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\begin_body

\begin_layout Title
Small Scale Plant Model
\end_layout

\begin_layout Author
Sean Coholan, Amanda Rodriguez, Molly Tierney
\end_layout

\begin_layout Author
Final Research Report Summer 2013
\end_layout

\begin_layout Date
7 August, 2013
\end_layout

\begin_layout Abstract
The Small Scale Plant Model team seeks to construct scale models of AguaClara
 plants that will, through their tangibility, facilitate AguaClara's educational
 outreach efforts and encourage the support and sponsorship of donors.
 The models will be small and durable enough to travel to Honduras, and
 they will clarify potentially confusing features of the plants they depict.
 Over the past semester, the Small Scale Plant Model team has identified
 target audiences, selected plant features for special clarification, performed
 materials analysis, and created model component templates in order to meet
 these goals.
 These model component templates were then optimized and saved as drawing
 files ready to be laser-cut.
 To facilitate plant construction, the team has also compiled 3-dimensional
 composite shots of the plant's components.
 The team has finished mock-up construction of select plant components and
 has finalized preparations for the construction of the final plant model
 in the semester to come.
\end_layout

\begin_layout Section*
Introduction
\end_layout

\begin_layout Standard
The purpose of the Small Scale Plant Model team is to build a water treatment
 plant model that will both educate those invested in water treatment and
 encourage sponsors to collaborate with AguaClara.
 The inspiration for the creation of our team was AguaClara's 2013 trip
 to Honduras, where team members who had never seen a full-scale AguaClara
 plant expressed how useful a visual representation was for understanding
 the AguaClara treatment process.
 This treatment process can be confusing, and researchers require a complete
 knowledge of its components to generate further plant improvements.
 Completion of a model, or multiple models, will allow for better understanding
 of the mechanics behind AguaClara water treatment plants for those involved
 with the team's research at Cornell and those who benefit from it abroad.
 Each model is intended to highlight the plant’s most significant parts
 and act as an informative, detailed, tactile, and easily transported education
 tool.
 So far this summer, the Small Scale Plant Model team has assessed materials,
 reevaluated and redesigned templates of plant components created last semester,
 and cut Plexiglas pieces for the purpose of model assembly.
 The final goal is to create a tangible representation of the water treatment
 plant complete with assembly instructions for creation of future models.
\end_layout

\begin_layout Section*
Literature Review
\end_layout

\begin_layout Itemize
http://aguaclara.cornell.edu/projects/ 
\end_layout

\begin_layout Standard
This page of the AguaClara website lists the eight completed plants in Honduras,
 their design flow in L/s, and other important statistics.
 So far, the average flow capacity is 13.75 L/s, which, when compared with
 existing plant designs, is closest to the capacity of 12 L/s.
 As a result, we've decided the 12 L/s plant best represents the existing
 AguaClara plants, and will use the 12 L/s plans in the designing of our
 scale model.
 It is the team's hope that the use of this flow rate will allow our project
 to be as broadly applicable as possible.
\end_layout

\begin_layout Itemize
http://designserver.cee.cornell.edu/Designs/etflocsedfi/5363/12Lps/Index.html
\end_layout

\begin_layout Standard
This page features PDFs, AutoCAD drawing files, and Word documents that
 depict a 12 L/s plant, including many dimensional and technical specifications.
 Various diagrams and figures illustrating plant processeshave aided our
 team's spatial understanding of the plant.
 The Spring 2013 team used the drawing (.dwg) file featured on this design
 page to create laser-cutting templates for all flat planes in the water
 treatment plant.
 These pieces were scaled with AutoCAD and Rhinoceros, an architectural
 modeling software.
\end_layout

\begin_layout Itemize
Component Templates: https://confluence.cornell.edu/display/AGUACLARA/Small+Scale+
Plant+Model+References
\end_layout

