possible in these areas http www protomold com ProtoQuote aspx p 190699t5xy 60 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote 2 This part is thick Sink marks internal voids excessive shrink and warp are possible You can expect better parts if you redesign your part to thin it out 3 If you require a textured finish on your part PM T1 light bead blast texture requires at least 3 degrees of draft and PM T2 medium bead blast texture requires at least 5 degrees of draft Faces colored red have a draft of less than 3 degrees and faces colored yellow have a draft of 3 5 degrees Additional draft will need to be added to these faces in order to accommodate your texture choice 61 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote 4 If you require a textured finish on your part PM T1 light bead blast t
38. he value in V2000 into the lower 16 bits of the accumulator The unused accumulator bits are set to zero V2000 0 0 5 0 O Accumulater DIV 4 9 V2006 V2006 Acc 1 012 0 0 0 0 JO 2 The value in the accumulator is divided by First stak location contains the value in V2006 the remainder OUT 0 2 V2010 V2010 Copy the value in the lower 16 bits of the accumulator to V2010 Handheld Programmer Keystrokes B STR 2 1 iu L D C A A A HI ANDST 3 gt 2 0 0 0 EINE D V E A A G 57 3 8 AND E 2 0 0 6 GX i V C A B A OUT 2 AND 2 0 1 0 ENI DL06 Micro PLC User Manual 3rd Edition Rev A 5 95 8 4 Appendix G Flow Chart of the PLC Program 49 Encoder 1 OS No Encoder 1 p Counter No Yes Counter 0 Timer 0 5 s T gt Divide T by Output to Increments of 400 No gt 10 gt 2010 0 15 1 Yes 1 0 Encoder 2 No Encoder 2 Counter O No Yes Counter 0 e u m s T gt Divide T by Output to 400 10 V2010 0 1s Yes T 0
39. if the design met or failed to meet the acceptable performance 12 Physical Properties Acceptable Performance Heen Performance Actual Measurement h 1 6 Dia lt 6 h 1 6 Dia lt 6 inches inches lt xlOls eee lt 10 lbs 12 24 the surface of the sand 6 18 slurry 4devies No devices 00 Not sand attractant or vvaste attractant Hard durable 77575 No visible leaches to filter water Prototype device be run off of common Yes 220 V power source Life and Replacement Acceptable Performance Can be replaced without replacing filter Yes Made from a material that does not absorb water after testing no marks or abrasions deeper than 1 8 Manufacturing Acceptable Performance Meets Performance Actual Measurement lt 1000 No Output NN LT TT Performance Meets Measurement Measure range Measure range capability 0 3 per minute 0 3 per minute 0 1 per minute 1 per minute PLC receives data output PLC receives data avoid PLC Series 300 95 Consistent within Zn 5 5 eror error ua location seconds of dropping below critical rate only Table 3 Specification evaluation against recommended prototype Thus in three specifications the design failed to meet the acceptable performance However in 13 specifications the designed met the acceptable performance With a major portion of design successes the sand bed turnover m
40. is calibration the red paint stirrer was attached to the encoder which displayed a range of 21 to 25 counts per 30 seconds on the PLC LCD screen Calculations were made such that the radial and linear rates were compared and it was verified that they were 17 not equal Thus the importance of the multiplier for calibration is essential In conclusion the radial rotating monitor gives an imitation rate that varies linearly with sand bed turnover but to obtain the true sand bed turnover rate each monitor must be calibrated Each monitor must be calibrated because each variance will divert the radial monitor from the actual sand rate such as bearing resistance and encoder resistance If all these parameters are kept the same for the four filter monitors then an actual differential in quadrants is still obtained The calibration number calculated for the monitor calibrated is an average of nine trials of one to two inch linear drop depth Then the linear drop depth was timed to obtain a linear sand bed turnover rate The average count was 24 counts per 30 seconds thus the multiplier if the rotation follows the sand rate turnover linearly is 0 00246875 inches count Calibration calculation 1 Where RI is the linear sand flow rate Rr 15 rotational sand flow rate and k 15 the multiplier constant that converts the rotational sand flow rate into the linear sand flow rate The linear sand rate 1s divided by two because th
