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Brian DeKock
Brenton Eelkema
Jacqueline Kirkman
Nathan Meyer
Brandon Vonk
December 6, 2010
Calvin College; Grand Rapids, MI
Engineering 339: Senior Design Engineering Capstone
Executive Summary
Food production, distribution and consumption have become a growing concern due to
population growth in developing countries and the movement of populations into more urban settings.
One way to mitigate the increase in costs for food production and decrease the amount of energy
expended on food production is to grow food locally. Local foods provide a more sustainable means for
consumption of produce without requiring consumers to decrease the amount of fresh produce purchased.
Sustainability is increased because the distance produce is shipped before reaching market is reduced,
thus resulting in the use of smaller quantities of fossil fuels. The HydroTower design was developed as a
means to decrease the cost of food production, decrease the number of miles necessary for producing
shipments and increase the number of people with access to fresh produce. HydroTower will accomplish
such a reduction in shipping distances and cost of food production by bringing the ability for consumers
to grow their own produce in optimized growing conditions. There will no longer be a need to have a
garden plot or ideal weather for produce to grow. HydroTower will allow consumers to grow their own
food without the need for a green thumb, plots of land or precious time to grow food. While
HydroTower provides numerous solutions, the overarching objective is succinctly stated as: feed people,
more efficiently, through hydroponics.
Initial project designs and analysis show that HydroTower is a feasible project that combines
interdisciplinary designs including biological, chemical, electrical and mechanical principles. This design
feasibility has been confirmed through hydroponic experiments along with engineering calculations and
analysis in LED Light System designs and structural designs. In addition, the HydroTower is a viable
project both economically and technically. Economically the HydroTower will produce the highest
quality food at a cost lower than that of comparable food items. Technically the HydroTower will provide
an innovative nutrient control system that combines both mechanical and electrical engineering
knowledge. Furthermore, market research has shown that HydroTower has economic competitors who do
not provide what the HydroTower will offer. A competitive price for the HydroTower of less than $200
will ensure that the HydroTower is a strong contender in the household hydroponic market.
Table of Contents
Table of Acronyms...........................................................................................................................iv
List of Tables ....................................................................................................................................v
List of Figures..................................................................................................................................vi
Introduction ..............................................................................................................................1
1.
1.1.
Project ...............................................................................................................................1
1.2.
Team ..................................................................................................................................2
2.
Requirements .....................................................................................................................3
2.1.
2.1.1.
2.1.2.
2.1.3.
2.1.4.
2.1.5.
2.1.6.
2.1.7.
2.1.8.
Hydroponics ........................................................................................................................10
3.
3.1.
3.2.
3.2.1.
3.2.2.
3.2.3.
Float .........................................................................................................................13
3.2.4.
Aeroponics ................................................................................................................14
3.2.5.
3.3.
3.4.
Proposed Design...............................................................................................................20
3.4.1.
4.
5.
6.
7.
4.1.2.
4.1.4.
4.1.5.
4.1.6.
Mechanical Systems.................................................................................................................32
5.1.
Requirements ...................................................................................................................32
5.2.
Size...................................................................................................................................32
5.3.
5.4.
Psychrometrics.................................................................................................................38
5.4.1.
Humidification ..........................................................................................................38
5.4.2.
Temperature .............................................................................................................41
6.2.
6.3
Mobility ...........................................................................................................................43
6.4
6.5
Aesthetics .........................................................................................................................46
Business Analysis.....................................................................................................................47
7.1.
Market Research..............................................................................................................47
7.1.1.
Customer ..................................................................................................................47
7.1.2.
Overview of Market..................................................................................................47
7.1.3.
7.2.
7.2.1.
7.2.2.
Design Norms............................................................................................................50
7.3.
7.3.1.
7.3.2.
7.3.3.
7.3.4.
7.3.5.
7.4.
7.4.1.
7.4.2.
7.4.3.
7.4.4.
7.5.
Competitor Analysis.........................................................................................................53
7.5.1.
7.5.2.
8.
8.1.
8.2.
8.3.
Management............................................................................................................................60
9.
9.1.
Project .............................................................................................................................60
9.2.
9.3.
Budget..............................................................................................................................63
9.4.
Website ............................................................................................................................63
9.5.
9.6.
Resources .........................................................................................................................63
10.
10.1.
10.2.
IEEE Engineering in Medicine and Biology Society Student Design Competition ........65
10.3.
11.
Conclusions..........................................................................................................................66
iii
Table of Acronyms
CPU
EC
Electro Conductivity
HydroTower
LCD
LED
MS
Microsoft
PCB
PPFS
SWOT
UI
User Interface
WBS
iv
List of Tables
Table 1: List of Engineering 339/340 Professors and Concentrations......................................................1
Table 2: October hydroponic experiments with soybeans and radishes................................................16
Table 3: October hydroponic Experiment #2.......................................................................................17
Table 4: Different options for touch-screen devices.............................................................................23
Table 5: Maximum loads on the power supply....................................................................................31
Table 6: Hoagland's Solution .............................................................................................................35
Table 7: Electrodes and interferences ................................................................................................36
Table 8: Psychrometric calculations variable list .................................................................................40
Table 9: Summary of wick humidifier design for fan usage .................................................................41
Table 10: Full assembly of second HydroTower prototype...................................................................45
Table 11: Census Bureau 2008 population..........................................................................................47
Table 12: Prototype Costs .................................................................................................................57
Table 13: Variable and fixed costs estimations for HydroTower ...........................................................58
Table 14: Tech-Lead positions for the HydroTower Team ....................................................................60
List of Figures
Figure 1.2: HydroTower: Gardening Solutions (Engr 339/340 Team 2) ..................................................2
Figure 2: Diagram of hydroponics .....................................................................................................10
Figure 3: Benefits of Hydroponics .....................................................................................................11
Figure 4: Diagram of flood and drain (Ebb and flow) system ...............................................................12
Figure 5: Top Fed Continuous Drip System ........................................................................................13
Figure 6: Float method of hydroponics ...............................................................................................14
Figure 7: Aeroponic method of hydroponics .......................................................................................14
Figure 8: Hydroponic grwoth over 3 weeks with 2 soybean plants and 4 radish plants ...........................17
Figure 9: Hydroponic growth over 2 weeks with 3 soybean plants and 3 radishes..................................18
Figure 10: Soybean plants at week 2 ..................................................................................................19
Figure 11: Radish plants at week 2.....................................................................................................19
Figure 12: soybean plant with signs of iron deficiency ........................................................................19
Figure 13: Radish plant with signs of iron deficiency ..........................................................................20
Figure 14: Initial Setup .....................................................................................................................25
Figure 15: Water Supervisor Program ................................................................................................26
Figure 16: Main UI ...........................................................................................................................26
Figure 17: Calculation for target amount of LEDs ...............................................................................27
Figure 18: Simulink Air Temperature Control System .........................................................................28
Figure 19: Schematic of control system for nutrient control .................................................................29
Figure 20: Plant light frequency response ...........................................................................................30
Figure 21: First HydroTower prototype design (circular) .....................................................................33
Figure 22: Second HydroTower prototype (rectangular) ......................................................................34
Figure 23: Survey results on likely aspects for purchasing HydroTower ...............................................49
Figure 24: Survey results on customers growing their own food...........................................................49
Figure 25: RotoGro 240 Rotating Garden ...........................................................................................53
Figure 26: Desktop Hydroponic system ..............................................................................................54
Figure 27AeroGarden Pro 200 ...........................................................................................................54
Figure 28: Biosphere Home Farming .................................................................................................55
Figure 29: Kitchen Nano Garden .......................................................................................................56
Figure 31: WBS Spring Semester.......................................................................................................62
Figure 30: WBS Fall Semester...........................................................................................................62
vi
1. Introduction
The introduction provides a brief overview of the project and team. The project fulfills
requirements of the 2010-2011 Calvin College Engineering Senior Design class and specifically, the
project selected has been titled HydroTower: Gardening Solutions.
