Assembly Procedures - EDGE



For Senior Design Project P13051, PIV in a Lung Model. These documents describe how to assemble each component of the system. Assembly ProceduresFor P13051, PIV in a Lung ModelTable of Contents TOC \o "1-3" \h \z \u Lung Tank and Model PAGEREF _Toc354564783 \h 2Tank PAGEREF _Toc354564784 \h 2Lung Model PAGEREF _Toc354564785 \h 2Pump System PAGEREF _Toc354564786 \h 3Pump Installation PAGEREF _Toc354564787 \h 4Piping Installation PAGEREF _Toc354564788 \h 4Common Headers PAGEREF _Toc354564789 \h 7Disconnect Instructions PAGEREF _Toc354564790 \h 8Pressure System PAGEREF _Toc354564791 \h 9Connection Procedure PAGEREF _Toc354564792 \h 9Lung Tank and ModelParts Needed:Part #DescriptionQuantitySupplier Part #Supplier1Acrylic Tank, 24"x24"x24", 1/2" thick1unitNASteve Ipacs11Acrylic Sheet, 12"x12", 1" thick2unit8560K357McMaster-Carr54Masterkleer PVC Tubing, 1/2" ID1ft5233k84McMaster-Carr49Clear K&B Silicone II 9.81unit48285Lowe’s57Loctite 10G 3-Pack1pkg7864Lowe’s63Double sided adhesive foam1unitLowe’s14Locking Ball Joint (Vanguard)1unitBBH-100Amazon7Acrylic Sheet, 24"x24", 1/4" thick1unit8560K214McMaster-CarrTankMachine 8 holes in the wall of the acrylic tank (Part 1) as specified in drawingMachine 8 manifolds out of acrylic, as specified in drawing, using Part 11 (4 manifolds per sheet)Affix through wall connectors to the inside of the tank walls, lining up the hole pattern with the tank holes, covering contact area with super glue (57).Apply a generous amount of silicone (49) to seal around the edge of each connectorMachine tank lid from 24”x24” acrylic sheet (7) as specified in drawingLung ModelStick ?” tubing (54) over the outside of mouth opening and glue in place using super glue (57). Hold firmly in place until glue dries (about 30 seconds).Add a layer of epoxy around the seam between the mouth and tubing to ensure it is a strong connection. Let the model sit overnight.Attach the top of the lung model to small metal plate using double sided adhesive foam (63)Place ball joint (14) on tank lid with ball joint attachment sticking through the 2” hole in the lid. Screw plate and lung model into ball joint so that it is attached to the lid. Thread the other end of the ?” tubing through the 0.8” hole in the tank lidPump SystemParts Needed:Part #DescriptionQuantitySupplier Part #Supplier15H75M Gear Pump1unitH75MSiewertVariable Frequency Drive1unitMotor1unit54Masterkleer PVC Tubing, 1/2" ID10feet5233k84McMaster-Carr17High-Pressure PVC Tubing, 1'' ID2feet5238K778McMaster-Carr18High-Pressure PVC Tubing, 1.5'' ID10feet52375K19McMaster-Carr20Tube clamps, 1.5''1Package*9579K84McMaster-Carr21Tube clamps, 1''1Package*5246K73McMaster-Carr22Tube clamps, 3/4"1Package*5246K72McMaster-Carr23Tube clamps, 1/2"1Package*5246K67McMaster-Carr511.5’’ to 1’’ reducing barbed coupling1unit1429-211Waterford Garden24Tube to pipe adapter, 1.25'', 1.5''1Package+5372K151McMaster-Carr581’’ to 0.5’’ reducing barbed coupling1units64291US Plastics521.5'' tube to 1.5 NPT adapter3units61160US Plastics27Valve, ball, 1.5''2units47865K27McMaster-Carr28Valve, ball, 1.25''1unit47865K26McMaster-Carr29Pipe, 1-1/2'', 4'', Male-Male2units44615K468McMaster-Carr30Coupling, 1 1/2''2units44605K188McMaster-Carr31Bulkhead, 1.5''2unitsBF1.5THD1-Ojehmco40Manifold, 4 port, 90deg1unitMS1004-90A1 manifold41Manifold, 10 port, 90deg4unitsMS10010-90A1 manifold53Tube to pipe, adapter, 3/8NPT, 1/2''1Package*5372K124US Plastics43Tube to pipe, adapter, 3/8NPT, 3/4''8Package*5372K149McMaster-Carr44Tube to pipe, adapter, 1/2NPT, 3/4''1Package*5372K132McMaster-Carr45Tube to pipe adapter, 1/2NPT, 1''1Package*5372K143McMaster-Carr46High-Pressure PVC Tubing, 3/4" ID10feet5238K768McMaster-Carr9Reservoir1unit4439T15McMaster-Carr*Package = 10 units; +Package = 5 units Pump InstallationMount pump (Part 15) to wood table or rubber matHook up VFD to 230 VAC 3 phase power and place controller in an easily accessible place. See VFD Quick Start guide for more information. On