41. mance of the resin selected meet the requirements of their application There is no provision within the Protomold process to make the tool steel safe Since dimensional tolerances are highly dependent on the material selected and on the part design we are not able to guarantee that a specific tolerance will be met A side shown in green B side ejection side shown in blue The expected tolerance in a well designed part in ABS Black Lustran 433 904000 is 0 003 in 0 002 in in Upload a new model for a quote If you would like to upload a revised model of this part click here Terms and Conditions ProtoQuote Seller As used herein Seller means Proto Labs Inc including both its First Cut Prototype Division and its Protomold Division a Minnesota corporation Offer and Acceptance This document from Seller contains the entire terms and conditions associated with this transaction Seller objects to any different or additional terms or conditions contained in any request for quotation purchase order or other document of the buyer and no such different or additional terms shall be effective or binding upon Seller unless agreed to in writing and signed by an officer of Seller If the buyer issues a purchase order or other writing addressing the subject matter of this transaction that writing shall be for the buyer s internal purposes only and the terms and conditions contained therein shall have no force o
42. n Sensor DA Cube LCD at Filter Labview Wall Outlet Option3 Acrylic Realer Upper Linear Motion Digital Optical Encoder Encoder Interface LED green red Option4 Hard Plastic PLC Display Encoder Software PLC Software Computer Figure 3 Morphological chart Highlighted in red are the design features that were selected at the Preliminary Design Review 2 9 Specifications A specification table shown below in Table shows the acceptable performance of the device needed to monitor sand bed turnover The four main general requirements are the physical properties durability manufacturing of prototype and output of results General Requirements Specific Requirements Acceptable Performance Physical Properties of Prototype Fits in a quadrant Can be mounted on top rails or Weight of device m central airlift _ Avoids effects from wash box Does not interfere MES and air lift Doesn t effect sand bed turnover Does not change rate of sand movement No metal Powered by common power Prototype device can be run off of Doesn t contaminate the clean water common power source Life and Replacement of Prototype Easily maintained amp replaced waterproof can be submerged into water sand Durable slurry Does not corrode or become abraised form the sand Manufacturing Creating Prototype Material Part cost assembly Low cost cost travel O
43. n option module Option module specifica tions are located later in this section 2 Our 1K program includes contacts coils and scan overhead If you compare our products to others make sure you include their scan over head 3 Input features only available on units with DC inputs and output features only available on units with DC outputs 33 1 800 633 0405 Features at a Glance DirectSOFT software DLO5 and 106 PLCs use the same familiar DirectSOFT programming soft ware that our larger PLCs use A FREE version of DirectSOFT gives you all the great features of the full version but with a 100 word PLC program download limita tion For programs larger than 100 words the full package is required The FREE Input status indicators Mode switch y Mounting tab Communication ports Output status indicators OUTPUT X1 X2 X5 X6 X7 YO Yi Y2 Y3 Ya Y5 PC DS100 software may be sufficient to 6626166266 2322222 5 7 program the DLO5 and DLO6 If you are Direct 05 programming with a full package version LOGIC annia prior to v5 0 you will need v2 4 or later ion status for the DLO5 PLCs and v4 0 or later for the indicators DLO6 We always recommend the latest version for the most robust features See Removable nm zir Gs GS GG Gn GS 12 terminal the Software section in this catalog for a eo e ez dl e block s pL iL iiL
44. ndex Ambient Temperature C F ndirect com dl05and06 PLC Products 32 2 45 www automatio 2 20 Features at a Glance The DLO5 and 0106 micro PLCs are complete self contained systems The CPU power supply and I O are all included inside the same housing Option modules are available to expand the capability of each PLC family for more demanding appli cations The standard features of these PLCs are extraordinary and compare favorably with larger and more expensive PLCs The specification tables to the right are meant for quick reference only Detailed specitications and wiring information for each model of the DLO5 and 0106 PLCs begin on page 2 33 Program capacity Most boolean ladder instructions require a single word of program memory Other instructions such as timers counters etc require two or more words Data is stored in V memory in 16 bit registers Performance The performance characteristics shown in the tables represent the amount of time required to read the inputs solve the Relay Ladder Logic program and update the outputs Instructions A complete list of instructions is available at the end of this section Communications The DLO5 and DLO6 offer powerful communication features normally found only on more expensive PLCs Special features The DC input and DC output PLCs offer high speed counting or pulse output Option module slots allow for discrete I O expansion analog