The Calvin College engineering capstone is designed to provide a real world experience to
engineering students in their final year of undergraduate education. Students within senior design
choose both their own teams and projects under the direction of five engineering professors, one in
each of the four concentrations (Electrical/Computer, Chemical, Civil/Environmental and
Mechanical). Table 1.1 shows the senior design professors and their corresponding concentrations.
Engineering 339 in the fall and then the subsequent Engineering 340 in the spring combine project
implementation with class lecture and discussion to prepare students to enter the workforce
following graduation.
Ned Nielsen
Mechanical
J. Aubrey Sykes
Chemical
Steve VanderLeest
Electrical/Computer
Wayne Wentzheimer
Chemical
David Wunder
Civil/Environmental
1.1. Project
In 2008, for the first time in history, more than half of the global population lived in
cities. Furthermore, projections for urban growth and development by research completed by
Dickson Despommier (author of The Vertical Farm: Feeding the World in the 21st Century)
concluded that by the year 2050, nearly 80% of the earth's population will reside in urban
centers. 1 Such a situation presents a unique opportunity to feed populations in cities which
subsequently living long distances from agricultural areas. Furthermore, the idea of hydroponic
vertical farming allows those persons without access to outdoor garden areas to produce their own
food. The specific product HydroTower was developed from Disckson Despommiers
commercial vertical farming ideas, but adapted for residential hydroponic growing use. Overall,
HydroTower will reduce the amount of fossil fuels used in food production, decrease the distance
produce is shipped to reach market and eliminate the use of pesticides and herbicides.
1
Despommier, Dickson. "The Problem." The Vertical Farm. Ed. Dr. Dickson Despommier Ph. D. Environmental Health Science
of Columbia University, n.d. Web. http://www.verticalfarm.com/
1.2. Team
The HydroTower Team is comprised of a mixture between electrical and mechanical
engineering concentrations and is also an interdisciplinary project combining electrical,
mechanical, chemical and biological knowledge and design. The learning experience for the
individual team members is benefitted by such diversity.
Figure 1.2: HydroTower: Gardening S olutions (Engr 339/340 Team 2). Back Row (Left to Right): Jacqueline Kirkman
(ME), Brandon Vonk (EE). Front Row (Left to Right): Brian DeKock (ME), Nathan Meyer (EE), Brenton Eelkema (EE)
Electrical concentration members include Brenton Eelkema, Nathan Meyer and Brandon
Vonk while the mechanical concentration members include Brian DeKock and Jacqueline
Kirkman. Brenton Eelkema will graduate with a BSE Electrical Engineering concentration and is
from Irvine, California. Nathan Meyer grew up in Elmhurst, Illinois and is studying Electrical and
Computer Engineering and is getting a minor in Physicsand he currently has an internship with
DornerWorks in Grand Rapids. Brandon Vonk is originally from Hamilton, Ontario, Canada, is
an Electrical Engineering Major with a Physics Minor at Calvin College. Brandon has also had an
internship with Johnson Controls Inc. Brian DeKock grew up in Salt Lake City, Utah and is
pursuing a BS in Mechanical Engineering. Brian currently has an internship with Temper in
Rockford and is also seeking a full time position after graduation. Jacqueline Kirkman will
graduate in May 2011 with a BSE Mechanical Engineering concentration and a minor in
International Relations. Jacqueline has interned at Westinghouse Electric Co in Pittsburgh, PA.
2
2. Design Specifications
2.1. Requirements
The following design requirements are assumed to be System-Level Design.2 These
requirements have an established concept development but are not fully implemented as a
detailed design. Therefore, these requirements have not been finalized and may or may not be
represented in the final prototype. However the following design requirements do represent the
current design direction and specification for HydroTower. Requirements headings are not ranked
in order of importance, however sub headings are ranked by the currently foreseen importance to
overall success and design of the product. The HydroTower will function according the
requirements stated below:
2.1.1.Functional Requirements
a. The HydroTower is designated for specific use as a hydroponic grower capable of growing
plants, vegetables, and herbs indoors.
b. HydroTower will be one base unit and two additional stackable units. The product will be
fully functional using only the base station or using the base station in combination with one
or two stackable additions.
c. Growing Ability: HydroTower will allow the growth of any plant, vegetable, or herb that is
height permitted to fit within HydroTower. HydroTower team will not specify what can and
cannot be grown, however certain plants will be suggested based on ability to grow in a
hydroponic environment.
d. Autonomous Ability: HydroTower will have the ability to function in an autonomous mode
capable of running without human intervention for seven consecutive days. Any significant
system failure within HydroTower will trigger a fail-safe automatic shutdown of the system
which must be reset by a human operator.
e. Location: HydroTower will be designed primarily for use in an indoor environment. In
addition HydroTower will be capable of handling moderate outdoor temperatures for
summertime growing. HydroTower will be able to operate in conditions between 100o F and
32o F outdoors. In an indoor environment HydroTower will be designed to operate at indoor
temperatures of between 40o and 85o .
f.