\begin_layout Standard
All Small Scale Plant Model component templates created by the Spring 2013
 team can be found in PDF form on the team's wiki page; these files were
 created in Rhinoceros by the team from existing AutoCAD design files.
 The templates are to-scale, facilitating the construction of our plant
 model and mock-up, with the scaling factor used indicated in in-page comments
 on the wiki.
 The team has processed and uploaded top views of the plant in both 1:20
 and 1:30, which lend perspective to the size of the plant model.
 These PDFs can be found under the 
\begin_inset Quotes eld
\end_inset

References
\begin_inset Quotes erd
\end_inset

 heading.
 Preliminary component templates of the totality of the plant models parts
 can also be found under the heading 
\begin_inset Quotes eld
\end_inset

Component Templates (1:20).
\begin_inset Quotes erd
\end_inset

 These include the entrance tank, flocculator, sedimentation tank, filter,
 staircase, main floor or 
\begin_inset Quotes eld
\end_inset

base
\begin_inset Quotes erd
\end_inset

 of the plant, and files separated and targeted for transparency.
 Again, each of these templates is scaled by a factor of 1:20.
 As PDFs, these files have the benefit of being easier to view than drawing
 files.
 They are also easily printed, a feature of which we have taken advantage.
 
\end_layout

\begin_layout Itemize
https://confluence.cornell.edu/download/attachments/207948359/SSPMFinalReportSprin
g2013.pdf?version=1&modificationDate=1368162794000
\end_layout

\begin_layout Standard
This final report prepared by the Spring 2013 Small Scale Model team details
 the progress that they made last semester towards completing a finished
 model.
 They determined the 1:20 scaling factor for the model by consolidating
 its need to depict specific technologies in the AguaClara process with
 its need to be compact and readily transportable.
 The team also laid the groundwork for the construction of the model by
 developing templates in AutoCad so that it can be assembled with plexiglass
 pieces.
 They also constructed a mock-up model of the plant from cardboard which
 included the main base of the plant, the flocculator, filter, and filter
 inlet.The Summer 2013 team intends to finalize the work started by the Spring
 2013 team and complete the model by first editing all of the templates
 to account for the finite thickness of plexiglass and then formating them
 to be used for water cutting instead of laser cutting.
 The team will also prepare a manual to allow for future small scale models
 to be built in a timely manner using the exisiting templates that we will
 have developed.
 
\end_layout

\begin_layout Section*
Methods
\end_layout

\begin_layout Subsection*
Consideration of Spring 2013 Work
\end_layout

\begin_layout Standard
Using the chip-board mock up that was created at the end of Spring 2013,
 we confirmed that 1:20 is the optimal scale for the model.
\end_layout

\begin_layout Subsection*
Template Evaluation and Labeling
\end_layout

\begin_layout Standard
The mock-up also aided in visualizing what modifications needed to be made
 to the laser templates.
 Because the templates had been initially created from AutoCad design files
 of a full-scale plant, the wall thickness did not correspond to the thickness
 of the Plexiglas.
 Rather than making the plant wall thickness to scale by doubling Plexiglas
 pieces, we decided to use a plant wall thickness equal to that of the Plexiglas
, 1/8
\begin_inset Quotes erd
\end_inset

.
 As a result, the Spring 2013 templates included duplicate pieces that were
 unnecessary, and so decided not to include them in the new templates.
 As we evaluated the Spring 2013 templates, we created a labeling system
 for the component pieces, which corresponded to the three-dimensional composite
 shots.
 The purpose of this is to aid in the physical assembly of the model and
 creation of an instruction manual.
\end_layout

\begin_layout Subsection*
Research of Different Methods to Cut Plexiglas:
\end_layout