45. nt Mount outer race in enough the No locations to keep it secure Mount outer race in multiple locations Mounting bearing from reading Filter Outer race not tack weld in 4 ensure that it is well supported system free spinning functions fine 3 fully supported spots 3 by top brace Do not add any Ensure that inner race is not additional friction restrictions to Inner race not allowed free movement touching top support adding friction and that it is free to inner race rotate No readings Bends out of broken Different materials or Test and observe different Shaft place pieces Non rigid shaft 16 shafts and research alternatives Choose correst type of bearing Keep avvay from dirt and be careful while banging on and vvater bearing Design an encoder casing that enables the encoder to Research an appropriate perform consistently design to keep the encoder in a under all weather steady state is this conditions necessary o EN May not spin Could affect Does not give or may hardly the reading actual sand Bearing spin process motion rate Weather moisture wears the Encoder Encoder fails No data components Encoder Output No Data Encoder Fails Collection 5 Too much load cl RB i GG Encoder May not give correct results Power Cord Fails LCD Fails DC Power Supply Fails PLC Fails Affect the reading Cc j n
46. ntact Customer Service for non standard index gating options 5 For non standard cable lengths add a forward slash plus cable length expressed in feet Example S 6 6 feet of cable Frequency above 300 kHz standard cable lengths only 6 Please refer to Technical Bulletin TB100 When to Choose the CE Option at www encoder com 7 Not available with commutation or extreme temperature V option 5 pin not available with Line Driver HV output Additional cable lengths available Please consult Customer Service 1 800 366 5412 www encoder com sales encoder com 29 Model 260 Model 260 Specifications Electrical Input Voltage 4 75 to 28 VDC for temperatures up to 70 C 5 to 16 VDC for 0 to 100 C operating temperature 5 VDC for 0 to 120 C operating temperature Input Current 100 mA max with no output load Output Format Incremental Two square waves in quadrature with channel A leading B for clockwise shaft rotation as viewed from the mounting face See Waveform Diagrams Output Types Open Collector 20 mA max per channel Push Pull 20 mA max per channel Line Driver 20 mA max per channel Meets RS 422 at 5 VDC supply lele e ME Once per revolution gated to channel A See Waveform Diagrams Max Freguency Standard Freguency Response is 200 kHz for CPR 1 to 2540 500 kHz for CPR 2541 to 5000 1 MHz for CPR 5001 to 10 000 Extended Frequency Resp
47. o others make sure you include their scan over head 3 Input features only available on units with DC inputs and output features only available on units with DC outputs 0106 CPU Specifications System capacity Total memory available words Ladder memory words V memory words User V memory Non volatile user V memory Built in battery backup D2 BAT 1 Total 1 0 Performance Contact execution Boolean 0 6us Typical scan 1K Boolean 2 Instructions and diagnostics RLL ladder style RLLPLUS flowchart style Stages Run time editing Number of Instructions Types of Instructions Control relays Counters Immediate 1 0 Subroutines For next loops Table functions Timed interrupt Integer math Trigonometric functions Floating point math Drum sequencers Bit of word Number type conversion ASCII in out print LCD instruction Real time clock calendar Internal diagnostics Password security System and user error log Communications One RS 232C One multi function RS232C RS422 RS485 NOTE RS485 is for MODBUS RTU only Protocols supported K sequence proprietary protocol DirectNet master slave Modbus RTU master slave ASCII in out Baud rate POM o beac 9 600 baud fixed selectable 300 38 400 baud default 9 600 Specialty Features Filtered inputs Interrupt input High speed counter Pulse output Pulse catch input 1 These features are available with use of certai
48. o M12 connector body 6 CE Option Cable KEE shield and M12 connector body is connected to internal 260CAT ARMD Flex Arm FB 5 pin p M12 cordsets M12 260CAT FB 0 55 MAX HEIGHT All dimensions are in inches with a tolerance of 0 005 or 0 01 unless otherwise specified 5 pi PiN connectors 8 pin M12 M12 12 1 800 366 5412 www encoder com sales encoder com 31 01 06 I O Specifications DL105 2 PL DO 06D D2 lt gt Note Refer to page 2 29 Power Budgeting 2 for Auxillary 24VDC current available DL205 Wiring diagram and specifications Se PLC EE P input wiring t point wiri D0 06DD2 Specifications 01305 AC Power Supply 95 240VAC SY 24 Specifications Yoltate Range 30VA di 2 0405 Number of Input Pts 20 sink source gt Number of Commons 5 isolated The La des E E Field Input Voltage Range 12 24VDC Software 177 Ye Input Impedance X4 X23 2 8K C more 12 24VDC DO 06DD2 HMIs 0 Current 11 12 13 14 15 16 20 4 Other HMI DC Input Voltage Level Specifications OFF Current Drives Voltage Level Response Time 0 3 4 23 Direct m OFF to ON Response 100us lt 8ms dn po heeii d 100us lt 8ms Motor Fuses None Controls and of Output 16 Sourcing B
