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UMAHS STEM | 1 HydroCap Project Proposal Upper Merion Area High School Amir Shanehsazzadeh, Dan Vallette, Riken Patel, Jonathan Deuber, and Alexander Ho

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UMAHS STEM | 1

HydroCap Project Proposal

Upper Merion Area High School

Amir Shanehsazzadeh, Dan Vallette, Riken Patel, Jonathan Deuber, and Alexander Ho

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Page

I. Executive Summary 3 ________________________________________________________________________

II. Statement of the Problem 4 ________________________________________________________________________

III. Implementation of STEM Disciplines a. Science 4

b. Technology 5

c. Engineering 5

d. Math 6 ________________________________________________________________________

IV. Design Process and Development 6 ________________________________________________________________________

V. Scale and Mass Production 7 ________________________________________________________________________

VI. Future Directions a. Short-Term Goals 8

b. Long-Term Goals 8 ________________________________________________________________________

VII. Proposed Budget a. Components of Prototype 9

b. Development Costs 10

c. Future Costs of Prototype 10 ________________________________________________________________________ VII. Appendix: References, Designs, Images, Code Utilized 11

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Overview: A ‘HydroCap’ model was designed in order to both regulate water flow and to detect the presence of common toxic ions and compounds in water sources. In its most basic sense, the product enables a user, through a touch-screen GUI, to request a certain amount of water (i.e. 1 tablespoon) be proportioned from the faucet. The device has the capability to measure and limit water flow to specific time intervals, as well as the function of detecting methane, and filtering, Chlorine, Calcium, and other VOCs. In essence, the shell casing of the HydroCap was 3-D printed from a Google SketchUp file, while the required sensors were connected to an Arduino motherboard and two spinning plates connected to a motor were used to regulate water flow. The end product will cost approximately twenty dollars if produced industrially. STEM Principles: The project heavily utilized STEM Principles. Initially, research was conducted in order to understand how to identify the presence of common toxic ions and compounds. The knowledge of the Arduino software, a Java-based variant, and the Arduino hardware was essential to the implementation of the projects features. The design was initially made in Google SketchUp, converted to STL/GCode, and finally 3-D printed. Additionally, the formulas for flow rate calibration and fractional area were paramount to optimizing the HydroCap’s functions. Design Process: Starting in October the team met weekly to brainstorm ideas and work on designing the project. The idea to produce a water regulation device had sprouted after the first week. Our initial idea was to create a product that regulated water flow and measured water purity. We then set forth on identifying appropriate materials and fully designing the device. After multiple 3-D prints and testing sessions we finalized our design, printed the final copy, and integrated all of the software and hardware into the product. Mass Production: The product can be printed as three components that can be quickly attached together. A CNC Machine will do the fabrication of the modeling automatically, while the assembly and circuitry can be done by workers, although industrial machinery would eventually take a prominent role. The expected construction time of the product will be cut from ~1 day to ~30 minutes. Future Goals: Optimizations to the current product that have been envisioned include decreasing its size, more effectively integrating the circuitry/hardware into the model, adding a universal sink attachment, adding additional sensors to measure ion concentration, eventually incorporating the model directly into sinks, and creating a battery that is partially or fully powered through hydroelectric power.

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Budget: The HydroCap model costed $150.81 to construct in its current form; additional expenses for designing are comparatively cheap and variable. The end product would cost approximately 20 dollars to produce.