Overall Size: HydroTower must be suitable for indoor use. Therefore the product must fit
through doorways and stand upright in a room without touching the ceiling. HydroTower
must be lower than 8 feet in height and less than 34 inches wide. Preliminary design of
Karl T. Ulrich and Steven D. Eppinger. Product Design and Development. M cGraw-Hill, New York, 1995. Print.
HydroTower has a height of 5 feet and a width of 34 inches. The base unit shall have a height
of approximately1 foot with each additional unit having a comparable height of 2 feet.
g. Overall Weight Unloaded: HydroTower base station must be able to be carried by an
average adult person regardless of gender capable of carrying 50 lbs. The maximum weight
for the base station without growing media or water will be less than 30 lbs. Each additional
stackable unit should weigh less than 20 lbs. when not filled with growing media or water.
The total weight of an unloaded HydroTower will be no greater than 80 lbs.
h. Overall Weight Loaded: HydroTower fully loaded should not be able to be pushed over or
toppled by a child under the height of 3 feet. The fully loaded base station should weigh
approximately 50 lbs. Each additional stackable unit should weigh no more than 30 lbs.
Therefore a HydroTower with base unit and two additional stackable units should weigh
approximately 110 lbs fully loaded.
i.
j.
Power Consumption: The HydroTower will not consume power greater than what is
available in a conventional 120 VAC outlet. Power on and shutoff switch will be easily
accessible and labeled near the user interface. Attachment Plugs and Receptacles along with
Fuses will be in accordance with UL standards. 3
k. Light Emitting Diodes: LEDs will be shielded by the outer shell of the HydroTower in order
to prevent retina damage from bright LEDs to users outside of the HydroTower. Warning
label will be placed on the inside of the HydroTower.4
l.
Strength: HydroTower will be able to endure the climbing and pulling of a small child or
animal no more than 3 feet tall and 30 lbs. HydroTower structural design will first and
foremost focus on the supports holding together the base unit and additional stackable units.
Secondly, HydroTower structural design will focus on building a strong containment
reservoir to ensure water does not escape HydroTower. In addition, the outer shell of
HydroTower will be able to endure a moderate amount of force exerted by accidents and
normal wear such as running into HydroTower while walking or usage past the specified
design life.
Water Resistance: Water resistance will be an utmost issue when dealing with almost all
major components of HydroTower. Water resistance will be assumed using the water criteria
set out in the earlier section titled, Water Reservoir and Usage. Water overflow will be
considered and overflow channels will exist on each level to ensure that water does not exit
HydroTower during standard operation.
a wide variety of plants that can be grown successfully in HydroTower, but will not
specify a listing of plants as stated in Growing Ability above.
d. Air Temperature: The air temperature of HydroTower will be based on the Location
requirements specified in the previous section Functional Requirements. Further
research is required to determine the optimum temperature for plant growth. Any
temperature for a sustained period that cannot support plant growth in HydroTower will
issue a shutoff command that stops all operation in HydroTower. Any sudden
temperature increase or decrease in HydroTower will issue a warning to the user.
(Sustained period and sudden temperature increase or decrease will be defined with
further research)
e. Water Temperature: Water Temperature will follow the same guidelines set out in
the previous subsection titled, Air Temperature.
2.1.3.
Interface Requirements
a. User Interface (General): The interface and interaction requirements for HydroTower
will assume a rugged design that is capable of usage with wet and dirty hands.
Emergency shutoff features and signals will be intuitive to the user without an
instruction manual. All controls for HydroTower will be located in the base unit.
Instructions on operation will not be included for the user interface on HydroTower.
These instructions will be provided separately in the user manual.
b. User Interface (Control Systems Interface): The user interface for the control system
of the project will feature a touchscreen controller that is capable of displaying
information related to growth time, chemical concentration, water usage, power usage,
and temperature controls. On the touchscreen, the size of the choice selection buttons
will be a minimum of one square inch.
c. User Interface (Power Options/Water and Nutrient Insertion): HydroTower will
feature intuitive buttons to turn on and off. In addition, an emergency shutoff switch
will be prominently displayed. Water and nutrient insertion points will be labeled and
capped to prevent accidents, tampering, or contamination from other users, children, or
pets.
2.1.4.
Environmental Requirements
i. Visual: HydroTower will have a uniform outer shell made of plastic that will be
a neutral color. An effort will be made to contain the LED light from
HydroTower to prevent the light from being a large distraction in the room
ii. Sound: HydroTower will not produce any sustained noise that is greater than 60
dB.
iii. Smell: HydroTower will not contaminate its immediate location with any smell
from inside the unit. Further research will determine if an air purifier is needed
during the operation of HydroTower.
iv. Humidity: The humidity of HydroTower will be optimized to a relative humidity
of 50%. Measurement and control of humidity will be taken care of by the
control system.
b. Outside Environment: The outside environment will be defined as any part of the
environment that that HydroTower interacts with both directly and indirectly.
i. Recycling: All attempts will be made to ensure that HydroTower is as
environmentally friendly as possible. This means further developing the already
stellar environmental achievements of hydroponic growing. Specific efforts will
be made in ensuring that recycled or recyclable materials are used in the creation
of HydroTower.
ii. Water and Nutrient Disposal: Water disposal will be based on the method of
hydroponics chosen in the second semester. Leftover water at the end of a
growing cycle will have little nutrients and will be discarded. Waste water will be
limited to, at most, half of water reservoir capacity.
2.1.6.User Requirements
a. Ergonomics: Defined as the efficiency and the usability of HydroTower:
i. Ease of use: As stated in the previous subsection User Interface, power,
emergency shutdown options, and water/nutrient insertions points will be easy to
find and use.
ii. Maintenance: Standard maintenance on HydroTower will be limited to cleaning
after plant cycles and possibly changing filters. This maintenance plan will take
no longer than one hour to complete for each plant cycle.
iii. Cleaning: All parts of HydroTower that need to be cleaned will be easily
accessible and removable when possible.
b. Assembly: HydroTower will be able to be completely assembled and disassembled in
less than one day by a select user of HydroTower.