49. oduct Data Sheets Appendix C Wiring Diagrams Appendix D Mathcad Appendix E Ladder View Logic Appendix F DivAppendix Appendix G Flow Chart of the PLC Program Appendix H DFMEA Appendix I Injection Mold Quote from ProtoMold 12 13 15 16 17 19 19 18 22 27 38 40 42 47 49 52 56 1 Executive Summary Blue Water Technologies has been selling Centra flo filtration systems for many years These filters can stop working correctly when the filter media sand becomes packed up which creates a void inside the filter This creates insufficient sand circulation and water filtration which 1s not only harmful to the filter but also dangerous to the environment as it is releasing unfiltered water to environmental streams and water ways Due to this problem Blue Water Technologies asked the University of Idaho s Capstone Senior Design team Aqua Tech to design a solution After two semesters of design fabrication and testing Aqua Tech has developed a solution to the given problem This solution includes a lightweight twisted shape suspended in the sand bed As the sand moves downward through its normal circulation the force of the sand rotates the device Attached to the shape is a long solid PVC shaft that connects the device shape to the top mounting bracket The mounting device consists of a top support structure on the filter with a sealed ball bearing and encoder The bearing provides support for the weight of the device
50. of steps that the encoder passes within the allowed time period Simultaneously a timer begins and is reset at 40 seconds The counter 10 is set to reset to zero when the timer reaches 40 seconds The counter then continues to count from zero Since the timer counts in increments of 0 1 seconds the timer value 1s divided by 10 to display in units of seconds When the timer reaches 30 seconds the counter 1s loaded into the accumulator and multiplied by 124 This allows the rate to be displayed without using two memory locations When a number is divided the remainder is output to the accumulator stack The DivAppendix shows this n Appendix F Multiplying the counter by 124 shifts the accumulator left three positions and thus allowing the rotational rate to be displayed using a single memory address The resulting number from this multiplication is then divided by the timer in terms of seconds and outputted to a memory address A partial flow chart of the program is shown below in Figure 9 A complete flow chart is shown in Appendix G Encoder 1 No Load to Encoder 1 gt Counter 0 s No Yes SUID Dy pide by gt Memory 400 124 2010 V2001 Yes Counter 0 Timer 9 ls gt Divide T by Output to Increments of 400 No gt 10 V2010 0 15 Yes T 0 Figure 9 PLC program for single
51. olutions not all disk resolutions available with every commutation option Low Profile 1 19 Up to 12 Pole Commutation Thru Bore and Hollow Bore Blind Styles Simple Innovative Flexible Mounting System Incorporates Opto ASIC Technology CE marking available Los The Model 260 s larger bore up to 0 625 and low profile make it the perfect solution for many machine and motor applications Available in two distinct formats a Hollow Bore and a complete Thru Bore the Model 260 uses EPC s pioneering Opto ASIC design The Model 260 uses EPC s innovative anti backlash mounting system allowing simple reliable and precise encoder attachment Unlike traditional kit or modular encoder designs it s integral bearing set provides stable and consistent operation without concerns for axial or radial shaft runout For brushless servo motor applications the Model 260 can be specified with three 120 electrical phase tracks to provide up to 12 pole commutation feedback The optional extended temperature capability allows servo motors to operate at higher power outputs and duty cycles Common Applications Brushless Servo Motor Commutation Robotics Motor Mounted Feedback Assembly Machines Digital Plotters High Power Motors elle ol MODEL BORE SIZE CYCLES PER REVOLUTION OUTPUT TYPE CONNECTOR CERTIFICATION 260 Ultra Versatile 01 1 4 0 250 1 10 000 OC Open Collector TYPE N None Commutated Thru Bor
52. onitor design project was a success An acceptable design 13 was fabricated and can be implemented in the large scale Centra flo filters with little design alterations Some of these alterations are discussed the Further Recommendations section 4 2 DF MEA Evaluation Risk analysis was performed on the sand bed turnover monitor design by using DFMEA evaluation DFMEA stands for Design Failure Mode and Effect Analysis t 1s a process that helps identify design risks and highlights the most risky design features Potential failure modes were identified which are 3D printer material 3D printer part mounting system shaft bearing encoder and PLC Then possible effects of the each of these potential failure modes were identified and rated on the severity of the potential effect Next likely causes of the effect were identified and rated on an occurrence level Design controls were identified to state ways to bypass the potential failure mode a detection rating was also identified Finally the RPN number a product of all the three ratings was calculated in order that each potential failure mode be properly weighted based on the three ratings The main purpose of the DFMEA evaluation was to highlight the most risky potential failure modes The highest rated possible failure modes were the PLC bearing shaft connection and 3D printer material All other potential failure modes had minimal risk See Appendix H for the