\begin_layout Standard
The Spring 2013 team made plans with Frank Parish, Manager of the Material
 Practices Facility in the College of Architecture Art and Planning, to
 laser cut the Plexiglas this summer.
 At the beginning of the summer, we tried multiple ways to contact Frank,
 including email and phone calls, but we could not contact him.
 As a result, we found another method of cutting the material at a local
 Ithaca company called Incodema.
 This method is Water Jet cutting, and uses little grains of sand pressurized
 by a jet of water in order to cut materials.
 This method, while more accurate than laser cutting, would cost about $200
 and would require more material, as each piece to be cut needed to be at
 least 1/8” away from other pieces.
 Regardless, we created templates for water jet cutting.
 This was time consuming because we not only needed to modify the size of
 some pieces from the optimized template, but also we needed to separate
 pieces, most of which shared edges with other pieces.
 We finally managed to contact Danny Salomon, who is in charge of the Material
 Practices Facility this summer while Frank Parish is away, in the first
 week of July.
 Recreating optimized templates from the modified water jet templates went
 much faster, and we completed this task by June 9th, which was when Danny
 said was the earliest we could have use of the facilities.
 
\end_layout

\begin_layout Subsection*
Laser Cutting
\end_layout

\begin_layout Standard
On July 9th, we met with Danny to learn how to use the laser cutting machine
 in AAP.
 This was a three hour process as nobody on our team had any experience
 with using this type of machine.
 We also found out that the size of the bed was a little larger than the
 anticipated 12” by 18” and were able to use 18” by 24” pieces of Plexiglas.
 So, we combined some of our templates so that we only needed 4 pieces of
 white Plexiglas, 1 piece of transparent Plexiglas, and 1 piece of blue
 Plexiglas.
 We now have 4 6” by 24” pieces of white Plexiglas, 2 pieces of 24” by 24”
 white Plexiglas, and 2 12” by 18” sheets of transparent Plexiglas remaining.
 This is useful in case we find out that we made mistakes in cutting component
 pieces as we’re assembling the model.
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig: Laser White"

\end_inset

 shows the laser cutting a piece of white Plexiglas and Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig: Laser Transparent"

\end_inset

 is a picture of the laser cutting a transparent piece of Plexiglas into
 components of the sedimentation tank.
 
\end_layout

\begin_layout Standard
We also successfully etched component labels onto the pieces corresponding
 with the labeling system we imagined in June.
 The system follows: 
\end_layout

\begin_layout Itemize
ET = Entrance Tank 
\end_layout

\begin_layout Itemize
St = Stairs 
\end_layout

\begin_layout Itemize
Sed = Sedimentation Tank 
\end_layout

\begin_layout Itemize
Fi = Filter 
\end_layout

\begin_layout Itemize
FiIN = Filter Inlet/Outlet Box 
\end_layout

\begin_layout Itemize
SedU = Channels underneath the Sedimentation Tank 
\end_layout

\begin_layout Itemize
Floc = Flocculator
\end_layout

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Laser cutting white Plexiglas pieces 
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name "fig: Laser White"

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Laser cutting transparent Plexiglas sedimentation tank pieces 
\begin_inset CommandInset label
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\begin_layout Subsection*
Assembly
\end_layout

\begin_layout Standard
Assembly of the component pieces into the final model has proven to be an
 arduous task.
 Because cutting the Plexiglas pieces wascostly in time and resources, the
 team did not proceed immediately to putting the pieces together with Plexiglue.
 We chose to first use tape and a hot glue gun to assemble various model
 components so that we could ensure each of the pieces fit correctly before
 they were attached permanently.
 This turned out to be wise as several pieces needed to be re-cut and the
 apparent difficulty of assembling components with angled pieces led the
 team to consider new options for creating the model entrance tank and sedimenta
tion tanks.
 This led us to explore the use of 3D printing for the creation of these
 components.
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:Plexiglas-Filter-Inlet"

\end_inset

shows the completed filter inlet and outlet box on the left and the staircase
 sanded to a matte finish to reduce visibility of Plexiglue stains on the
 right.
\end_layout

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Plexiglas Filter Inlet and Outlet Box, Staircase 
\begin_inset CommandInset label
LatexCommand label
name "fig:Plexiglas-Filter-Inlet"

