CHAPTER III RESEARCH METHODS
3.7. Components Design Revision
3.7.3. Collector Frame Assembly Revision
For the collector frame, the important things that need an attention is the frame should be able to hold all the collector components which are reflector plate, collector tube, and the glass. The initial concept of this project is shown in figure
Figure 37: Initial Collector Frame Design
The red circle in the figure above indicates the collector holder plates. The holder will be welded into the leg frame and all the collector components will be placed above it. At the assembly process, it is found that this design could work, but the thickness of reflector plate or the foundation that hold the other collector components need to be around 5 mm or above depends on the material, and as the research of the reflector plate material, it is founded that the cheapest plate material (acrylic) with the thickness of 5 mm cost about Rp. 800.000. As the consideration of material price, the revisions of the design need to be done in this concept.
Figure 38: Collector Frame Design Revision
Figure above shows the revised design of collector frame. It may looks more complicated than the old design, but with this revised design, it makes the reflector plate can be so thin for the thickness. For this design, the reflector thickness material that had been used is 0,1 mm and the total price for the assembly is cheaper than the old design. The joint method to attach the reflector plate to the collector frame is using rivet joint method. The difficulties are in the rivet joint because it needs special tool to make the rivet can went through the hollow gray cast iron plate. The rigidity of the frame is tested by applying some amount of external forces to the frame when there are only reflector plates placed.
Chapter IV – RESULTS AND DISCUSSIONS 4.1. Introduction
The solar water heater components has been designed, tested, and assembled with a methodology and design that are explained in chapter 3. The results of the tested is described in this chapter and discussed. The experiment is tested using flow sensor and temperature sensor that are integrated by using arduino.
4.2. Project Results 4.2.1. Tank
In the assembly process of the solar water heater, tank is the last components that are need to be assembly but the first components that need to be built.
The consideration for this case is because the design of the assembly method of the tank to the frame is using bolt joint method, so the tank need to become the basis in determining the position of the bolt hole. The result of the tank is shown in figure below.
Figure 39 Tank Results
Figure 40: Manhole Installation Result 4.2.2. Collector
In this collector results, there are some improvement that had been make after the evaluation of the testing results, it is shows there are patching components that exist in both header as shown in figures below, it is because the position of inlet and outlet of the old design is hard to be realized, so the new concept is the position of the inlet is at the side of the collector header.
Figure 41: Top View of The Collector Results
The revision of the position of the inlet and outlet is based on the consideration of to reduce the cost of manufacturing procedures when improving the efficieny of the water flow with the natural convection method. The position will make the water flow to come out and inside at the tank will be faster because all the inlet could flow the hot water and cold water at the same process time.
Figure 42: Revision of Inlet and Outlet Position 4.2.3. Frame
From all the assembly process of solar water heater components of this project, frame are the hardest assembly than other components, this is the result from there are so many bolts that had been used as the connection for the frame.
For the method, the first frame that are need to be assembly is the tank frame since all other frame assembly will follow the positioning of the tank frame.
The whole assembly of the frame is shown in figure below.
Figure 43: Tank Holder Frame Assembly
Figure above shows the tank holder position result, which make the position of the tank are rigid enough from the external forces to the tank.
4.2.4. Inlet and Outlet Position Results
There are 4 inlet and outlet hole that are installed at the solar water heater assembly. The figures below are shown the position of each inlet and outlet and the function of it.
Figure 44: Inlet of the cold water from the tank to collector position
The position of the inlet at the above figure is from the consideration of the position of cold water will be at the bottom side of the tank by the density theory, so this position will make the efficiency of the cold water flow from the tank to collector could be maximized.
Figure 45: Inlet of Cold water To the Collector
Figure above show the positioning of the cold water inlet of the collector.The position of the inlet is located at the bottom header is the contemplation of the natural convection theory which concluded that the hot water will flow to the upper side, so by using this positioning procedure, the cold water will come to the bottom side of the collector then when the heating process is done, the hot water will flowing up before finally go inside the tank automatically.
Figure 46: Inlet of the hot water from collector to the tank
The figure above shows the positioning of inlet of hot water into the tank.
Position of the inlet will make the hot water that are assumed will be located at the upper header in collector to flow directly to the tank. The two inlets is the consideration to makes the flow of hot water is bigger in terms of volume.
Figure 47: Flow Measurement Sensor
Figure above shows the position of the outlet water from tank to the customer, the position are located at the center of the tank diameter to make the intensity of hot water that can be flowing out to be maximized.
4.2.5. Assembly Components
There are 2 components that used in the assembly process which are ball tap valve and flank. Ball tap is used for the flow control at the tank, so it will makes the limit level of water at the tank. Ball tap will prevent the backflow to occur. It is installed at the inlet for water input from the pump to the tank. The second components is flank, flank is used to joint 2 components. In this project flank is used as a joint at the piping assembly. The schematic of the components are shown by the figure below.
