Team 12Amelia House

Paul JaffaJohanna MillerBrian Ortega

Introduction• Develop, manufacture and sell laboratory

instruments which photometrically analyze 1 μL samples

• For measuring absorbance of DNA, RNA, dyes, protein

Current Procedure• Fill syringe with product

• Use compressed air to dispense into 2mL vials

• Time consuming, significant waste, expensive

• Very viscous material

Objective

Project Goal

To design and develop a device that

will fill and label 2 mL vials with a

cleaning substance while eliminating

tedious tasks and to provide a more

efficient system

Project Scope

• Original scope intended for a completely automated system that:– Filled vials– Capped vials– Labeled vials

• Redefined scope as filling vials for project

Customer Wants

1. A higher output of vials 2. Easier to Fill the container than

Current Method (Syringe)3. Minimize Operator Handling Time4. Minimize the product waste 5. Fit on a Desk Top 6. Have a Labeling Process

Background Research

• Researched various processes used for dispensing viscous fluids

• Too large a scale to apply to project

Figure 1

Figure 2

Metrics and Target Values

Metric Target Values

  Current State Future State

Vial Fill Rate 30 per day 100 per hour

Operator Handling Time per Vial 10 min Less than 10 seconds

Vial Fullness 70-100% 90% Full

Waste of Product per Vial Over 100% Less than 15%

Load Time and Cleaning 1 hour Less than 10 min

Initial Concepts

• Implement gravity and pressure

• Utilize shipping container as pressure vessel

• Peristaltic pump

• Heating to reduce the viscosity of the product

Initial Concepts

• Implement gravity and pressure

• Utilize shipping container as pressure vessel

• Peristaltic pump

• Heating to reduce the viscosity of the product

Concept Selection & Description

•Heating is advantageous – proved by experimentation

• Viscosity at 70° F = 4500 mPa*s• Viscosity at 130° F = 100 mPa*s

•Gravity for dispensing•Controls through PLC and current LabView system

Heating Subsystem

• Aluminum container to conduct heat

• Pinhole to prevent vacuum

• Band heating element that will be self controlled

Heating Subsystem

TemperatureReading

< 130°F > 130°FTurn ONHeater

Turn OFFHeater

Temperature Control

Objective:– To control the temperature so the operator can

focus primarily on filling the vials.– Regulate the temperature in the container so that

the liquid inside does not get too hot and separate, or get too cold and clog the machine.

Wiring Schematic

•A – Power source from wall

•B – Power control to band heater

•C – Input from thermocouple

•D – Temperature controller

A

B

C

D

Wiring

ABC

D

Wiring - Back View

A

B

Wiring – Front View

D

Container

•5 inch diameter aluminum pipe

•Bottom cap adhered to pipe

•Top cap fits firmly

•Band heater at bottom

Clamp

•Rear portion thick to support container

•Flanges for system to bolt together

•Front made from bent aluminum

•Two clamps, one for the top and one for the bottom

Stand

•Triangular bases for stability

•Mounted to sheet metal base

•Thick to prevent bending due to weight of container

Placement

•Places vial in exact location for no mess filling

•Vials slides in so nozzle is close to opening

•Hole so vial cannot slide back toward user

•Mounted to sheet metal base

Dispenser

Final Prototype

Dispensing Subsystems

• Product placed in aluminum vat for dispensing

• Utilizes a valve and solenoid

• LabView Program developed to control valve

DispensingAdvancement

Temp reading of 130°F

Push start

Input x number of vials

Spout opens

Time < TTime >= T

Conveyor advances

L

Number of vials < x

Delay t seconds

Spout closes

Spout stays open

Number of vials

>= x

Program turns OFF

Main Focus: Dispensing

Spout opens

Time < TTime >= T

Spout closes Spout stays open

DispensingAdvancement

Temp reading of 130°F

Push start

Input x number of vials

Spout opens

Time < TTime >= T

Conveyor advances

L

Number of vials < x

Delay t seconds

Spout closes

Spout stays open

Number of vials

>= x

Program turns OFF

LabView Program

• User inputs desired time

• Starts program

• Will end when completed

• Run as many times as needed

Wiring for Dispensing

• LabView program only allows for 5 V signal

• Solenoid valve requires a 12 V signal– Received from power source

• Relay opens or closes due to program– Able to control flow as a result

Wiring for Dispensing

Power SourceRelay

LabView Board

Wiring for Dispensing

Testing

• Initially performed with water

• Trying to establish a basis

• Valve alone• Used tubing to create

head pressure

Water Testing With a Constant Flow Rate

Time (s) Volume Filled (mL)

5 20 +

1 3

0.75 2.5

0.5 2

0.35 1.5

Testing

• Testing determined that the valve suggested by the manufacturer did not yield desired results

• Plate vs. Pinch valve testing required– Current system is a plate valve

Cost AnalysisProduct Cost

Junction Box $250

Solenoid Valve $150

Band Heater $300

Machining $1,800

Total Cost of Prototype $2,500

Engineering Labor $50,000

Total Cost $52,500

Benefit to Customer

  Current Projected

Load Time (min) 8 15

Vials per hour 30 100

Clean Up Time (min) 15 5

  Current Projected

Labor Cost for 100 Vials 120 35

Income from 100 Vials 2500 2500

Profit from 100 Vials 2380 2465

• Clean up time will be decreased three times

• Set up time increased– Does not require user to

be present

• Average savings of $100 per filling of 100 vials

Benefit to Customer

  Current Projected

100 vials per week for a year 124000 128250

Profit Increase   $ 4250

• Anticipated increase in vial demand ~100 per week• Mechanism will pay for itself in one year

Path Forward

This design can be improved by:• Inserting a flow meter • Having a nozzle • Pressurizing the system• Implementing an advancement system • Labeling system• Modify the LabView program to

accommodate these changes

Recommended Products

Product Company Quantity Cost Each Total Cost

Converyor Belt e-bay.com 1 500.00 500.00

Needle Nozzle thetoolwarehouse.com 1 20.00 20.00

Flow Rate Indicator Cole Parmer 1 143.00 143.00

Flow Sensor Cole Parmer 1 210.00 210.00

Labeling System   1 20,000 20,000

Questions?