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\end_layout

\begin_layout Subsection*
3D Printing
\end_layout

\begin_layout Standard
Through word of mouth from other team members and research, we learned that
 the PopShop in Collegetown has two 3-D printers that could be used to print
 components the size we needed.
 We got in contact with Eric Morris who informed us that the Pop Shop was
 willing to support AguaClara’s cause and would thus allow us to use their
 3-D printers free of charge.
 Use of the printers was relatively simple: we were able to convert the
 AutoCad drawings of the full scale model to a unitless format which preserved
 their relative dimensions and then printed them in a new scale which we
 inputted.
 The process was somewhat lengthy, as the entrance tank took nearly 10 hours
 to print, although the printer did not have to be monitored once the first
 few layers were printed (about half an hour after start time).
 This turned out extremely well since it enabled us to create a model entrance
 tank with angles identical to that of the actual plant.
 The main downside was that there were some extra layers that had to be
 scraped off of each component that was printed, since the printer requires
 structural support under each printed layer.
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig:support"

\end_inset

 shows the MakerBot printing the first layer of structural support for the
 Entrance Tank.
 Figure 
\begin_inset CommandInset ref
LatexCommand ref
reference "fig: ET first layer"

\end_inset

 shows the first layer of the actual Entrance Tank piece, distinguished
 by a honeycomb shape rather than rectangular zig-zags, printed on top of
 the structural support.
 Overall use of 3-D printing was a success, so much so that we decided to
 also print the sedimentation tanks, even though a Plexiglas model of these
 tanks was already sized correctly and ready for assembly, because of how
 much more accurately the angles of the tank could be depicted.
 It was also determined that 3-D printing could be a cost effective method
 of producing more component pieces for future models, since the amount
 of material needed to produce the entrance tank costs about $10.
 The sedimentation tanks could be assembled using a combination of 3-D printing
 for the interior and Plexiglas for the walls.
 We would print two sedimentation tanks attached to each other and permanently
 attached to the plant, and the third would be separate and detachable from
 the plant with transparent walls.
 
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\begin_layout Plain Layout
PopShop MakerBot printing the first layer of the structural support fo the
 Entrance Tank 
\begin_inset CommandInset label
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name "fig:support"

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First layer of the Entrance Tank printed on top of the structural support
 
\begin_inset CommandInset label
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name "fig: ET first layer"

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Build Time: 10 hours and 8 minutes
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\begin_layout Plain Layout
Entrance Tank Complete!
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\begin_layout Section*
Problems Encountered
\end_layout

\begin_layout Standard
This entire project proved to be more compliated than expected.
 We spent the first month of the summer working with the AutoCAD files to
 make sure all the dimensions were right in order to minimize errors.
 Components such as the staircase and filter inlet and outlet box were simple
 to assemble since all of the pieces connected at right angles.
 The sedimentation tank and entrance tank however had multiple pieces that
 connected at angles that were not 90 degrees.
 As a result, we had trouble creating a two dimensional template for these
 pieces.
 Initially we thought we could angle the edges of the pieces we needed to
 connect at acute angles in the shop.
 The smaller entrance tank pieces ended up being very time consuming, about
 15 minutes a piece.
 The sedimentation tank pieces had to be cut with an angled blade, which
 has been misplaced this summer.
 So, we were unable to finish these pieces using Plexiglas due to setbacks
 in our fabrication methods.
 Although we successfully 3-D printed the entrance tank, that piece was
 close to the maximum size the MakerBot at PopShop could handle.
 The sedimentation tank is atleast three times the size of the entrance
 tank, so in order to 3-D print that component we would either need to print
 multiple parts which would be adhered together, or find access to a larger
 3D printer.
\end_layout

\begin_layout Standard
Initially we thought the flocculator would be much wider than it actually
 is.
 So we had to recut the tranparent blue Plexiglas for the baffles.
 However, 1/8
\begin_inset Quotes erd
\end_inset

 Plexiglas proved to be too thick to accurately depict the flocculator design,
 so the Small Scale Plant Model team must find a replacement material for
 the baffles before completing assembly of the flocculator.
 Similarly, the main filter structure cannot be assembled until a decision
 has been made about how to comprehesively depict the path of water during
 backwash and filtration.
 We're thinking of solving this problem by making the filter completely
 transparent, with one side showing filtration flow path, one showing backwash
 flow path, one showing manifold design from one point of view, and another
 showing manifold design from a perpendicular point of view.
 A transparent base could also provide understanding of manifold structure
 with the slotted pipes.
 