Examination of the Product: You’ve heard it all before- a dripping faucet wastes 3,000 gallons a year, you use 20 gallons just to take one shower and pour 2,000 gallons a year right down the drain if you keep the water on when you brush your teeth [1] - statistics that are meant to scare you but ultimately attribute to little more than a cohesive societal sigh as citizens continue to worry about the issues that affect them in an obvious manner. But here’s something that cannot be ignored: water is a limited resource on our planet and as the global population continues to increase we place more and more stress on our supply. Making efficient use of our water is therefore becoming an increasingly critical issue of our time; at our current pace of consumption, over half the world’s population will live in regions of high water stress by 2030[2]. Our device, the HydroCap, will help limit this by directly modulating the rate of water flow by prompting the user with real time statistical data on water usage and by allowing for user input regarding how long water streams should stem from faucets or even how much water they would desire to receive. Moreover, the increase in pollution producing-industrial activity in Pennsylvania, such as fracking and other sources of groundwater pollution, has the potential to negatively impact water quality in homes. In addition to its regulatory functions, the HydroCap will also possess sensors to detect Methane concentration. Key Statistics for Consideration: -46.7 Billion Gallons of Water Wasted Per Year in PA [3] -4,000 Fracking Related Well Violations [4] -At Least 45,000 Live with Lead in Their Drinking Supply in PA [4] -12,000 Pennsylvanians Currently Have Natural Gas Contaminants in Their Water [4] -Water Leaks from Faucets Alone Cost Pennsylvanians 23 Gallons Per Person Per Year [1] -87,000 Pennsylvanians Live on Well Water [1] -By 2039, PA is set to be a Water Scarce Region [2] -The HydroCap Would Save 2.56 * 108 Gallons of Water in PA Per Year if Implemented in Every Home [3]

Science: Clearly, the environment is a major concern and water quality is a major issue nearly

everywhere around the world. Methane is a major issue in Pennsylvania. Methylation of water

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results in poisoning via both diffusion into the approximate atmosphere as well as via consumption by local residents. Hydraulic fracturing, a common practice in PA, results in contamination of water with natural gas, of which methane is a major constituent.

Environmental science is highly relevant to this project. Trickling, percolation and the relationships between different stages of the water cycle all play a part in groundwater contamination. A major deterrent to water quality is toxification via ions such as Lead as well as non-biodegradable substances. Detecting, identifying, and filtering the most prominent contaminants in PA’s water sources is paramount to the development of the HydroCap’s key functions. Technology:

The HydroCap incorporates two types of sensors. It utilizes two water level sensors to detect the presence of water, allowing it to accurately measure the time it takes to fill up a certain calculated volume. From this volume and the elapsed time, the HydroCap is calibrated to provide the exact amount of water specified through a simple calculation.

The second type of sensor is a methane detector, which is utilized to measure the methane concentration within the water. This sensor is linked to a buzzer which is set to go off if the methane concentration goes above 1800 parts per billion (the methane concentration of the atmosphere). Eventually, sensors for VOCs, Lead, and Chlorine will be incorporated into the product. The HydroCap is already fit with a basic filtration device to remove particulates like Chlorine and Calcium from the water source.

The Arduino motherboard was programmed using Arduino’s trademark open source code, which is based off of Java. Learning to code was an essential aspect of this project as the program works to calibrate the HydroCap and essentially maintain its function. The motherboard is wired to the various sensors, and serves to facilitate the HydroCap’s predominant functions. The touch screen interface is also wired to the motherboard and attached to the flat side of the HydroCap.

Engineering:

We used 3-D printing software to create the HydroCap’s frame and overall model. Google SketchUp was used to create designs for all major components. These designs were converted to STL files, which were subsequently converted to GCode files that were utilized by a 3-D printer to print the model. The design required several engineering aspects, as we had to make considerations for both size and function. We began with initial designs and subsequently printed these out and redesigned repetitively to weed out inadequacies. After doing so repeatedly, we settled on a final design.

The principle of engineering we based our design on is functionality and optimization. In designing this device, there were a couple of parameters to be looked at and the overall shape and form that the device would eventually take was dictated by the function it was meant to fulfill. For one thing, we did not want to mess with the direction and flow of the water to an extent that would compromise the flow rate too much. We also wanted to create enough space to

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house the devices we needed to support certain functions. Lastly, we wanted the design to be compatible with the cylindrical spouted faucets found in average households. All of these requirements led to a very specific design that will be seen in more detail later on. Math:

Starting in October the team met weekly to brainstorm ideas and work on designing the

project. The idea to produce a water regulation device had sprouted after the first week. Our initial idea was to create a product that regulated water flow and measured water purity. Afterwards we began designing an STL file using Google SketchUp. Multiple rough drafts were produced in order to get an idea of what we wanted the product to look like. After we gained a general sense of the structure, we began searching for materials. We unanimously agreed that the Micro-Arduino motherboard would be ideal for a project such as this due to its small size and versatility. After discussing with our advisor, our science teachers, and Upper Merion Sewage Management, we realized that the major issue with Pennsylvania water was a result of fracking.