Figure 48: Ball Tap Mechanism
The other additional components in this project is flange as shown in figure below. Flange is the connector that are commonly used to connecting pipes, the reason is based on the strength ability to prevent the leakage at the enormous amount of pressure and the sustainability from corrosion. (Sawa et al., 2008)
Figure 49: Flange Technical Drawing 4.3. Result of Flow and Temperature Using Arduino Sensor
The figure above shows the instalment position of the flow meter arduino sensor.
The flow meter are located at the outlet of the water from the tank to customer usage because it will be indicates the volume that coming out from the system
more precisely. The flow meter then connected to arduino board with the schematic that had been illustrated in the wiring diagram at figure below.
Figure 50: Flow Meter Wiring Diagram
After the flow meter are connected as shown in the figure above, the arduino board will be connected into the laptop to become the power supply and to load the program to the arduino uno board. After upload the flow meter program to the arduino board, then the flow meter data of the project could be taken by opening the serial monitor. The results are shown at the below figure:
Figure 51: FlowMeter Sensor Result
The result of the flow meter sensor that are shown in figure above shows that the natural convection occurs in this solar water heater system, since at the time that tank already full, there are still some flow detected which means the circulation of water flow still happens which shows the heating process is approved, the amount of flow indicates are changing due to the volume of heating is different at some times. It means that the natural convection is happens because the hot water is generated by this convection to be able to move to the upper level of the tank.
Figure 52: Thermo Recorder Result (1st Testing)
The figure described the value of temperature rise at the first testing that held in condition that there are no insulation components that installed in the collector and outlet of the solar water heater system. The results of maximum temperature that detected by the sensor is 39,4 which the results is still not close to reach the objectives to be clost to 50 .which means that some improvement needs to be done to got a better results.
Figure 53: Thermo Recorder Result (2nd Testing)
The results shown in the figure above shows the result from the 2nd testing. The condition is that the insulation components are installed at the solar water heater systems that are shown in the results of solar water heater that are stated in chapter 4.
The highest temperature that are shows in the thermo recorder is 44,4 which already close to reach about 50 . For the 2nd testing there are 9 thermocouple PT100 sensor that are used to detected all temperature changing that occurs at all position in solar water heater systems. The results indicates that the radiation is occurs at the solar water heater systems because the temperature that are detected by the thermocouple that are installed at the collector shows that the temperature always larger than the ambient temperatures.
Figure 54: Thermo Recorder Result (3rd Testing)
The condition for the third testing is at the weather is cloudy, that means that the solar radiation at the ambient is low. The water temperatures that are shown is 37,1 . The results also shown that the temperature of all collector components is did not much different that the ambient temperature which approved that the radiation occurs that are catches by the solar water heater system is low and its affected the results of heating process in the solar water heater.
CHAPTER 5 – CONCLUSIONS AND RECOMMENDATION
5.1. Conclusions
The solar water heater system can be easily assembled and disassembled.
The cost for the assembly is less than 5 million rupiah, so the affordable aspect is justified
The frame is able to hold up to 400 kg load from the solar water heater assembly. (Tank = 70 Kg + Weight of Water = 300Kg )
The result of flow meter shows the natural convection happens at the water flows in solar water heater.
The objectives to heat up the water yp to 50 still not achievable. Current maximum temperature is 44
5.2. Recommendations
Find another material with good emmisivity and price to improve the heating performance in collector.
Add the number of tube in the collector to make the heating process of 300 Litre of water faster.
.Learn more about the radiation, conduction, and convection method to be able in improving the performance of the current project.
Imrpovement of the insulation system at the collector components and the piping tube of water flow.
Improving the performance of heating process at the solar water heater system.
GLOSSARY
Thermosyphon : a method of passive heat exchanger that are based on natural convection to flow the liquid of the system without using additional system such as pump.
Flowcharts : a type of diagram which represent the process of some system or algorithm, which are represents by boxes for the step and arrows for the order.
Conduction : the process of electricity or heat is directly transmitted through a substance when there is a difference of temperature or electrical potential without a movement of the material.
Radiation : an emitted or transmitted energy in the forms of waves or particles through a space or material medium.
Convection : a process of liquid or gas that are depends on the different amount of energy in terms of particles or less heat energy.
Modular : terms of which a systems component may be separated or recombined by using some kind of system or joint method.
Efficiency : the state or quality of being efficient in terms of the ratio of the useful work performed by a machine or in a process to the total energy expended or heat taken in.
