P-14054 Smoking machine

P-14054 SMOKING MACHINE

Chris Boise

Eric Cawley

Gideon Oladunjoye

Jose Pardes

Matt Cross

Megan Guarnieri Cleary

OVERVIEW• Problem Statement• Customer/Engineering Requirements• System Overview• Final Design• Problem Tracking• Current State• Test Results• Future Tasks

PROBLEM STATEMENT• In order to simultaneously collect emissions

and transport undisturbed casts for analysis, current hollow cast models will be combined with the existing side stream smoking machine. Device will operate using acquired data from the wPSMD. Unit needs to be self-contained, portable, fit on a workbench, and user friendly. The unit must also be production ready for identical machines in other labs. During operation smoke needs to be ventilated responsibly and the unit must be interfaced with LabVIEW.

CUSTOMER REQUIREMENTS

Customer Rqmt. #

Importance Description Comments/Status Status

CR1 9 Puff cigarettes at different progammable flow rates Data will be obtained from wPSMDCR2 9 Collect mainstream emissions and transport them to NTID chemical lab Collected simultanesously with CR3CR3 9 Collect sidestream emissions and transport them to NTID chemical lab Collected simultanesously with CR2CR4 9 Incorperate hollow lung cast into mainstream emissions test Dr. Robinson is in charge of the cast after the test.CR5 9 Must be self-contained and portable Must fit on a workbench CR6 3 Must be user friendlyCR7 1 Must be able to be assembled in other labs Not for mass production.CR8 3 Smoke must be ventilated to an outside enviornment Improve upon current systemCR9 9 Direct exaust from main stream through side stream machine

CR10 3 Humidify main stream smoke Be aware of ISO standardCR11 1 Design to ISO/Coresta standards If production is hindered, ignore standardsCR12 9 Incorperate Electronic cigarettes

ENGINEERING REQUIREMENTS

rqmt. # Importance Source Engr. Requirement (metric) Marginal ValueIdeal Value Comments Status

S1 9 CR1 Design/create puffing profile from the data obtained from wPSMD mL/min - - Units of pump logicS2 9 CR1 Reproduction of generated puff profile % 5% <5%S3 3 CR5 Fit on a workbench and be portable m2 1.5 <1S4 9 CR6 Create a user-friendly manual for machine operation - - - Pass or fail test S5 9 CR6 Make a user-friendly LabVIEW interface - - - Pass or fail test S6 9 CR2,CR3 Collect mainstream and side stream emissions simultaneously - - - Reduce from 5 cigarettes to 1S7 9 Deliverables Generate Labeled and documented flow diagrams of Pressures Pascals - - To identify potential leaks in the systemS8 9 Deliverables Generate Labeled and documented flow diagrams of Flow Rates ml/s - - To identify potential leaks in the systemS9 9 Deliverables Generate labeled and documented wiring diagram V - -S10 9 Deliverables Label system according to respective diagrams - - -S11 1 Deliverables Generate parts list with BOM per vendor specifications - - -S12 3 CR12 Incorporate adaptor to smoke electronic cigarettes - - -S13 3 Deliverables Improve ventilation system from prior projects. - - -S14 3 CR6, CR11 Consistent polypro tubing size/connector size mm 9.5 (3/8 in) make standard throught system, no rubber per ISOS15 3 CR9 Vent main stream exhaust to side stream system - - - Pass or fail test S16 3 CR11 Cigarette holder needs to be level deg +5 deg 0 deg per ISO standardS17 1 CR11 Ash tray below cigarette mm 20-60 40 per ISO standardS18 3 CR11 Pressure drop of complete flow path for 17.5 mL/sec Pascals 300 0 per ISO standardS19 3 CR11 Dead volume mL 100 0 per ISO standard S20 3 CR11 Pressure drop across filter system Pascals 250 0 per ISO standardS21 9 CR11 Puff termination device - - - per ISO standard, pass or fail testS22 3 CR11 Temperature and Relative humidity chamber measurement - - - per ISO standard, record before testingS23 3 CR11 Flameless first-try ignition - - - per ISO standard, pass or fail testS24 3 CR11 Fishtail chimney testing height above ash tray mm - 6 per ISO standardS25 3 CR11 Side stream smoke flow rate L/min +/- 0.1 3 per ISO standard

rqmt. # Importance Source Engr. Requirement (metric)Unit of

Measure Marginal ValueIdeal Value Comments Status


rqmt. # Importance Source Engr. Requirement (metric) Marginal ValueIdeal Value Comments Status


SYSTEM OVERVIEW

SYSTEM OVERVIEW

FINAL DESIGN

FINAL DESIGN• Electronic cigarettes• 2 syringe pumps• Sliding access door• No filter between chimney and impinger• No pressure or temperature sensors• Limit switches• Termination and reset program• Overhead exhaust vent• H-bridge with protection• Larger DAQ interface

PROBLEM TRACKINGIdentifying & Selecting

ProblemPSP 1

AnalyzingProblem

PSP 2

Generating PotentialSolutions

PSP 3

Selecting & PlanningSolution

PSP 4

Implementing SolutionPSP 5

EvaluatingSolution

PSP 6

Rating R1 R2 R3 Y4 Y5 G6

Filter Change OutUnable to get to Cambridge filter to be changed by one person in an efficient

manner.