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Fracking results in heightened methane concentrations of water, which causes considerable damage when consumed. We thus implemented a methane sensor into the HydroCap as we deemed it a necessary function to the project. We also realized that to measure water flow we needed some form of sensor. A quick search provided us with the water level sensors we implemented in our design. Programming began as soon as we acquired the sensors. As a power source we used a portable, rechargeable “lipstick-shaped” battery since its size was optimal for our structure and its consumer accessibility is easy. The program incorporates multiple functions, including the ability to measure flow rate, regulate water output, and measure methane concentration. After multiple 3-D prints and testing sessions we finalized our design, printed the final copy, and integrated all of the hardware into the product.

Current Design: The HydroCap was designed to be as small as possible in order to be easily integrated

into any household or business. The model is currently a cylinder with a 10.0 cm height and 9.0 cm diameter. This size is comparable and even smaller than most water filters on the current market. The current HydroCap model is produced by a 3-D printer. The shell of the HydroCap consists of 2 pieces: the main body and a base piece. Using 2 pieces to construct the shell is efficient enough, however the main drawback arises from motorizing the disks using the gear chain. The disks have to be printed separately and individually connected to the base plate and gear chain using a 3-D printed shaft. We have designed the base piece to incorporate an internal gear chain. As such we can more easily attach the components together without having to manually motorize the disks.

After doing this the product can be printed as two components and quickly attached. The second task in construction is the placement of the hardware into the main shell, which is relatively quick once the circuitry is completed. The motherboard, inputs (sensors), and outputs (motors) need to be integrated into one component, which can be placed inside the shell and then adjusted to fit the pieces.

The activated charcoal water discs are cut into smaller discs that are fit into the HydroCap’s water conducting cylinder allowing for filtration of Chlorine, Calcium, and other VOCs. At the end, the touch screen is wired and mounted to the flat side of the HydroCap and a beveled attachment is inserted at the top water entrance. Mass Production:

The product can be printed as two components that can be quickly attached together. A CNC Machine will do the fabrication of the modeling automatically, while the assembly and circuitry can be done by workers, although industrial machinery would eventually take a prominent role. The expected construction time of the product will be cut from ~1 day to ~30

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minutes through the following time estimates: 5 minutes for hardware creation through the industrial CNC, 15 for incorporation of hardware through the assembly line, 5 minutes for the fitting of mold components through the assembly line, and a 5 minute error bound.

The incorporation of heavy-duty industrial machinery would theoretically cut the time of construction down under 2 minutes per unit of the product. The cost of production of one HydroCap under these conditions would be a total of ~$20, with $16 for hardware, and 4$ for the model and labor.

Short-Term Goals: Compacting the hardware into a smaller volume will allow the hardware space

requirement to be reduced, allowing us to either reduce the size of the model, or implement said space for other functions, such as a larger conducting channel or more sensors.

To further promote integration of the HydroCap we plan on allowing the attachment to sinks to be universal. To accomplish this we will redesign the attachment site to be a conical bore with collapsible adhesive walls. Additionally, we plan on placing a hole on the attachment site to prevent dislodging due to the buildup of pressure. Improving the sensor capabilities of the current model is also a goal. It currently has the potential to measure flow rate and methane content, however we plan on integrating a pH probe which would serve to measure another aspect of water quality: acidity and ion content. Long-Term Goals:

A key development goal for the HydroCap is to develop a mobile application, which would permit integration of the HydroCap to the majority of Pennsylvania citizens. The addition of a Bluetooth module will permit users to easily control the HydroCap with the click of a button. After adding in the Bluetooth module we will program the application using XCode for the iOS and Android Studio for Android platforms. The app will be modest and will provide the same three functions that the touch screen interface currently provides.