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APPENDIX A - Solar Water Heater Results and Bill of Material
APPENDIX 1 – Bill Of Material Solar Water Heater Components
Appendix 2 - Solar Water Heater Front View
No Name of Material Dimension Number of
Pcs Price Total
1 MS Hollow Tube 50 x 50 mm 5 cm x 100 cm x 3mm 7 Rp 27.500,00 Rp 192.500,00 2 MS Hollow Tube 50 x 50 mm 5 cm x 180 cm x 3mm 2 Rp 55.000,00 Rp 110.000,00 3 MS Hollow Tube 50 x 50 mm 5 cm x 55 cm x 3mm 2 Rp 25.000,00 Rp 50.000,00 4 MS Hollow Tube 50 x 50 mm 5 cm x 120 cm x 3mm 2 Rp 35.000,00 Rp 70.000,00 5 MS Hollow Tube 50 x 50 mm 5 cm x 90 cm x 3 mm 1 Rp 27.500,00 Rp 27.500,00 6 Stainless Steel Plate 122 cm x 244 cm x 1,5 mm 1 Rp 1.125.000,00 Rp 1.125.000,00 7 Galvanized Pipe dia. 1/2" 2,5 cm x 190 cm x 1,5 mm 4 Rp 20.000,00 Rp 80.000,00 8 Galvanized Pipe dia 1 1/2" 4 cm x 100 cm x 2,5 mm 2 Rp 42.500,00 Rp 85.000,00
9 Zinc Plate 100 cm x 200 cm x 0,1 mm 1 Rp 80.000,00 Rp 80.000,00
10 Bolt 12 mm 12 mm x 8 cm 8 Rp 1.000,00 Rp 8.000,00
11 Bolt 10 mm 10 mm x 8 cm 30 Rp 800,00 Rp 24.000,00
12 Flangs 1/2" 5/5 5 cm x 5 cm 4 Rp 84.500,00 Rp 338.000,00
13 Stainless Steel Pipe 1/2" 200 cm 1 Rp 78.000,00 Rp 78.000,00
14 Ball Tap 1/2" 1 Rp 147.500,00 Rp 147.500,00
15 RockWool 150 cm x 250 cm x 2,5 mm 1 Rp 300.000,00 Rp 300.000,00
16 Wave Zinc Plate 80 cm x 180 cm x 0,3 mm 1 Rp 80.000,00 Rp 80.000,00
17 Steel Plate 122 cm x 244 cm x 0,5 mm 1 Rp 110.000,00 Rp 110.000,00
18 Glass Wool 120 cm x 230 cm 1 Rp 110.000,00 Rp 110.000,00
19 Metalizing Tape 2 Rp 9.000,00 Rp 18.000,00
20 Tank Fabrication Rp 250.000,00 Rp 250.000,00
21 Collector Welding Rp 100.000,00 Rp 100.000,00
22 Glass (Transparent) 100 cm x 200 cm x 5 mm 1 Rp 340.000,00 Rp 340.000,00 Grand Total Rp 3.723.500,00
Appendix 3 – Solar Water Heater Side View
Appendix 4 – Input Water Position Results
Appendix 5 – Output Water Position Results
APPENDIX B – ARDUINO CODE
Programming code to measure the flow of water at the system using flow sensor YF- S201.
/*
Liquid flow rate sensor -DIYhacking.com Arvind Sanjeev
Measure the liquid/water flow rate using this code.
Connect Vcc and Gnd of sensor to arduino, and the signal line to arduino digital pin 2.
*/
#include <SPI.h>
#include <SD.h>
#include <SoftwareSerial.h>
const int chipSelect = 10;
byte statusLed = 13;
byte sensorInterrupt = 0; // 0 = digital pin 2 byte sensorPin = 2;
// The hall-effect flow sensor outputs approximately 4.5 pulses per second per // litre/minute of flow.
float calibrationFactor = 7.5;
volatile byte pulseCount;
float flowRate;
unsigned int flowMilliLitres;
unsigned long totalMilliLitres;
unsigned long oldTime;
String result;
void setup() {
// Initialize a serial connection for reporting values to the host Serial.begin(9600);
while (!Serial) {
; // wait for serial port to connect. Needed for native USB port only }
Serial.print("Initializing SD card...");
// see if the card is present and can be initialized:
if (!SD.begin(chipSelect)) {
Serial.println("Card failed, or not present");
// don't do anything more:
return;
}
Serial.println("card initialized.");
// Set up the status LED line as an output pinMode(statusLed, OUTPUT);
digitalWrite(statusLed, HIGH); // We have an active-low LED attached
pinMode(sensorPin, INPUT);
digitalWrite(sensorPin, HIGH);
pulseCount = 0;
flowRate = 0.0;
flowMilliLitres = 0;
totalMilliLitres = 0;
oldTime = 0;
// The Hall-effect sensor is connected to pin 2 which uses interrupt 0.
// Configured to trigger on a FALLING state change (transition from HIGH // state to LOW state)
attachInterrupt(sensorInterrupt, pulseCounter, FALLING);
} /**
* Main program loop
*/
void loop() {
String dataString = "";
if((millis() - oldTime) > 60000) // Only process counters once per second {
// Disable the interrupt while calculating flow rate and sending the value to // the host
detachInterrupt(sensorInterrupt);
// Because this loop may not complete in exactly 1 second intervals we calculate
// the number of milliseconds that have passed since the last execution and use
// that to scale the output. We also apply the calibrationFactor to scale the output
// based on the number of pulses per second per units of measure (litres/minute in
// this case) coming from the sensor.
flowRate = ((60000.0 / (millis() - oldTime)) * pulseCount) / calibrationFactor;
// Note the time this processing pass was executed. Note that because we've // disabled interrupts the millis() function won't actually be incrementing right
// at this point, but it will still return the value it was set to just before // interrupts went away.
oldTime = millis();