the suction side, everything from the tank to the pump should be 1.5” or larger to ensure good liquid flow into the pump. Coming out of the pump, you should maintain 1.5” as far as you can until you have to branch off or adapt down to connect to your model.Any questions can be directed to Bruce Javits of Siewert Equipment, 585-482-9640, BJavits@. Piping InstallationThe schematic attached in the appendix is provided as a guide for final installation. The pump will initially be set up for inhalation. Instructions for disassembly are included. Use pipe thread tape for all threaded connections and hose clamps for all barbed connections. Modify the Reservoir tank (9)Drill a 2 3/8 in hole near the top of the tank. This will be used by the outlet tube to return the glycerin mixture to the tank. On the opposite side, drill a 2 3/8 in hole, 5 inches from the bottom of the tank. This will be used by the suction side of the pump.Insert 1.5’’ bulkhead (31) into the two holes drilled into the reservoir tank. Screw in a 1.5’’ pipe to 1.5’’ tube barbed adapter (52) into each bulkhead. Take the 2 - 1.5’’ (27) ball valve and insert a 1.5’’ pipe to 1.5’’ tube barbed adapter (52) into each side.Take the 1.25’’ ball valve (28) and insert a 1.25’’pipe to 1.5’’ tube barbed adapter (24) into each side of the ball valve. Insert the 4’’ long, 1.5’’ NPT pipe (29) into the outlet side of the pump. Insert 1.5’’ NPT coupling (30) onto the end of the pipe. Insert a 1.5’’ pipe to 1.5’’ tube barbed adapter (52) into the coupling. Repeat for suction side of tank. Insert approximately 6 in of tubing on to the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) at point 2 (in reference to the above schematic.) Use the correct hose clamp to secure the connection. Connect a modified 1.5’’ ball valve (27) to the end of the tube and secure with the correct size hose clamps.Using 1.5’’ tubing, connect the modified 1.5’’ ball valve (27) located on the outlet side of pump to the 1.5’’ to 1’’ reducing barbed coupling (51). Use minimum amount of 1.5’’ tubing (18) and secure with the correct hose clamp. Using 1’’ tubing, connect the 1.5’’ to 1’’ reducing barbed coupling (51) to the 1’’ to 0.5’’ reducing barbed coupling (58). Use the minimum amount of 1’’ tubing (17) and secure with the correct size hose clamp. Connect other end of 1’’ to 0.5’’ reducing barbed coupling (58) to lung model using the minimum necessary amount of ?’’ tubing (54). Connect 1.5’’ tubing (18) from the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) on the suction side of pump to a modified 1.5’’ ball valve (27). Connect 1.5’’ tubing (18) from the other side of the ball valve to the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) located at the bottom of the reservoir tank. Secure all connection with the correct size hose clamp. Common HeadersInsert 3/8’’ pipe to 1/2’’ tube barbed adapter (53) into each 3/8’’ port of the 20 port, 90 degree manifold. Repeat for remaining 3 manifolds (41).Insert 1/2’’ pipe to 3/4’’ tube barbed adapter (44) into one 1/2’’ port of each 20 port, 90 degree manifold (41).Insert 3/8’’ pipe to 3/4’’ tube barbed adapter (43) into each 3/8’’ port of the 4 port, 90 degree manifold (40).Insert 1/2’’ pipe to 1’’ tube barbed adapter (45) into one 1/2’’ port of 4 port, 90 degree manifold (40).Insert threaded plug into every remaining hole on both manifolds.Insert tubing from needle valve onto the 3/8’’ pipe to 1/2’’ tube barbed adapter (53)on the 10 port, 90 degree manifold (41). Organize outlets so that similar flow rates are seen in each manifold. (example: group generation 4 outlet with generation 16 outlets) Secure with correct size hose clamp.Connect 3/4’’ tubing (46) from the 1/2’’ pipe to 3/4’’ tube barbed (44) on the 10 port, 90 degree manifold (41) to the 3/8’’ pipe to 3/4’’ tube barbed adapter (43) on the 4 port, 90 degree manifold (40). Use minimum amount of tubing. Secure with correct size hose clamp. Connect the 1/2’’ pipe to 1’’ tube