2.1.7.Manufacturing Requirements
a. Development Time : The HydroTower prototype will be completed by May 7, 2011.
b. Project Development Cost: HydroTower development cost will be less than $2,000.
c. Development Capability: HydroTower will be mass produced based on the
documentation of the HydroTower team. This documentation will be specified in the
Delivery Requirements section.
d. Product Quality: The quality of HydroTower will be based on the design norms
chosen by HydroTower team and specified in these requirements.
e. Product Cost: HydroTower will cost less than $100 to produce.
5
f.
g. Sellable Unit: A sellable unit of HydroTower will include two versions: the base unit
and stacking unit. Included in the base unit are all components of HydroTower in
addition starting seed packages and a users manual. The stacking unit will include a
brief instruction guide on how to attach to the base unit. The stacking unit will not
include any seed packages or an additional users manual.
2.1.8.Delivery Requirements
a. PPFS: The PPFS will be completed by December 5, 2010
b. Final Report: The Final Report will be completed by May 7, 2011.
c. Working Prototype : The working prototype will be created by May 7, 2011.
d. Team Website: The team website will be created by November 25, 2011 and updated
monthly.
e. Design Competition: HydroTower team plans on entering three design competitions.
Entrance deadlines are specified outside the requirements section and are located in the
Design Competition sub section.
3. Hydroponics
This section details the basics of hydroponics such as various growing methods, and various
advantages and disadvantages to each growing method mentioned. Some of the advantages and
disadvantages are in regards to growth times, ease of use, portability, maintenance, and complexity.
There are many advantages of having a soilless medium to grow plants. Since no soil is
needed and the replacement medium does not grip the roots like soil does, the plants can be
transported from one place to another. This will allow for easier access for conducting disease
inspection and treatment, as well as allow for repositioning during growth for greater plant
density, light access, and other minor adjustments. Another advantage of using a hydroponic
system is that the efficiency of plant growth. Nutrients can be delivered to the plant roots as is
described in the next section. Lou Albright, a Professor at Cornell University has been able to
"Deficiency Symptoms Of Elements | Tutorvista.com." Tutorvista.com - Online Tutoring, Homework Help for M ath, Science,
English from Best Online Tutor. N.p., n.d. Web. 05 Dec. 2010. <http://www.tutorvista.com/content/biology/biology iv/plant-nutrition/deficiency-symptoms-elements.php>.
10
achieve harvests of head lettuce within 35 days after seeding and produces 58 heads per
square foot, per year (approximately 400 tons per acre per year)7 . This is compared to average
yields of head lettuce being ready for harvesting in 70 to 80 days after seeding 8 and producing
17 tons per acre9 per year. While these numbers are quite significant, one must remember that
hydroponic systems allow for year-round production, and are not generally exposed to harsh
outdoor environments. Figure 3 10 shows the benefits of hydroponics in the area of reducing the
number or resources used in growing plants. In a conventional soil system, water reaching plant
roots is dependent upon the soil type, which at times can lead to waste of water. However, water
is controlled in HydroTower thus reducing the amount of water both used.
A brief summary of the benefits of using hydroponics is the growing time is decreased by
over fifty percent, the amount of nutrients and land used is decreased by over 75 percent, and the
total water used is decreased by almost ninety percent.
"BEE Faculty - Lou Albright." Department of Biological and Environmental Engineering. N.p., n.d. Web. 05 Dec. 2010.
<http://www.bee.cornell.edu/cals/bee/people/profile-albright.cfm>.
Sanders, Douglas C. "Lettuce Production." North Carolina Cooperative Extension: Home. N.p., n.d. Web. 05 Dec. 2010.
<http://www.ces.ncsu.edu/depts/hort/hil/hil-11.html>.
Jackson, Louise, Keith M ayberry, Frank Laemmlen, Steve Koike, Kurt Schulbach, and William Chaney. Iceberg Lettuce
Production in California. Vegetable Research and Information. University of California, n.d. Web.
<http://ucanr.org/freepubs/docs/7215.pdf>.
10
"Cityscape Farms: Soilless Farming." Cityscape Farms: Home. N.p., n.d. Web. 05 Dec. 2010.
<http://www.cityscapefarms.com/soillessfarming/>.
11
3.2.2.Continuous drip
11
12
"Dual Flow Hydroponic System Ebb and Flow NFT." Hydroponics Supplies Darlington County Durham. N.p., n.d. Web. 05
Dec. 2010. <http://www.secretgardenhydroponics.co.uk/product/Dual_flow_01-015-005>.
"Pros and Cons of Ebb and Flow Hydroponics | Easy Hydroponics." Hydroponics | Easy Hydroponics. N.p., n.d. Web. 05 Dec.
2010. <http://www.easyhydroponics.net/pros-and-cons-of-ebb-and-flow-hydroponics.html>.
12
The continuous drip method of a hydroponic system is one where the nutrient solution is
fed at a small rate onto the top of the roots of a plant through a drip nozzle where gravity allows
the small amount of solution to flow over the roots.
An advantage of using the continuous drip method is that the nutrient solution does not
need to be aerated because the roots are constantly covered with a thin film that allows for air to
penetrate and reach the roots. However, a disadvantage of this system is that the drip nozzle
needs to deliver one drop at a time, it is quite possible for the nozzle itself to become clogged.
The need to manually unclog a nozzle could have a negative impact on the low maintenance of
the HydroTower.
3.2.3.Float
The float method of a hydroponic system is one where the nutrients are simply being
circulated in some type of reservoir. On top of the reservoir is a flotation device that holds the
plants. There are holes in the flotation device that allow the roots to grow into the water. The
circulation of the water is typically performed by submerged pump in the corner of the
apparatus.
13
"Build Your Own Hydroponics System | BGHydro." Hydroponics | Hydroponic Supplies. N.p., n.d. Web. 05 Dec. 2010.
<http://www.bghydro.com/bgh/static/articles /0806_byos.asp>.
13
An advantage of using the float method is that it is one of the simplest systems to
implement because the nutrients do not need injection into the water. Instead, a slow circulation
and aeration of the water is provided by the pumps.