53. ons are in inches with a tolerance of 0 005 or 0 01 unless otherwise specified 30 1 800 366 5412 www encoder com sales encoder com 11 qa ENCODER Waveform Diagrams Model 260 Three Point Flex Mount XF NF 4 40 OR 6 32 OUTPUT A OUTPUT A L OUTPUT B m _ OUTPUT B 180 e A e T RO 4 INDEX 2 B 260NF XFCAT1B 1 05 BORE DEPTH FLEX MOUNT WITH 1 27 LDSIGC 1 575 40 mm BC Flex Mount SD OUTPUTU El E OUTPUTU d 00 218 USE 4 40 OR M2 5 NE ge A 120 BUTTONHEAD SCREWS Fe A W OUTPUT V w OUTPUT V 01 575 lir 40 00 f 120 i m Olurum o 1 00 BLIND t 2 OUTPUT W BORE DEPTH ROTATIONAL ADJUSTMENT 1 19 260 sdflex A CW ROTATION OF SHAFT AS VIEWED LOOKING AT THE ENCODER FACE NOTE ALL DEGREE REFERENCES ARE ELECTRICAL DEGREES Flex Arm FA Wiring Table R IL 30 ROTATIONAL CLOCKWISE ROTATION ADJUSTMENT NOTE ALL DEGREE REFERENCES ARE ELECTRICAL DEGREES Qo a er O mm a er mi O D mm o Black CE Option Cable 0 73 shield bare wire 1 is connected A Brown 4 1 tointernal case 100 BLIND F Option BORE DEPTH able shield is ESSERE connected t
54. onse optional is 300 kHz for CPR 2000 2048 2500 and 2540 Noise Immunity Tested to BS EN61000 6 2 BS EN50081 2 BS EN61000 4 2 BS EN61000 4 3 BS EN61000 4 6 BS EN55011 Symmetry 180 18 electrical Quad Phasing 90 22 5 electrical Min Edge 67 5 electrical Accurady Within 0 019 mechanical from one cycle to any other cycle or 0 6 arc minutes Commutation Up to 12 pole Contact Customer Service for availability Comm Accuracy 1 mechanical Mechanical Max Shaft Speed 7500 RPM Higher shaft speeds may be achievable contact Customer Service Note For extreme temperature operation de rate temperature by 5 C for every 1000 RPM above 3000 RPM Bore Size 0 250 through 0 625 5 mm through 15 mm Bore Tolerance 0 0000 0 0006 User Shaft Tolerances Radial Runout 0 007 max Axial Endplay 0 030 max Starting Torque IP50 Thru Bore 0 50 oz in IP50 Hollow Bore 0 30 oz in IP64 Thru Bore 2 50 oz in IP64 Hollow Bore 2 0 oz in Note Add 3 0 oz in for 40 C operation Moment of Inertia 3 9 X 1077 oz in sec Max Acceleration 1 X 10 rad sec Electrical Conn 18 cable foil and braid shield 24 AWG conductors non commutated 28 AWG commutated 5 or 8 pin M12 12 mm in line connector with 18 cable foil and braid shield Housing
55. otational Rate vs Number of Counts 5 5x10 4x10 e 8 3x10 2 2x10 S O 22 10 0 0 10 20 30 Cn Counts 40 41 Appendix E Ladder View Logic 42 5 7 2009 Sand flow rate program 06 Final Path c directsoft5 projects final prj Save Date 05 07 09 15 56 59 Creation Date 04 29 09 15 26 26 PLC Type 06 Class ID DirectLogic 06 Series 43 5 7 2009 Sand flow rate program 06 Final X0 CNT CTO TAO K400 KO CTO TMRA 7 TO TAO K400 KO em TO LD TAO DIV K10 OUT V2010 V2010 K30 LD CTAO MUL K124 DIV V2010 OUT V2001 CNT 1 CTI TAO K400 KO 44 5 7 2009 Sand flow rate program 06 Final V2010 K30 LD 1 MUL K124 DIV V2010 OUT V2002 V2010 K30 V2001 V2002 CO LI pe PD CO CNT CT2 V2001 V2002 KO Ey CTA2 K4 V2010 K30 V2002 V2001 C1 ZI E PD C1 CNT p CT3 V2001 V2002 KO CTA3 K4 gt 1 CTA2 K4 C2 LI PD C2 LCD Line Number K1 Check Filter 45 5 7 2009 Sand flow rate program 06 Final CTA3 K4 C3 II LCD 4 Line Number K
56. oupling the 0 5 outer diameter shaft is only one inch long The 0 5 shaft then fits into the encoder 3 2 Mounting By the end of last semester Aqua Tech had narrowed the scope of mounting options to focus on the caster design Throughout the process of the detailed design an idea that incorporated both the caster and double bearing designs was created The final method for mounting the sand bed turnover monitors 1s shown below in Figure 7 Figure 7 The mounting system is mounted on top of the acrylic model The bearings are shown in white The encoders are black and bronze The mounting design is created out of two 3 wide stainless steel flat bars There are two smaller 1 inch by 3 inch flat bars welded to each of the larger bars to add 4 inch of space between them This creates one surface for the encoder to sit on and act as the caster while the other surface holds a bearing to add extra weight support This device 1s then placed on the top lip of the acrylic model filter The edges of the bottom flat bar are bolted to the holes on the pre existing on the filter model lip Using these bolt holes allows the device to be mounted without modification of the current filter design 3 3 Mechanical to Electrical Interfacing The data acquisition system DAQ uses two encoders for the data collection The encoders being used in this design are the Encoder Products Company s Accu coder Model 260 Specifically the model numbe
