#LyX 2.0 created this file. For more info see http://www.lyx.org/
\lyxformat 413
\begin_document
\begin_header
\textclass article
\use_default_options true
\maintain_unincluded_children false
\language english
\language_package default
\inputencoding auto
\fontencoding global
\font_roman default
\font_sans default
\font_typewriter default
\font_default_family default
\use_non_tex_fonts false
\font_sc false
\font_osf false
\font_sf_scale 100
\font_tt_scale 100

\graphics default
\default_output_format default
\output_sync 0
\bibtex_command default
\index_command default
\paperfontsize default
\use_hyperref false
\papersize default
\use_geometry false
\use_amsmath 1
\use_esint 1
\use_mhchem 1
\use_mathdots 1
\cite_engine basic
\use_bibtopic false
\use_indices false
\paperorientation portrait
\suppress_date false
\use_refstyle 1
\index Index
\shortcut idx
\color #008000
\end_index
\secnumdepth 3
\tocdepth 3
\paragraph_separation indent
\paragraph_indentation default
\quotes_language english
\papercolumns 1
\papersides 1
\paperpagestyle default
\tracking_changes false
\output_changes false
\html_math_output 0
\html_css_as_file 0
\html_be_strict false
\end_header

\begin_body

\begin_layout Title
Fabrication
\end_layout

\begin_layout Abstract
The AguaClara philosophy of minimizing the use of materials that aren't
 locally available and also minimizing specialized proprietary components
 means that we need to develop fabrication techniques to assemble specialized
 components from generic materials.
 The component are generally assembled at the plant construction site using
 a small number of tools.
 The plant sites often do not have electricity available.
 The challenges are to improve the tools that are used for fabrication,
 design jigs for faster assembly of components, and to devise improved component
s.
\end_layout

\begin_layout Labeling
\labelwidthstring 00.00.0000
students 2PT
\end_layout

\begin_layout Labeling
\labelwidthstring 00.00.0000
skills fabrication, 
\end_layout

\begin_layout Section
Car battery connection for battery powered drill
\end_layout

\begin_layout Standard
The cordless drill used at AguaClara construction sites is a 12
\begin_inset space \thinspace{}
\end_inset

V DeWalt.
 The run time for a single battery charge is variable, but at continuous
 full load the battery only lasts a few minutes.
 Given the frequent lack of electricity at construction sites it would be
 useful to have a power source that could run the drill for a full day of
 work.
 A car battery should be able to power a drill all day.
 The challenge is to create a safe method to connect the 12
\begin_inset space \thinspace{}
\end_inset

V cordless drill to a car battery.
 The extension cord between the car battery and the drill will need to be
 able to provide 285
\begin_inset space \thinspace{}
\end_inset

W at 12
\begin_inset space \thinspace{}
\end_inset

V (Suggest a 12-gauge wire of 4-5 meters in length).
 The extension cord will need battery terminal clamps and a fuse installed
 near the battery to eliminate the risk of a dangerous short in the extension
 cord or drill.
 The connection between the extension cord and the drill can be made by
 acquiring a used battery back (perhaps from a battery recycle center),
 removing the battery cells, drilling a hole through the plastic battery
 cover for the extension cord, and attaching the extension cord ends to
 the battery terminals inside the battery pack.
 This will make it possible to easily switch between using car battery power
 and using the standard DeWalt batteries.
 The extension cord needs to have strain relief where it passes through
 the battery pack.
\end_layout

\begin_layout Standard
The challenge is to acquire the components, build this system, and test
 it prior to July 28 so that it can be shipped to Honduras this summer.
 Before acquiring the system, compare the cost with the cost of acquiring
 enough battery packs to make it through a day of work.
\end_layout

\begin_layout Standard
\begin_inset Float figure
wide false
sideways false
status open

\begin_layout Plain Layout
\begin_inset Graphics
	filename 12V Drill.png
	scale 50

\end_inset


\end_layout

\begin_layout Plain Layout
\begin_inset Caption

\begin_layout Plain Layout
12
\begin_inset space \thinspace{}
\end_inset

V DeWalt drill used at AguaClara construction sites.
\end_layout

\end_inset


\end_layout

\begin_layout Plain Layout

\end_layout

\end_inset


\end_layout

\begin_layout Standard
A related challenge is to identify a 12
\begin_inset space \thinspace{}
\end_inset

V hammer drill (see for example Milwaukee 2411-22 Cordless Hammer Drill/Drivers
 12V 3/8) that can be used for drilling holes in concrete.
 The hammer drill will need the same conversion to car battery power.
\end_layout

\begin_layout Standard
Note that it would be ideal if we could get a hammer drill and a standard
 drill from the same manufacturer with identical battery packs.
 Will DeWalt produce a 12
\begin_inset space \thinspace{}
\end_inset

V hammer drill soon or should we switch to a different manufacturer?
\end_layout

\begin_layout Standard
The AguaClara/APP team has a portable data acquisition system with deep
 cycle batteries.
 Investigate the possibility of using those batteries and acquiring appropriate
 connectors for an extension cord.
\end_layout

\begin_layout Section
Improved hole saw 
\end_layout

\begin_layout Standard
The LFOM, Inlet Manifolds, Plate Settlers, and Floc Baffles all require
 creating large diameter holes in PVC pipe or in plastic sheets.
 The team in Honduras currently uses a hole saw to create these holes.
 The hole saw creates a rough hole and when the drilling operation is over
 the "hole" is inside the hole saw and must be removed.
 The entire process is time consuming.
 We need a better way to create these holes.
 The goal is to come up with improved methods of drill holes that can be
 tested at the Alauca plant that is being constructed now.
 Review the fabrication team recommendations from spring 2011 and acquire
 a better hole saw for the team in Honduras.
 
\end_layout

\begin_layout Section
Plate Settler Modules
\end_layout

\begin_layout Standard
Plate settler spacing may be reduced to 1 cm or even 0.5 cm in the near future.
 In any case we would like to be able to build plate settler modules with
 reduced spacing to test their effectiveness in a full scale plant (perhaps
 at Cuatro Comunidades).
 We need a method to fabricate plate settler modules with very small spacings
 between plates.
 It may be possible to use the same fabrication technique as we are using
 currently or there may be an easier method.
 The fabrication team from spring 2011 invented a guide to position the
 plate settlers.
 Test this method and assemble a few modules to see if you can invent further
 improvements.
 
\end_layout

\end_body
\end_document