Some disadvantages of using this system are that the roots of the plants will not have full
access to the open air. As a result, the nutrient solution will need to be aerated to provide proper
oxygenation to the roots of the plants. Furthermore, this system is not as fast as some of the
other alternatives as a result of the aeration problems.
3.2.4.Aeroponics
The aeroponic method is where the plants are held suspended by some apparatus while
the nutrient solution is sprayed onto the roots. Some further variations of aeroponics include
spraying constantly, spraying for a few minutes per hour, etc.
14
14
An advantage of using an aeroponic system is that the roots receive more oxygen than the
other methods due to the naturally aerated nutrient spray, and the roots exposed roots. As a
result, this method yields some of the fastest growing plants in hydroponic systems.
A disadvantage of this system is that the roots of the plant need to be exposed to the open
air which means that a base medium can not obstruct airflow to the roots. Growing mediums
capable of providing sufficient airflow to the plant roots will not allow sufficient grip for the
roots in order to support the plant. As a result, separate mechanisms are needed to either suspend
the plant, or provide enough support to keep the plants from falling over.
Hydroponics Growing Systems Explained One by One." Hydroponics Gardening - Start a Small Garden Indoors- Helpful
Guide. N.p., n.d. Web. 05 Dec. 2010. <http://www.jasons-indoor-guide-to-organic-and-hydroponicsgardening.com/hydroponics-growing-systems.html>.
15
growth speed and availability in the biology department. These seeds were first placed in a
plastic bag between a moist paper towels for five days in order for germination to occur. The
germinated seeds were then transplanted to plastic cups with a water nutrient system that is
further described in the Nutrient section of this report. Soybean seedlings were placed in two
cups and radish seedlings were placed in four cups for a total of six cups. Cups 1 and 2 used two
times the normal concentration Hoaglands Solution. Cups 3 and 4 used 50% concentration
Hoaglands solution. Cups 5 and 6 used the normal 100% solution Hoaglands Solution is the
standard liquid nutrient used to feed plants in a hydroponic system. This solution consists of 12
elements dissolved into water to supply all of the plants needs and is again discussed in the
Nutrients section of this report.15 The table below tracks the growth over three weeks.
Table 2: October hydroponic experiments with soybeans and radishes
#
1
2
3
4
5
6
Type/Hoaglands%
Soybean/200%
Radish/200%
Radish/50%
Soybean/50%
Radish/100%
Radish/100%
The graph below represents the hydroponic growth over three weeks. Five out of the six
plants show a quality rate of growth.
16
Week 1
Week 2
Week 3
Plant Number/Hoagland %
Figure 8: Hydroponic grwoth over 3 weeks with 2 soybean plants and 4 radish plants
In three weeks, only plant one showed no growth. The two soybean plants, numbers four
and six, showed the highest growth rates. The radishes showed a lower but still comparable
numbers between plants. The above results would indicate that 50% Hoaglands solution is the
best choice to grow plants. However these results may be deceiving due to the fact that these
experiments were not carried out over the full life cycle of the plants. Results will need to be
confirmed during Engr 340 to show that 50% Hoaglands solution is in fact detrimental to the
overall growth of the plants. In the second week, three more soybean plants and three more radish
plants were started. Each of these plants were placed in 100% concentration Hoaglands solution.
The results are displayed in the table below.
Table 3: October hydroponic Experiment #2
Type/Hoagland%
Week 2 (g)
Week 3 (g)
Soybean/100%
4.2
6.8
Soybean/100%
4.64
7.4
Soybean/100%
4.89
6.8
Radish/100%
4.32
5.7
Radish/100%
3.55
4.83
Radish/100%
4.26
5.93
17
Week 2
Week 3
Figure 9: Hydroponic growth over 2 weeks with 3 soybean plants and 3 radishes
The above graph shows that the weight of some of the soybeans nearly doubled.
The radishes showed a slightly low speed of growth. These results confirm that plants can
be grown in Hoaglands solution and thus Hoaglands solution will be used in
HydroTower. However, there were some signs of fatigued growth on many of the plants.
The pictures below show the soybean and radish plants, respectively. The next two pictures
following the week 2 growth pictures show the beginnings of iron deficiency. This is indicated by
the curled leaves and slightly brown color.
18
19
20
reservoir for growing plants will be beneficial for implementing the control system. Having a
separate reservoir inside HydroTower allows for filtering of foreign materials out of the system
(eg: plant leaves or root debris). Speed of growth using this system meets the requirements the
Team set. Lastly, with the flood and drain system, little resources are wasted due to a water
recycle system.
21
22
program and operate basic functions of the HydroTower even if the instruction manual was not
read by the user.
HydroTower will use a touch screen interface for the UI because of the previously
described advantages. The next decision to make is on which specific touch screen LCD to
implement because all requirements must be met. Hence, cost is a large factor in selection of a
touch screen LCD. Since it was decided that the HydroTower will use an Arduino microcontroller
(discussed in the Data Management and Processing section) to run the higher level automation
and UI program code, the touch screen chosen needs to be compatible with this platform.
Outlined in the table below are three alternatives that will satisfy the needs of the touch screen
device.
Table 4: Different options for touch-screen devices
Device/
Screen
Manufacturer
Size
Nuelectronics16
BLTFT240320PLUS17
TouchShield Slide 18
Resolution
Support
Price
2.8
QVGA
Datasheets
$57
3.2
QVGA
Datasheets
$60
3.2
QVGA
Datasheets, Larger
user community
$175
Availability
Sold Out
(as of 11/30/2010)
Sold Out
(as of 11/30/2010)
Good
When comparing these alternatives, it is hard to see a clear choice that is superior to the
rest. The TouchShield Slide would prove to be a more reliable option but is also the most
expensive, costing almost three times more than the competition. The TouchShield Slide device,
however, does provide the clearest documentation, providing sample code, and support to make
development easier. The BL-TFT240320PLUS is also a possible option because the the BLTFT240320PLUS has the same 3.2-inch screen as the TouchShield Slide but has a lower price.
16
17
18
"2.8 TFT Color LCD,touch Screen Shield V1.2 for Arduino 168/328 - 35.00 : Nuelectronics.com, Arduino Freeduino
Projects." Nuelectronics.com. N.p., n.d. Web. 05 Dec. 2010. <http://www.nuelectronics.com/estore/index.php?main_
page=product_info&cPath=1&products_id=19>.