57. r 11 2008 from P201 Compatible Rotary Encoders Website http www protura co uk encoders htm R N personal communication 18th Sept 2008 VXB Ball Bearings Retrieved March 15 2009 from Ball Bearings Website http www vxb com Merchant2 merchant mvc 21 Appendix A Drawing Package 22 ed doe m PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED G r DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION materiales Pari Drawings Ag le ch DEFAULT TOLERANCES UNVERSTY OF IDAHO ME DEPARTMENT ua 4 30 2009 Part Finished Assem QTY DRAWN BY Amanda McGrath scale 1 7 337 ye 10 00 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED C C TLL eg DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION 46 DEFAULT TOLERANCES 0 50 10 Material ABS Plastic r DRAWN BY Amanda McGrath CHECKED BY FILE NAME WiSTer
58. r effect Quotations A quote is valid only for the 3D CAD model on which it was based Any change to the 3D CAD model requires an updated quote Quotes are valid for 30 days after which pricing may change without notice Delivery Title Risk of Loss Premium delivery options are subject to review at the time of order All parts are shipped i for deliveries within the United States F O B at Seller s facilities in Maple Plain Minnesota and ii in all other cases FCA Incoterms 2000 at Seller s facilities in Maple Plain Minnesota Title passes to the buyer at the time and place of 28 http www protomold com ProtoQuote aspx p 190699t5xy 4 27 2009 Protomold Rapid Plastic Injection Molding ProtoQuote delivery to the carrier Taxes Duties Etc The buyer shall pay all duties and sales excise use or other taxes arising in connection with this transaction other than taxes based solely on Seller s taxable income Warranties Seller assumes no responsibility for the design of the goods that are the subject of this transaction To the extent that Seller s personnel recommend design modifications or provide design analysis simulation or advice they do so to help meet the requirements of Seller s own manufacturing process The buyer retains sole legal responsibility for the design specifications and performance of the goods that are the subject of this transaction SELLER MAKES NO REPRESENTATION OR WARRANTY WHETHER EXPRE
59. r is 260 N R 10 L 1270 Q OC 1 S NF 2 N The specifications of the encoder are located in Appendix B The encoder that was chosen uses a 5 pin M12 connector type There isa DC power input DC power ground cable shield and two outputs A and The 24V DC power supply of the PLC 15 connected to the encoders power inputs the cable shield is connected to ground and outputs A and B are connected to the PLC inputs In this design the output signal B is not used but is still connected to the PLC A diagram of the wiring method used 1s located in Appendix C These particular encoders have 1270 different steps Each step is 0 00124 inches apart as shown in the Mathcad Appendix D Therefore each time the encoder rotates 31 4 um signal A will output a high signal into the PLC input Figure 8 Encoder used in final design 3 4 Data Analysis with the PLC Blue Water Technologies provided Aqua Tech with a PLC from Automation Direct with model number D0 06DD2 Along with the PLC Blue Water Technologies also provided the DirectSoft 5 software for programming of the PLC DirectSoft 5 uses ladder logic to program the PLC Standard RFF instruction a type of ladder logic was used to calculate the rotational rate of the encoders Appendix E shows the program that Aqua Tech created for the PLC As the PLC input transitions from a high to low signal along with the encoder a counter within the PLC counts each transition This counts the amount
60. rmation under its control Force Majeure Seller shall not be liable for any failure to manufacture deliver or provide or for any delay in the manufacture delivery or provision of any goods to be provided hereunder if such failure or delay is caused by acts of God fire storm strikes blackouts labor difficulties riots inability to obtain materials equipment labor or transportation governmental restrictions serious public health nuisance or any similar cause over which Seller is unable to exercise control U S Export Laws The goods that are the subject of this transaction may be subject to U S laws restricting the export and reexport of certain sensitive products and technology These laws include export regulations administered by the U S Department of Commerce and the U S Department of State as well as economic and trade sanctions programs administered by the U S Department of Treasury collectively U S Export Laws By receiving these goods the buyer agrees it is legally responsible for using or distributing these goods in compliance with U S Export Laws and that it will comply with these laws including not selling or distributing the goods to prohibited parties or end users as described in the U S Export Laws and obtaining all necessary export licenses or approvals that may be required if the buyer sells or exports the goods to parties or countries for which a license or approval is required Seller reserves the right to stop
