Date of Award

2021

Degree Type

Capstone Project

First Advisor

Dr. Bahram Nassersharif

Abstract

Team 04H was selected by Professor Nassersharif to solve Miniature Casting Corporation's water cooling system problems. The objective entailed designing an innovative water cooling system that would keep uid temperatures at ideal levels for cooling their die casting machines while also serving as an entirely closed loop system with no city water dependency. The goals of the solution also included the elimination of over 4.7 million gallons of city water used per year and to not exceed an initial cost of $50,000 or at least have an extremely favorable return on investment (ROI). To accomplish this, the current system was extensively analyzed to obtain an adequate understanding of the current conditions. This allowed the team to identify possible areas of improvement and expansion. Possible solutions were thoroughly researched after patent and literature searches where bene cial technology and technical applications could be found to assist in the design creation. After acquiring more knowledge and meeting with the sponsor, the team came up with 90 possible design concepts. A Pugh Analysis and Quality Function Deployment were performed in addition to receiving feedback about the top three designs from the sponsor. After meeting with our sponsor after the concept proposal phase, the team decided to move forward with a hybrid system that included two of the top three concepts.

The  nal system includes a geothermal loop, an adiabatic cooler, and the two uid air coolers and expanded plate and frame heat exchanger. A key component of this system would be the ability to run it fully in series or break the heat load into three or two equal loops to be delivered to each individual component. This concept provides Miniature Casting Corporation with a cheaper cooling method per Refrigerant Ton (RT) and gives the facility the ability to cool all of its water year round without the use of external water. This concept also has multiple areas capable of future expansion and growth incase of an increased heat load from new or additional machines.

Our engineering analysis evolved from using a working Excel model to a much more comprehensive MATLAB model by the name of Simulink to analyze the proposed system in an all-in-one modeling program. A representative model was created this semester using Simulink and the Simscape Fluids toolbox.

Comments

Sponsor: Miniature Casting Corporation

Sponsor/Mentor: Stephen Toljian

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