"BL-TFT240320PLUS V2." Circuit Ides Design. N.p., n.d. Web. 05 Dec. 2010. <http://www.circuitidea.com/dev-board/BLTFT240320PLUS-V2.html>.
"Liquidware : TouchShield Slide." Liquidware : Open Source Electronics. N.p., n.d. Web. 05 Dec. 2010.
<http://www.liquidware.com/shop/show/TSL/TouchShield Slide>.
23
Unfortunately, the BL-TFT240320PLUS overall is a less feasible option since it is more difficult
to acquire. This shield only has one listed supplier, www.thaieasyelec.net19 , who lists the product
as sold out as of November 30, 2010. The fact that Nuelectronics touch screen is also sold out
disqualifies it from being a viable alternative. Due to these factors, the HydroTower will include
the TouchShield Slide.
19
Arduino - 3.2 Inch TFT Touch Screen with Arduino Interface V2." ThaiEasyElec.net. N.p., n.d. Web. 05 Dec. 2010.
<http://www.thaieasyelec.net/index.php/Arduino/3-2-inch-TFT-Touch-Screen-with-Arduino-Interface-V2/p_68.html>.
20
Arduino - HomePage. N.p., n.d. Web. 05 Dec. 2010. <http://arduino.cc/en/>.
24
along with verifying the system reservoirs are properly setup. The next program function will be
the general function that will handle the water pumping and nutrient replenishment in the system.
This is shown in Figure 15.
Welcome
Set Date/Time
Check Nutrient
And Water Levels
Low Levels
Prompt to
Address
Reservoir
Levels
Levels OK
Prompt to Start
Plant Cycle
No
Enter Sleep
mode
Yes
Begin Growth
Cycle
Program
25
Begin
X=1
Flood Level X
Wait while
Roots Soak
Increment X
Drain Level X
Check Nutrient
Concentrations
Low Nutrients
OK
No
Calculate and
Inject Make-up
Nutrients
All Levels
Watered?
Yes
End
The User Interface on the touch screen will need to give several options and controls over
the HydroTower system. The high level view of this menu is shown in Figure 16. From here the
user can control the lighting and pumping schedule of the HydroTower. Also, the user can let the
system know that they have added or removed plants from the system. Another menu provides
the user a way to read and address maintenance alerts.
Status Screen
Scheduling Editor
Add Plants
Maintenance Alert
Manager
26
4.1.4.1.
Water Flow
The first system will manage the flow of water to the plants. At the current stage in the
design, two different delivery methods are proposed. The first method uses flood and drain to
soak the plant roots in water for 15 minutes every four hours 21 . The second method uses nozzles
to deliver a controlled amount of water to the roots of the plants. In both methods a pump will
drive the water through the pipes. The Arduino microcontroller will have programmed times to
drive the pump in either method. The decision for which method to use is dependent on the result
of the research currently being conducted for which nutrient injection method the HydroTower
will use, this research is discussed in Mechanical Nutrient Systems section.
4.1.4.2.
Lighting System
A second control system in the HydroTower will control the light to the plants. Plants
require two frequencies of light, 650nm and 450nm. There are several common light sources used
in hydroponic systems, including LED, fluorescent, and halogen. The LEDs chosen for
HydroTower specifically match the required light for plant growth. The LEDs need to deliver
brighter light than is used in average applications of LEDs. For this reason, the lighting system
will utilize 30 1W LEDs. This number was calculated in MathCAD and is shown in Figure 5.1.
21
Resh, Howard M. Hydroponic Food Production. 6thth ed. Mahwah, NJ: NewConcept, 2004. Print
27
The microcontroller will illuminate the LEDs based on a summer daylight schedule,
allowing for a shortening day, since this is a trigger to some fruiting plants to bear fruit because a
shortening day indicates fall and the onset of the end of the growing season. The lighting system
will also allow for the LEDs to be shut-off when there is ample light being supplied externally.
4.1.4.3.
Temperature Control
The next control system will be responsible for maintaining the temperature of the water
and air in the system. The microcontroller will take in voltage information from thermocouples
installed in HydroTower, and turn on and off separate heaters accordingly to regulate the
temperature required. The system will likewise enable exhaust fans installed in the HydroTower
to bring in cool air from the outside environment if the inside temperature rises above the
allowable range specified in Temperature of the Mechanical section. The Simulink model below
shows the preliminary air temperature control system.
The air temperature control system will include a thermostat that will monitor the air
temperature inside the HydroTower. The maximum temperature allowed in the system is 80F.
Above this temperature the heater will shut off allowing for cooling from the exhaust fans. The
minimum temperature allowed is 70F. Below this value the heaters will turn on. Influences on
this system include the conductive and convective heat transfers from outside the HydroTower
via the walls and the fans, but more analysis will be performed during Engr 340.
The water temperature control system will be nearly the same as the air temperature
control system. However, in this case, there will be no influence from exhaust fans. The desired
water temperature will be the same as the air temperature (70F). This system will include a
separate thermostat. To control the temperature of the water, a water heater will be employed
which will turn on at the minimum temperature and turn off at the maximum temperature via
28
thermostat control. The dissipative conduction and convection will provide the cooling of the
water, and the water heater will provide heat.
The temperature control system is currently being expanded to provide a qualitative cost
analysis of running the heaters in the system. With this analysis, the microcontroller will be able
to minimize costs of the system whilst changing the thermostat maximum and minimum values to
be used in Engr 340.
4.1.4.4.
Nutrient Injection
The Arduino microcontroller will decide when and how much concentrate to add based
on one of two methods. The open-loop method includes a schedule that is determined based on
how many plants are in the system and a predetermined rate of consumption for each nutrient.
29
The closed-loop method involves determining what the concentration of nutrients is in the
recycled water and compensating to replenish absorbed nutrients. The closed-loop method is
more accurate and represents an ideal solution for HydroTower, however currently there is no
proven method to determine the necessary concentrations in real time, and such issues are
discussed in the Nutrient System portion of the Mechanical Systems section. The first method has
the benefit of being simpler to implement, however it cannot respond to unpredictable situations.