Cut two doorways. Make a movable side. Use different connections. Widen

the access door.Make a moveable side.

Ran trials with team members to ensure everyone can change a filter within the 5

minute limit.Solution Passes trials.

Pump Program does not run consistently

When the program is run the pump will react to it sometimes or it will not

Give pump more time to react, run the pump multiple times so that it works at

least once.

Call company to see if it's a common problem

Company offered an easy code to fix the problem

Pump now able to load profile off excel spreadsheet

Lighter coil set cigarette on fire Pump program failed and stopped working

Restart computer after crash, Switch pumps, boosted priority level to high on computer, killed power of whole

machine and turned it back on

After restarting and setting priority level to high pumps were switched

Ran tests after switching pumpsProgram stopped crashing after pumps were switched, ran 10

consistent trials

Unacceptable/Non-Repeatable DataDifferent amounts of tar for the same

cigarette tested

Clean out tubing and make sure that initial conditions are the same for all

tests

Run many test to see if there are anomalies. Most of the time our data is

over the maximum

Create scatter plot in mini-tab and point our the outliers

See technical paper for results

Inconsistent CigarettesFluctuation in amount of tar and nicotine

in cigarettesObtain new pack of research

cigarettesObtained a new pack of research

cigarettes

Ran trials with new pack of cigarettes and evaluated how spread out the values of tar

and nicotine are

Cigarettes were not allowed to reach proper humidity and it swayed the

data obtained

LabVIEW Timing Inconsistent Actuator Movement

Close out LabVIEW and reset program after each trial, increase

priority on computer. Reset computer after certain number of tests.

Increase priority level, able to run 5 tests before LabVIEW and computer have to be

restarted.

Ran trials to measure progression of actuators.

Able to run 10 trials on high priority before computer needs to be restarted

Poor Ventilation Smells likes smoke

Change filters in EcoFlo or find the leak in the system, allow time for

cigarette to burn out, speed up ecoflo to vent out faster

Allow time for cigarette to burn outRan trial and waited 5 minutes for cage to

clear before opening

Visually saw cigarette go out and allowed smoke to clear the chimney,

reducing the smell of smoke.

Uncontrolled Actuator MovementDoes not stop or start when

programmed to

Check connections to make sure they are set up correctly and check program, install limit switches

Installed limit switchesRan test to stop actuators using limit

switchesLimit switches killed power to actuator

in order to avoid collisions

No Ignition of Cigarette Tobacco is being dragged out by lighting coil

Test lighting coil and check that all connections are wired correctly, make

sure lighting coil does not touch cigarette tip

Make sure lighting could does not touch cigarette tip

Changed time actuator moves so that it stops before cigarette tip

Lighting could stops before cigarette tip but is still close enough to light with

pump inhale

Loss of flow rate Leaking T-connectionsUse solid 5-hole block to replace tubing with T-connections and Y-

connections

Utilize a block found in the lab and drill and tap 5 holes to connect to push-to-connect

fittingsUsed pipe gel to minimize the risk for leaks

Saved space as well as time plus it no longer leaks

Display Side of Cage Obstructed Vertical actuator mounting bracket and

door in viewable spaceSwitch the two sides of the cage around, deal with the issue as is

Unbolt the two sides of the cage and cut the epoxy

Unbolted, switched around, and relied. Resulted in about 40 min of extra

work. Problem solved

H-bridge Not FunctioningNo actuator movement after it had been

workingWhen actuators his bottom/top dead

center the current when to highOrder another one or take to CIM building

for analysis and look into why it blew

Ordered a backup as well had the first one repaired. Using limit switches before the actuators bottom out and draw too much

current.

Resulted in about a week of downtime. Waiting on parts.

ORDINARY

Critical

MAJOR

CURRENT STATE• Proven results for research cigarettes • Electronic cigarettes capable• Lung cast produced and all parts delivered• Internal lung cast pressure program • Labeling all required parts and wires• Program reset• Customer documentation

TEST RESULTS• 36 Total Research Trials (1R5F)• Eliminated non-7 puff trials and anything with

percent error > +/-70%• Resulted in 15 samples

• TPM avg.= 2.145 mg• % Error avg.= 3.13%

TEST RESULTS

FUTURE TASKS• Fix/reduce actuator creep through

LabVIEW or limit switches• Automated puffing profile from WPSM

device• Calibrated/verify puff using flow meter• Automated parallel correction to puffing

profile• Lung cast deposition incorporation• Puff selection drop-down menu

SUMMARY• Problem Statement• Customer/Engineering Requirements• System Overview• Final Design• Problem Tracking• Current State• Test Results• Future Tasks

QUESTIONS?

Documents

P-14054 Smoking machine