61. rt Shaft QTY Scale 1 10 SHEET 4 OF 4 Appendix B Product Data Sheets 27 1 2 Mounted Bearing UCFL201 8 2 Bolts Flanged Cast Housing Ball Bearings V XB 1 2 Mounted Bearing UCFL201 8 2 Bolts Flanged Cast Housing Quantity in Basket None Part Number Kit7328 Our Low Price 9 95 Shipping Weight 1 20 pounds add to basket Quantity 1 add to basket Shaft Dia Dimensions mm Bearing Housing Unit No d H L L A A E N S MA Bolt Size No No Mass kg in mm N UCFL201 8 1 2 113 90 60 15 11 25 5 333 115 12 7 37 5 M10 UC201 8 FL204 0 51 VXB Bearings Home gt 1 2 inner diameter 0 500 inch 1 2 Mounted Bearing UCFL201 8 2 Bolts Flanged Cast Housing 28 http www vxb com Merchant2 merchant mvc Screen PROD amp Store Code bearings amp Pro 5 8 2009 o O r O a O 5 est m 5 O o mm o 10 ENCODER PRODUCTS COMPANY Features Model 260 Ordering Guide Blue type indicates price adder options Not all configuration combinations may be available Contact Customer Service for details Model 260 CPR Options 0001 thru 0189 0200 0250 0254 0256 0300 0360 0400 0500 0512 0600 0720 0800 0840 1000 1024 1200 1220 1250 1270 1500 1800 2000 2048 2500 2540 3000 3600 4096 5000 6000 8192 7200 10 000 Contact Customer service for availability Contact Customer Service for other disk res
62. sions and Installation It is important to understand the installa tion requirements for your DL05 or DLO6 system Your knowledge of these reguire ments will helo ensure that your system operates within its environmental and electrical limits Note there is a minimum clearance requirement of 2 51mm between the panel door or any devices mounted in the panel door and the Plan for safety This catalog should never be used as a replacement for the user manual You can nearest DLOS component purchase download tree or view online the user manuals for these products The DO USER M is the publication for the p 50mm DLO5 PLCs and the DO O6USER M is the publication for the DLO6 PLCs The DO OPTIONS M is the user manual for the option modules These user manuals T contain important safety information that 0900 must be followed system installation ITA 2 should comply with all appropriate elec trical codes and standards min 50mm Panel Ground braid cop per lugs b W Panel or single point ground Star washers Star washers See the enclosure section to find an enclosure that fits your application Environmental Specifications for DLO5 and DLOG 4 F 158 F Storage Temperature 20 C to 70 C Ambient Operating 32 F 131 F Temperature 0 to 55 C 5 to 95 relative Ambient Humidity humidity non condensing
63. smetic finish to Protomold discretion Sample Quantity 100 Delivery Sample parts ship in 15 business days standard delivery Material x The highlighted materials are preferred for their availability and or cost 7 Review Issues VIEW IN 3D Required Changes 0 Moldability Advisory 4 Other Info 1 The following illustrations indicate general information about how your part will be molded and areas in which the molded part will differ from the geometry of the CAD model due to the milling process used in mold manufacture http www protomold com ProtoQuote aspx p 190699t5xy Thank you for the opportunity to quote your parts We look forward to working with you on this project Should you have any questions please do not hesitate to contact us at 763 479 3680 Your Price Tooling cost 12 645 Parts 6 92 692 TotalUSD 13 337 Continue i View notes E mail ORDERS UP TO 100 000 PARTS Piece price quotation in USD for future additional orders based on the following material ABS Black Lustran 433 904000 Enter lot size 1500 Price part 6 92 Ouantity 500 Setup charge 750 Total USD 4 210 57 4 27 2009 Protomold gt Rapid Plastic Injection Molding gt ProtoQuote 1 Solid arrows and faces with corresponding colors indicate undercut features that will be formed by using side pull cores Notes Customers are responsible for ensuring that the properties and perfor
64. surement regarding sand flow rate Aqua Tech also recommends that Blue Water work with future senior design teams to find an alternate electrical component to measure the sand flow rate This could significantly reduce the overall cost of the design since approximately 90 of the cost was spent on the encoders Lastly Aqua Tech would like to thank Blue Water Technologies for providing the budget and all other supporting information without which the project would not have been possible Aqua Tech would also like to thank the professors and friends at University of Idaho who helped during the course of design and made this project a success 20 Un ON NO References Automation Direct Retrieved January 15 2009 from PLC Website http web2 automationdirect com adc Home Home Blue Water Technologies Retrieved December 11 2008 from Applications Website http www blueh20 net applications html Centra flo Filters Retrieved December 11 2008 from Products Website http centra flo com products htm Encoder Products Company Retrieved December 15 2008 from Encoder Website http www encoder com model260 html National Instruments Retrieved December 11 2008 from Optical Encoder Fundamentals Website zone ni com devzone cda tut p 1d 4672 Protomold Retrieved April 27 2009 from Injection Plastic Molding Website http www protomold com Protura Retrieved Decembe