Currently the team is pursuing both methods to determine which one is feasible for the final
design direction of HydroTower, which is also discussed in the Nutrient System portion of the
Mechanical Systems section.
4.1.5.Lighting System
The HydroTower Lighting system will consist of Light Emitting Diodes (LEDs) which
will be mounted on the ceiling levels of the HydroTower to provide light to the plants. Given the
calculation in section the Lighting System section, 30 1W LEDs will be used. As can be seen in
Figure 20 below, the wavelength of light that plants use is only in two specific electromagnetic
frequencies between 425nm and 660nm. Therefore, the two frequencies for the HydroTower
LEDs will be red and blue.
The LEDs needed were donated by SoundOff Signal Inc. The acquired LEDs will need
heat sinks to be designed to run them at 1W such that heat can be dissipated away from the LEDs
22
"PHOTOSYNTHESIS." Estrella M ountain Community College. N.p., n.d. Web. 05 Dec. 2010.
<http://www2.estrellamountain.edu/faculty/farabee/biobk/BioBookPS.html>.
30
for proper operation. The best option for these LEDs is to run them at 1W with an ambient
temperature of 80F, and maximum junction temperature of 257F. This means that using copper,
heat sinks in the shape of a square (notches cut for leads as in datasheets23, 24 ) will require a side
length of up to 4 centimeters for red and 6 centimeters for blue. Full analysis of the selected red
and blue LEDs are contained in Appendix C and D.
Component
Voltage
Current
Watts
Base (x1)
Pump
24V
3A
72W
Arduino
5V
0.5A
2.5W
Valves
25V
.5A
12.5W
Heater
25V
3A
75W
LED's
12V
2A
24W
Exhaust Fans
12V
0.25A
3W
Max Power
243W
The power system will supply power not only for the base unit and the first growing unit,
but also for a second growing level. The largest power draw in each of the growing units will be
the LED lighting. Each unit will need sturdy electrical connections to ensure stable operation and
stand up to repeated assembly and disassembly.
23
"LR W5SM ." OSRAM Opto Semiconductors - Product Catalog. N.p., n.d. Web. 05 Dec. 2010. <http://catalog.osramos.com/catalogue/catalogue.do?favOid=000000000003f86200020023&act=showBookmark>.
24
"LD W5SN." OSRAM Opto Semiconductors - Product Catalog. N.p., n.d. Web. 05 Dec. 2010. <http://catalog.osramos.com/catalogue/catalogue.do?favOid=000000030002a14801f30023&act=showBookmark>.
31
5. Mechanical Systems
5.1. Requirements
HydroTower mechanical components range from the structure of the housing unit to the
pumping, piping and heating of HydroTower. The specific requirements from the mechanical
systems are based upon heating/heat transfer and the structure/frame for HydroTower.
The plants within HydroTower must be in a temperature range no lower than 40F and no
higher than 85F wherein the optimum temperature is 70F.25 Furthermore, the mechanical
system must maintain the interior of HydroTower at a relative humidity no lower than 30% and
no higher than 70% wherein the optimum relative humidity is 50%. 26 Another aspect of the
heating/ventilation of HydroTower is in regards to the housing of the electrical components and
controls. The current HydroTower prototype design has the electrical housing contained within
the base unit.
5.2. Size
Based upon the objectives and goals for HydroTower, the unit size was developed to fit
within a residential dwelling. Thus, some design specifications were made such that HydroTower
accommodates a range of users from third world countries in villages to apartment dwellers in the
United States or classrooms in schools. Specifically, HydroTower is designed with a 2.5 foot
diameter and is no more than 6 foot tall. The current prototype of the HydroTower is fabricated
from wood provided by Calvin College. Figures 21 and 22 depict the main designs for
HydroTower. While the first built prototype is circular and has a 2.5 foot diameter, the Team has
decided to change the HydroTower structure design to a rectangular module with a short end
length of 32 inches. Figure 22 depicts the next HydroTower structure design. A rectangular
structure was chosen for several reasons. First, while circular shapes are assumed to be more
aesthetically pleasing, a rectangular shape is more functional when placed in a room. The
HydroTower Team rationalized that most likely, the placement of a HydroTower unit would be in
a corner of a room, thus making rectangular a more feasible option. Secondly, in regards to
manufacturing of HydroTower, square and rectangular components are made faster and more
easily. The dimension of 32 inches for the short end was based on standard widths of doors in
houses. Team HydroTower assumed that a HydroTower unit would be situated in a living room
25
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
26
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
32
or den area in a house and/or in a corner of an apartment or other building. Standard widths for
door frames are 34 inches, but Team HydroTower took into account extra clearances.27
27
DoItYourself. What is the Standard Door Fram Width? Nov 30, 2010.
<http://www.doityourself.com/stry/what-is-the-standard-door-frame-width>
33
6 . Precedence has been set by many hydroponic growers as well as other gardeners to use
Hoaglands solution as the nutrient supplements because all of the nutrients found in Hoaglands
solution are found in natural soil and are further known as necessary nutrients for plant growth. 29
The macro-nutrients listed in the first five rows of Table 6 would be added as individual liquidmolar concentrations and directly injected into the water feed stream before the pumping of the
water through the flood and drain process occurred. Such a method would first add the needed
nutrients to the water supply and would secondly adequately mix the water supply and nutrients
before pumping to the plants. For the initial design, the direct injection of the nutrients would be
28
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
29
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999. Ch 30. Print.
34
performed by low-pressure valves. However, as indicated later in this section, since the nutrient
system is still in preliminary designs specific valves and calculations regarding proper mixing
will be performed once a final design direction has been selected. Real time measurements of the
water would determine the amount of nutrient makeup necessary before the water would re-enter
HydroTower for plant feed, thus implementing a recycle stream for HydroTower. The water
measurements would occur in the base unit water reservoir to ensure a clear reading occurs
representative of the entire water system.
