• Add to Collection
  • Tools Used
  • About

    About

    This is a multiphysics project I worked on at Parametric Solutions for a company by the name of Aquastel. See http://www.aquastel.nl/?id=1&taal=e… Read More
    This is a multiphysics project I worked on at Parametric Solutions for a company by the name of Aquastel. See http://www.aquastel.nl/?id=1&taal=en&em=0 for more details. Read Less
    Published:
INTRODUCTION
This is a multiphysics project I worked on at Parametric Solutions for a company by the name of Aquastel. What was great about this project is that I wore many hats. I designed the entire layout of this system. This includes, the frame, plumbing, controls layout, etc. A dear friend, Patrick Keay is an electrical genius! Without his amazing guidance, this project would not have been successful and none of this would have been possible. Thank you!!!
 
This project was incredibly complex and takes hours to explain the details. You're not here to read (personally, I prefer pictures for all my words) and this will already be a wordy write up so here's the website if you're so inclined. http://www.aquastel.nl/?id=1&taal=en&em=0 
Otherwise, let's get started on the pictures and explanations...
THE SYSTEM IN ITS ENTIRETY
CONTROL PANEL AND CELL BOX
THE TRANSFORMER
CUSTOM TOROID TRANSFORMER
Knowing that high current loads will produce high temperatures, the design of the unit underwent thorough thermal analysis. Pictured here,  is a toroid transformer, note its location in the above images. Heat rises, and now note the fans…
 
I made two thermocouples and sent them to the manufacturer or the transformer and had them both installed when they built this custom toroid. I was now able to not only monitor but also control (turning cooling fans on/off) the temperature with a safety shut off added into the PLC program. Even though two thermocouples is redundant, the wire for each was only about 50 cents but protected a transformer valued at about $500.00. Piece of mind...
THE PLC SYSTEM
For controlling transformer temps, we used the now dated Siemens S7 200 PLC suite. The EM231 proved to be the best module for this task.
THE HEART OF THE SYSTEM
For anyone who has ever fried a wire or two, this is where all the magic smoke is contained.
 
Another shot of the electrical box. Once again, note the position of the components. Heat sinks at the bottom, transformer at the top, fans at the top, air vents directly below the heat sinks allowing for maximum air flow directly through maximum surface area. Taking advantage of the fact that heat rises, the components are designed so that in the event of a fan failure, the temperature differentials actually drive airflow and provide adequate cooling.
THE CELL AND SHORT BREAK
This is the hydraulic box. The black cylinder on the right is where electrolysis takes place. The clear cylinder on the left serves two purposes:
1.               Removes Hydrogen Gas which allows us to control pH
2.               Opens the circuit:
                   a.      Long story, but the water goes through the electrolysis tube twice. To put it simply, this creates a short circuit. If you run electricity through electrolytic fluid, it conducts electricity like a wire. For example, connecting a wire between the positive and negative terminals of your car battery will destroy the wire. The same thing happens with a “water wire” but the water is trapped. In a case like this, the electrodes (Anode & Cathode) fail. In order to open the circuit and prevent the short, the water has to be aerated. The coolest part about this little cylinder is that I designed it to do all this with NO moving parts. And it was all controllable from the PLC. 
TESTING, TESTING AND MORE TESTING
The unit underwent thorough testing as you can see here. Chlorine gas generation (yes this is dangerous!) was also constantly monitored and testing was done in a "blow through" facility to keep us safe.
Finally, the unit was submitted to UL for approval. 
SPECIAL THANKS GOES TO:
Aquastel, Patrick Keay, Joel Haas, Mike Howell, and the Parametric Solutions Team.