65. tion To the extent that Seller s personnel recommend design modifications or provide design analysis simulation or advice they do so to help meet the requirements of Seller s own manufacturing process The buyer retains sole legal responsibility for the design specifications and performance of the goods that are the subject of this transaction SELLER MAKES NO REPRESENTATION OR WARRANTY WHETHER EXPRESS OR IMPLIED OF ANY KIND WHATSOEVER WITH RESPECT TO ANY GOODS OR SERVICES INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR NON INFRINGEMENT Without limiting the generality of the foregoing Seller assumes no responsibility or liability for the selection of any materials for the goods that are the subject of this transaction The buyer is solely responsible for ensuring that materials selected for goods to be manufactured by Seller meet any regulatory requirements or specifications including but not limited to Directive 2002 95 EC on the restriction of the use of certain hazardous substances in electrical and electronic equipment RoHS Directive together with any national legislation implementing such Directive ISO FDA UL CSA CE TUV FCC NSF and USP Any statements made by Seller personnel or specifications provided by Seller regarding materials should be verified by the buyer with the manufacturer of that material LIMITATION OF DAMAGES IN NO EVENT SHALL SELLER BE LIABLE FOR ANY INCIDENTAL
66. utput Results of Prototype Measures the sand 2 Rate in in min movement No permanent installation h 1 6 Dia 6 inches 12 24 below the surface of the sand slurry Different devices do not read different rates keep al variables constant except the size shape of the monitoring device Use PVC with marks as a control No visible leaches to filter water Powered by wall outlet battery or computer Can be replaced without replacing filter Made from a material that does not absorb water after testing no marks or abrasions deeper than 1 8 Measure range capability Q 3 per Electronic data output Data output to PC Rate displays on a computer Must display dependable and consistent results Accurate Results Must display results that are Consistent results 95 Consistent within accuracy 5 error Must be able to read from a remote Access reading on display at Easy to acquire Results play location desired location Alarm that alerts the proper Alerts Alarm person within 5 seconds of dropping below critical rate Table 1 These specifications are for the prototype created by Aqua Tech during the first semester 3 Design Solution Over the course of two semesters of rigorous design and testing Agua Tech is recommending the design solution shown below in Figure 4 The sand bed turnover monitor shown in the solid model is only designed to monitor two guadrants Two of these devices coul
67. while still allowing the shaft to rotate The rotational data is collected using a digital encoder and analyzed using a PLC To validate this design Aqua Tech tested the solution in an acrylic filter model Multiple shapes were compared and tested against the optimal shape to confirm that the recommended shape was in fact optimal All successful shapes took between nine and ten minutes to do a quarter of a rotation inside the filter model The optimal shape fell within this time frame and the prototype was produced using the 3D printer which allows for this shape to be reproduced 2 Introduction 2 1 Background Blue Water Technologies is a company committed to the treatment of wastewater One of Blue Water s solutions to wastewater filtration is the Centra flo filter These filters work by continuously circulating the filter media sand The functionality and simplicity are illustrated in Figure 1 Sand in the tank 3 is driven down to the bottom of the tank by gravity where it is then lifted to the top of the tank with the patented air lift design 5 At the top the sand 1s separated from waste particles with another patented design of Blue Water Technologies called a wash box 9 Wash box discharge 2 exits the tank while the sand 1s treated with chemicals and dropped back into the filter Water enters the tank 7 and 1s piped to the bottom of the sand As the water 1s forced up through the media the pollutants attach to the sand

Sand Bed Turnover Monitor Design Report Team Aqua Tech

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