Even farther in the future, we plan to improve the filtering capabilities of the HydroCap. This issue is not as applicable to Pennsylvania since the water is relatively clean, despite the potential methane hazards. A micro-scale filter for methane is not plausible, but we could implement a more standard micro filter, which would serve to filter out harmful organisms and other VOCs. This filter would most likely implement the usage of an iodine tablet. The filter application may be more applicable to locations with poorer water quality, such as 3rd-world countries.

The product will eventually be scaled down to 60% of its current size, allowing for it to be directly sold as a part of a sink in order to provide greater value to consumers and to help to limit overt water usage through the HydroCap’s regulatory functions.

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Components of Prototype

Item Quantity Cost ($) Description Arduino Micro 1 22.48 The micro-arduino serves

as the motherboard of the project and works to

efficiently integrate all of the functions.

Breadboard Jumper Pins

1 7.99 The pins were used to connect the sensors and

motors to the micro-arduino.

Mini-Servo Motor 1 3.93 The servo was implemented to provide

torque to produce rotation of the disks.

Rechargeable Battery 1 12.99 This battery serves as a power source for the micro-

arduino. It can be easily removed and charged using

a micro-USB charger. Liquid Level Sensor 2 19.80 The two liquid level

sensors work to calibrate the HydroCap by

measuring the flow rate of the water

Methane Sensor 1 7.48 The methane sensor is positioned near the water-

conducting shaft and works to detect the level of methane in the water.

Vinyl and Electrical Tape

1 5.06 This water-safe, electrical vinyl tape was used to attach sensors and the conducting shaft to the

main body of the model. Buzzer Alarm 1 6.87 The alarm is set to produce

a loud noise in the event that methane concentration

is abnormally high. Plumber’s Putty 1 1.97 The Plumber’s Putty was

used as a water-safe adhesive in the model.

HydroCap Body (3-D Printed)

1 4.93 The body of the model provides a route for water flow as well as space for

the hardware. Breadboard 1 0.99 The breadboard serves as

additional pin space for the micro-arduino.

100uF Polarized Capacitor

1 0.69 Wired from power to ground, prevents voltage

surges from damaging the

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servo and sensors

Water Filter Discs 1 8.69 These activated charcoal discs are incorporated into the HydroCap’s conducting channel and allow for filtration of Chlorine, Calcium, and other VOCs.

Beveled Sink Attachment

1 5.99 This piece allows the HydroCap to be attached to upwards of 80% of sinks

Touch Screen Interface

1 34.95 This interface allows users to easily access the functions of the HydroCap.

SD Card 1 6.00 The SD Card stores graphics for the touch screen interface.

Total N/A 150.81

Development Costs

Item Quantity Cost ($) Description

3-D Printing of Early Designs

N/A .23/m (Total: 12.00) 3-D Printing of the initial designs was done to troubleshoot issues

directly and to test the efficacy of the designs.

(Additional) Mini-Servo Motor

1 3.93 The servomotors had to be purchased in packs of

two, only one was implemented in the

prototype. Total N/A 15.93

Future Costs of Prototype

Item Quantity Cost ($) Description

pH Sensor 1 29.50 Will be useful in finding the ion concentration and

pH of the water Bluetooth Shield and

Module 1 15.59 The model will use

Bluetooth to communicate with mobile phones,

allowing for implementation of the

mobile application. Mobile App

Development 1 Unknown Development of a mobile

app will serve for more effective integration of HydroCap in today’s

market. Total N/A 45.09

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References

[1] "Private Water Systems FAQs (Water Quality)." Water Quality (Penn State Extension). Penn State College of Agricultural Sciences. Web. 1 Feb. 2017.

[2] Society, National Geographic. "Water Conservation Facts and Tips." National Geographic.Web. 1 Feb. 2017.

[3] "The Numbers Behind Pennsylvania's Leaking Water Systems." NRDC. Natural Resources Defense Council, 15 Jan. 2017. Web. 1 Feb. 2017.

[4] Tong, Tom and Scheck, Scott. "EPA's Late Changes to Fracking Study Downplayed Risk of Polluted Drinking Water." APM Reports. American Public Media, 30 Nov. 2016. Web. 1 Feb. 2017.

Designs:

The following images show the progression of our designs from the HydroCap’s beginning phase to its completion.