\end_layout

\begin_layout Standard
Assembly using Plexiglue was also difficult as Plexiglue is not a viscous
 solution at all so application was hard to control.
 Once Plexiglue is on a piece of plastic, it leaves a dull mark and eliminates
 the initial polish of the piece.
 Sanding down the staircase to a matte finish ended up looking very nice,
 but this was a little time consuming.
 
\end_layout

\begin_layout Section*
Future Work
\end_layout

\begin_layout Standard
Although much progress has been made in the creation of the first small-scale
 model, some contruciton and assembly still remains.
 All of the tranparent and nontrasparent Plexiglas have been cut and now
 require some creativity on exactly how to assemble them.
 The parts of the plant that still remain to be built include the sedimentation
 tank, filter and flocculator.
 Due to pieces that connect at acute and obtuse angles, we have determined
 that the sedimentation tank should also be made by a 3-D printer.
 Once we've decided how we can print such a large piece, we can bring prepared
 files to PopShop to be printed.
 The filter and the flocculator still have some deisgn details that need
 to be worked out before they are actually assembled.
 Finally, we must look into applying a clear or white lacquer to the delicate
 3-D pieces to add strength, polish and uniformity.
 Figure shows a close up of inconsistently printed entrance tank walls.
 
\end_layout

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Gaps in entrance tank walls due to replicator inconsistencies 
\begin_inset CommandInset label
LatexCommand label
name "fig:Gaps-in-Entrance"

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Printed entrance tank with support structure removed, unfinished 
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\begin_layout Standard
The laser templates and 3-D printing alone do not model the entire plant
 or filtration process, however.
 Parts of the plant that are not included in the laser templates include
 piping, the Linear Flow Orifice Meter (LFOM), plate settlers, diffusers,
 chemical storage tanks, sand in the filter, and the floc blanket.
 In order to model the piping of the plant, model Plexiglas tubing or Plexiglas
 rods must be further researched.
 Factors to consider are pipe length, pipe diameter, curves in pipes, cost
 differences between using solid rod or hollow tubing, and feasibility of
 using hollow tubing in smaller holes.
 Given the relatively small size of the LFOM in the entrance tank, it is
 unlikely that a 3-D printer will be able to print details necessary for
 portraying the LFOM.
 The plate settlers or lamella in the sedimentation tanks will be modeled
 with thin sheets of plastic which need to be obtained in order to stay
 to scale.
 The diffusers on the inlet manifold will require creativity to model the
 bends in the plastic.
 The sand in the filter can be easily added and should not be difficult
 to obtain.
 Ideally, the floc blanket will be a 3-D model, but use of an image printed
 on a thin transparent plastic sheet can be explored as an alternative.
 All of these smaller, yet significant, pieces still need to be modeled
 and will be looked into.
 Once the final model is completed, the Small Scale Plant Model team can
 evaluate the usefulness and viability of the model and explore making more
 models which can be used in different places.
\end_layout

\begin_layout Standard
The last step of the model is to create a instruction manual for future
 teams or really anyone to assemble their own models in a much easier and
 timely manner.
 The user-guide and instruction manual will include detailed lists of component
 pieces that need to be cut and assembly diagrams.
 The templates already are labeled so the next step would be to convert
 the AutoCAD files to SolidWorks draw clear diagrams on there.
 The manual will include exactly how to attach each Plexiglas piece and
 where to obtain all the other materials.
 After this is completed the manual can be printed and distributed.
 
\end_layout

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