TEAM DUST

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TEAM DUST

• Dan Sauber Naeim Rozak Tyler Fuchs
• Josh Jacobs En Lee
• Advisors
• Dale Fitterer Al Barstad Tim Mullen

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Project Background

• Andersen Corporation has a dust infiltration
  problem with their 200 series windows in the
  Mid-West Texas area
• Seen most often in dry and windy situations
• Worse during the spring time due to the lack of
  moisture
• Worse on lower level windows
• Bad Installation makes issue worse

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Objectives

• To design a testing apparatus that will simulate
  the dust infiltration
• Develop a measurement standard and scale for
  rating dust performance
• Results will show correlation to real world
  applications
• The design does not fix the dust infiltration
  problem, but allows replication of problem so
  others can fix it

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Current Method

• Andersen has existing testing procedure for water
  leakage and air infiltration
• No method currently exists to test windows for
  dust infiltration
• Conducted site visit to look at their testing
  device as reference

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Customer

• The end customer of this project would be
  Andersen Corporation
• Andersen will be able to utilize project data and
  solve dust infiltration problem

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Design Process

• The following steps were taken in order to make
  progress on this project
• Customer Need
• Product Definition
• Concept Generation
• Concept Selection

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Critical Customer Requirements
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Design Specifications
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Concept Selections

• Blower
• Fan
• Thrower
• Sand blaster
• Magnetic Filing

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Blower
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Fan
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Thrower
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Sand Blaster
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Magnetic Filings
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Concept Selection Chart
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Prototyping

• Will help determine the final design
• Will Help understand how to replicate real world
  conditions
• Allows for testing of multiple concepts
• Custom enclosure to control the environment

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Prototype (Test 1)

• Results
• No conclusive results
• Test was not long enough
• Multiple tests must be run
• Design seems to work properly
• Talcum powder feed well into the blower
• Powder seems to flow well and continues to cycle
• Talcum powder is messy
• Enclosure needs to be more tightly sealed

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Prototype (Test 1)

• Improvements needed
• Research more options for dust replication
• Use black paint on window sill
• Find gauges to measure differential pressure
• Measure the velocity of the blower
• Make one side with a Plexiglas window for
  visibility
• Dust feeding design needs improvement

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Moving Forward

• Biggest technical challenges ahead of the team
• Containing the dust Air and dust naturally want
  to escape the pressurized chamber
• Simulating dust Infiltration No dust
  infiltration as of today (only 1 test)
• Dispensing and circulating the dust Can the
  dust be re-circulated or will it need to be
  constantly dispensed at a steady rate?
• Dust media- Is talcum powder the best model?

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Moving Forward

• The most urgent prototyping need
• Slow steady dispensing of powder and/or
  recirculation techniques to get to infiltrate the
  window seal.
• Need to prototype other promising particle
  accelerating techniques Sandblasting,
  compressed air, etc.
• Important analyses to conduct over remainder of
  semester
• Differential internal/external pressures Team
  may need to pull a vacuum to get dust through
  window seals.
• Developing a sound rating system based on amount
  of infiltrated dust Some windows should perform
  better than others.

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Scheduling
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Milestones

• Full Products Specs Done Oct 2
• Window Fixture Built Oct 16
• Dust Delivery System built Oct 17
• Presentation Completed Oct 21
• Mid-Semester Review Oct 23
• Field Results Simulated Oct 30
• Site Visit Nov 11
• Final Design Built Nov 20
• Final Report Completed Dec 2

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Work Breakdown Structure
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Balancing Resources

• The work load is evenly distributed to ensure the
  project stays on track.
• Scheduling shared tasks allows resources to be
  shifted to keep tasks from falling behind.

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Materials and Supplies

• Windows supplied by Andersen
• Most materials bought from Menards (wood, tape,
  etc)
• Talc (baby powder)from Target
• Blower given by Performance Plumbing and Heating
• Electronics from Ax-Man
• Gauges from online distributors

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Prototyping is Important!

• 3 weeks scheduled for fixture and delivery system
  redesign, with an additional 2 weeks of slack.
• Different designs must be considered if current
  prototype does not simulate field results.
• If final design is found early, extra time will
  be used to test other prototypes to improve
  performance.

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Documentation

• Each individual is responsible for documenting
  progress and results
• Results are compiled when final design is
  finished
• Additional review sessions are scheduled for
  Mid-Semester Review and the Site Visit

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Summary

• Our deliverables
• Test fixture that simulates dust infiltration
• Create a rating system for test results
• Link results to real world application