This document discusses the design of a system for filling and heating trays. It considers different options for the trays, heating methods, and filling mechanisms. For the trays, materials like steel, ceramic, and silicone are considered. For heating, options evaluated include high temperature infrared, heating rods, regenerating heat, and a low heat oven. A low heat oven is selected for the final design due to steady and consistent temperatures. For filling, piston pumps, gravity flow, and peristaltic pumps are reviewed, with peristaltic pumps chosen for the final design due to no direct contact and easy cleaning. The document also outlines cleaning concepts like steam, rotating brushes, and pressurized water jets before selecting

1. Filling Section
Ross Gilsenan
Shiyas Basheer
Peter Taaffe
Conor Tiernan
Gearóid Jones

2. Tray Concept Design
 Parameters
 Types of trays
◦ Steel
◦ Ceramic
◦ Silicone

3. Final Design-Tray
•Strong
•Robust
•Flexible
•Durable

4. Heating Concept Design
 High Temperature Infrared Module
 Heating rods
 Regenerating heat
 Low Heat oven

5. High Temperature Infrared
Module
Advantages
 Quickly heats the trays up
Disadvantages
 Inferred module blinking on and off
 Hard to get consistent temperatures
amongst the trays

6. Heating rods
Advantages
 Elements in each tray
 Activated by a sensor
 Maintained at the exact temperature
Disadvantages
 Electrical danger
 Difficulty connecting the power
supply
 Unnecessary

7. Regenerating heat
Advantages
 Recycling heat loss from motors
 Possible due to small rise in
temperature required
 Could also be used in other areas
Disadvantages
 Better used in trying to obtain a zero
carbon footprint
 Its over complicated

8. Low heat oven
Advantages
 Steady temperature
 There would be a constant heat
transfer
 Simplistic
 Ideal for low change in temperature of
heating
Disadvantages
 Calculations based on the trays
coming in at a constant temperature

9. Final Design-Heater
 Low heat oven
 Overcoming the heat energy loss after
the heater
 Solid works
 Ladder logic
 Using a dead-band

10. Filling Concept Design
 Parameters
 Types of pumps
◦ Piston pump with rotary valve
◦ Vertical piston pump
◦ Gravity flow
◦ Peristaltic pump

11. Piston pump with rotary valve
 Issues
• Excess
chocolate
• Piston size
• Pumping
distance

12. Vertical piston pump
 Issues
• Excess
chocolate
• Piston size
• Pumping
distance

13. Gravity flow
 Advantages
◦ Few moving parts
◦ Low energy input
◦ Low maintenance
 Disadvantages
◦ Constant height

14. Peristaltic pump
◦ No direct contact
◦ Easy to clean
◦ Constant flow
◦ Easy maintenance

15. Final Design-Filling
 Dimension
 Structure
 Power

16. Dimensions
 Tube
◦ Sizing
◦ Material
◦ Noncorrosive
 Rod Dimensions
◦ Linear Velocity
◦ Ratio of length

17. Structure
 Shaft Size
◦ Compression forces & Torsion
◦ ≥26.6mm
 Bearings
◦ Low rpm
◦ Bushing
◦ Negligible Axial Force

18. Power
 Source of power
◦ Pump requirements
◦ Timing

19. Power
 Power transmission
◦ Timing belt
 Quiet
 Lightweight
◦ Gear Ratio
 1:1.085
◦ Clutch
◦ Tension
AE-23NOV2011

20. Power
AE-23NOV2011

21. Power
 Bending on shaft
AE-23NOV2011

22. Tank
 Guarantee continuous
flow
 0.0624m3 Volume
 Screw
 Heated Tank

23. Final Design

24. Cleaning Concept Design
 Parameters
 Types of cleaning
◦ Steam Cleaning
◦ Rotating brush design
◦ Pressurized water jet

25. Steam Cleaning
 High
Temperatures
◦ 110°C - 130°C
 Chocolate
liquefies
 Power
consumption

26. Rotating brush design
 Water supply
 Reaction force
against tray
movement
 Cleanliness

27. Pressurized water jet
 High pressure
 Angled Water Jet
 Water Based Detergent
 Heated Water Jet

28. Final Design - Cleaning
 Pressurised Water Jet
 2.8 m/s
 4891 Pa
 Nozzle Diameter 5 mm
 Flow Rate 13.76×10-5
m3/s
Nozzle
0.3 m
0.1 m
Z1 , P =
0
Pressure
Vessel
Water Jet
50°C
Z2 , P =
0

29. Final Design - Cleaning
 Limit Switch
 Drainage System
 Daily water usage
1.782m3

30. Final Design

31. Questions?