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Images of the HydroCap:

Front View

Rear View

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Side View

Bottom View

Top View

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Lid

Hardware

Powered Circuitry

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Main Page

Methane Detection

Calibration

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Volume Flow

Operation with Volume

Time Flow

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Operation with Time

Closed Leaves

Open Leaves

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Program Code: // some input to start flow rate test… button or text input? // turn servo 30° //feedback loop where var ++ every microsecond //break when sensor 2 reads HIGH //turn servo back 30° //output flow rate (volume/time) //Check methLevel //output methLevel #include <Servo.h> Servo myServo; float methLevel = 0; //pin for methane sensor float safeLevel = 1800; int water1 = 0; //pin for low water sensor float elapsedTime; //var for fill timer float flowRate = 0; //final flow rate float tubeVolume = .25; //volume of cylinder (L) int loopTimer = 0; //var for water level input, counter float openTime = 0; //var for time that hole is open int beginTimer = 0; float incomingVolume = 0; //var for input of volume desired int x = 0; int y = 0; float n; int servoClose = 80; //val for close hole int servoOpen = 140; //val for open hole int beginPour = 0; int scriptRepeat = 0; String volumeString; void setup() { Serial.begin(9600); pinMode(2, INPUT);//low sensor water1 pinMode(3, INPUT);//high sensor water2 myServo.attach(4); myServo.write(servoClose); } //program begin

void loop() { delay(2000); if(beginTimer == 0){ beginTimer = beginTimer + 1; tone(5, 392, 500); delay(500); tone(5, 659, 500); delay(500); tone(5, 523, 500); delay(300); myServo.write(servoClose); Serial.println("Begin Pouring Now!"); } while (digitalRead(2) == HIGH) { //if water is in contact with bottom sensor while (x == 0){ if (digitalRead(3) == HIGH) { //water has reached top sensor myServo.write(servoOpen); //open hole w/ servo delay(300); elapsedTime = 13.6/ elapsedTime; //calculation of flow rate, / by volume, * by 1000 milli to s Serial.print("Flow Rate: "); delay(500); Serial.print(elapsedTime); //actually flow rate, labelling Serial.println(" mL/Sec"); methLevel = analogRead(A0); x = 1; if(methLevel > safeLevel) { tone(5, 2300, 1000); delay(2000); tone(5, 2300, 1000); delay(2000); tone(5, 2300, 1000); delay(1000); Serial.print("WARNING!!! The methane level is too high! The concentration is "); Serial.print(methLevel);

Serial.println(" parts per billion"); } else { delay(200); tone(5, 392, 200); delay(200); tone(5, 523, 400); Serial.print("Safe Methane levels! The concentration is "); Serial.print(methLevel); Serial.println(" parts per billion"); Serial.println(""); } //inside code after flow rate is printed, was working } else { //water has not reached top sensor elapsedTime += .05; //add .1 seconds to time delay(50); //wait 200 milliseconds } } } // close while while(x == 1){ delay(500); if(loopTimer == 0) { //first time through Serial.println("Input the volume of water required (in mL):"); loopTimer = 1; myServo.write(servoClose); } while (Serial.available()) { //if data available char c = Serial.read(); //stores the input volumeString += c;

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delay(5); } if(volumeString.length() > 0) { n = volumeString.toInt(); beginPour = 1; Serial.print (n); Serial.println(" mL will be added"); Serial.println(" "); delay(5); while (beginPour == 1){ openTime = n / elapsedTime;//open time in sec Serial.print("Begin Pouring Now: it will take "); Serial.print(openTime);

Serial.println(" seconds to complete."); Serial.println(""); delay(1000); myServo.write(servoOpen);//open hole scriptRepeat = 0; delay(200); while(scriptRepeat == 0){ delay(50); openTime -= .05; if(openTime < 0){ myServo.write(servoClose); //close hole loopTimer = 0; Serial.println("Filling complete:"); Serial.print(n);

Serial.println(" mL added!"); Serial.println("."); Serial.println("."); Serial.println("."); beginPour = 0; scriptRepeat = 1; delay(1000); } } } volumeString = ""; } } }