barbed adapter (45) of 4 port, 90 degree manifold (40) to the 1.5’’ to 1’’ tube barbed reducing coupling (51). Use 1’’ tubing (17) and a length of 6 inches. Secure with correct size hose clamp.Connect 1.5’’ tubing (18) from the 1.5’’ to 1’’ tube barbed reducing coupling (51) to the 1.25’’ ball valve (28) using the minimum amount of tubing. Secure with correct size hose clamp. Connect the 1.25’’ pipe to 1.5’’ tube barbed adapter (24) of the 1.25’’ ball valve (28) to the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) located at the top of the reservoir tank. Use 1.5’’ tubing (18) and the minimum amount of tubing. Secure with correct size hose clamp.Disconnect InstructionsRemove power from the pump motor.Close the three ball valves. Remove tubing from 1.25’’ pipe to 1.5’’ tube barbed adapter (24) of the 1.25’’ ball valve (28) that connects to the 1.5’’ bulkhead (31). Place a cap on the 1.5’’ tubing (18). Remove tubing from the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) of the 1.5’’ ball valve (27) located on the suction side of the pump, closest to the pump. Place a cap on the 1.5’’ tubing (18). Remove tubing from the 1.5’’ pipe to 1.5’’ tube barbed adapter (52) of the 1.5’’ ball valve (27) located on the outlet side of the pump, closest to the pump. Place a cap on the 1.5’’ tubing (18). Using the attached diagram as a guide, reconnect the system as shown. Ensure all connections are secured with a hose clamp.Open all three ball valves.FabricationThe reservoir tank needs to be modified in order to install the two 1.5’’ bulkheads. Two holes need to be drilled on opposite sides of the tank, one at the top and another at the bottom.FacilitiesInstalling the tubing and the pump must be done in laser lab, with every component in its final location. All other steps can be carried out in the senior design lab. ScheduleFor the small scale assembly (20 outlets), the assembly will take approximately 8 hours for one person. The large scale assembly (80 outlets) will take approximately 12 hours for one person. Personnel RequirementsThis process can be completed by one person if schedule permits. It can be accomplished by any team member. Pressure SystemParts needed:Part #DescriptionQuantitySupplier Part #Supplier54Masterkleer PVC Tubing, 1/2" ID (ft)505233k84McMaster-Carr66Clear Polyurethane Tubing 1/4" OD (ft)105195T64McMaster-Carr67Tubing (1/8") (ft)10TYUTH-31618-100OMEGA641/4 to 1/2 expansion coupling (10 per unit)21VRW6Grainger34Minature Voltage Sensor17PX40-100G5VOMEGA35Needle Valve1722325US Plastics37T-Splitter (10 per unit)23YNE5Grainger391/4 to 1/8 reducing coupling (10 per unit)21VRW3Grainger531/2" Nylon Threaded Adapter With 3/8 NPT Thread17A6-8BNUS PlasticsConnection ProcedureWith model secured in tank push ?” OD tubing (66) into the push-to-connect adapter on the desired outlet of the lung model.Applying small amount of adhesive to the 1/4” barb X 1/2” barb expansion coupling (64), push 1/4” tubing (66) on one end and ?” ID tubing (54) on the other end.Running ?” tubing (54) to tank wall connect this to the 3/8” NPT X 1/2” barb adapter (53) that is screwed into the manifold.An identical 3/8” NPT X 1/2” barb (53) should be coming out of the wall on the other side of the wall, connect ?” tubing (54) to the barb and connect other end to ?” end of T splitter (37) after applying small amount of adhesive.The ?” tubing (54) should then be connected to the opposite side of the T splitter (37) and then be connected to the Needle Valve (35) in the same fashion.Connect ?” tubing (66) to the unconnected outlet of the T splitter with adhesive and run to the 1/4” X 1/8” reducer (39) connecting in the same fashion.Attach the 1/8” tubing (67) to the reducer (39) with adhesive then connect free end to pressure sensor (34) with adhesive as well.Sensor (34) should be appropriately hooked up on breadboard according to sensor calibration documentation. ................
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