Stock Solution
202g/L
236g/0.5L
15g/L
493g/L
80g/L
2.86g/L
1.81g/L
0.22g/L
0.051g/L
0.09g/L
0.12g/L
136g/L
mL Stock
Solution/1L
2.5
2.5
1.5
1
1
1L
0.5
Recycle streams would require water analysis based on both pH and electro-conductivity
(EC)using electrodes measuring the amount of nutrients in the stream. However, electrodes
capable of measuring individual ions from within a solution do not exist thus leading to possible
design changes in the direction of the HydroTower project. As indicated previously, the initial
theoretical design had the objective of measuring and making up the absorbed nutrient in realtime. However, the initial theoretical design also intended to use EC electrodes to measure each
individual ion, which is not possible to do for two reasons. No electrodes exist capable of
measuring the ions wherein the ions are in solution with other ion nutrients. Table 7 30 contains the
electrodes capable of measuring ions, but also shows the problem in that ions have interferences
30
35
in the Hoaglands Solution. For an example of interference, in Hoaglands Solution one of the ion
nutrients to measure is NO3 , but one of the interferences for NO3 is ClO4 . Cl2 is one of the miconutrients, and when ClO4 dissociates in solution, Cl2 is left, thus inhibiting the NO 3 electrode. The
mentioning of dissociation of ions in solution is what leads toseveral alternative solutions or
directions for HydroTower and measuring the nutrients in real-time. Currently, two alternative
designs are occurring t along a parallel time basis. One design alternative will become the new
HydroTower design direction by January 2011.
Table 7: Electrodes and interferences
Model Ion
ISE20B Ammonium
NH4 +
ISE21B Bromide
BrISE22B Cadmium
Cd2+
ISE23B Calcium
Ca2+
ISE24B Chloride
ClISE25B Copper
Cu2+
ISE26B Cyanide
CNISE27B Fluoride
FISE28B Fluoroborate
BF4 ISE29B Iodide
IISE30B Lead
Pb2+
ISE31B Nitrate
NO3 ISE32B Perchlorate
ClO4 ISE33B Potassium
K+
ISE34B Silver/Sulphide
Ag+/S2ISE35B Sodium
Na+
ISE36B Surfactant
X+/XISE37B Water hardness
Ca2+/Mg2+
ISE50B Ammonia
NH3
ISE51B Carbon dioxide
CO2/CO3 2ISE52B Nitrogen oxides
NOx
Sensor
polymer
Range (M)
5.10-6 - 100
Range (ppm)
0.1 - 18000
C
0 - 50
Interferences
K+
pH
4 - 10
Electrolyte
NaCl
solid state
5.10-6 - 100
0.4 - 79900
0 - 50
KNO3
solid state
10-7 - 10-1
0.01 - 11200
0 - 50
polymer
5.10-6 - 100
0.2 - 40000
0 - 50
solid state
5.10-5 - 100
1.8 - 35500
0 - 50
1 - 12
KNO3
solid state
10-8 - 10-1
0.00064 - 6350
0 - 50
2 - 12
KNO3
solid state
5.10-6 - 10-2
0.13 - 260
0 - 50
11 - 13
KNO3
solid state
10-6 - sat.
0.02 - sat.
0 - 50
OH-
5- 8
KCl
polymer
7.10-6 - 100
0.1 - 10800
0 - 50
2.5 - 11 (NH4)2SO4
solid state
5.10-8 - 100
0.006 - 127000
0 - 50
0 - 14
KNO3
solid state
10-6 - 10-1
0.2 - 20700
0 - 50
3- 8
KNO3
polymer
7.10-6 - 100
0.5 - 62000
0 - 50
polymer
7.10-6 - 100
0.7 - 99500
0 - 50
2.5 - 11 (NH4)2SO4
polymer
10-6 - 100
0.04 - 39000
0 - 50
Cs+, NH4 +
2 - 12
NaCl
solid state
10-7 - 100
0 - 50
Hg+, Hg2+
2 - 12
KNO3
glass
10-6 - sat.
0.01 - 107900
0.003 - 32000
0.02 - sat.
0 - 50
5 - 12
NH4Cl
polymer
10-5 - 5.10-2
1 - 12000
0 - 50
2 - 12
KCl
polymer
10-5 - 100
5 - 10
KCl
0.01 - 17000
0 - 50
volatile amines
11 - 13
NH4Cl
4.4 - 440
0 - 50
0 - 50
KNO3
KCl
2.5 - 11 (NH4)2SO4
36
The first alternative to the flood and drain system with the direct injection of nutrients is
an aeroponic/spray hydroponic technique. Such a system would change the design of
HydroTower in that the spray nozzles would direct the flow of water to plant roots and
Hoaglands solution would be added directly into the water spray. One objective of the spray
technique would be to minimize the amount of waste water from such a process of spraying the
plants throughout the day. Despite a change in design for HydroTower, the Team is maintaining
the initial goals of providing sustainable methods for growing produce and other plants. The need
to eradicate waste water left over from watering/feeding the plants is environmentally unsound in
two ways. First, the waste water would contain the nutrients, which should not be introduced
directly into a water treatment system (eg: should not be poured down a residential drain). It is
not environmentally appropriate to implement a design which would require users to dispose of
the chemical waste through residential water/drainage systems. While the nutrients are found
naturally in soil and nature, introducing higher concentrations and having the only method of
disposal as residential drains does not align with the goals or objectives of HydroTower as being
a sustainable design. Secondly, wasting water is not efficient for the overall delegation of water
as a resource and is thus not a feasible option for the HydroTower design project.
The second alternative for the flood and drain system with the electrode analysis would
be to research solutions for analyzing individual ions in the water nutrient system. The premise
behind the second design alternative is based upon knowledge that when compounds are in
solution, ions dissociate and are thus individual elements. For example, NH3 is a compound in
Hoaglands Solution, but in theory, the second alternative would use an electrode which measures
for N elements. Electrodes for N, Mg, Ca, K and possibly Fe would be used in research to
measure the conductivity of the water solution and analyze for specific algorithms to add the
makeup nutrients. Professor Doug VanderGriend will also be assisting team HydroTower in
researching possible ways to isolate the dissociated elements in solution using electrodes much
like the initial design intended. Furthermore, Professor VanderGriend would assist in analyzing
the data collected from the electrodes to see if any empirical relations may relate the element ions
to the amount of nutrient in the water solution. Said research will begin at the very end of first
semester and will continue into January 2011. However, a time limit on the research and design
of electrodes capable of analyzing the water solution after which the first design alternative will
be implemented fully.
A final design direction will be selected by the middle of January 2011.Currently, the
Team has been split into two sub-groups, one group looking into the first alternative of the spray
system and the second sub-group focusing on research for the electrodes. Until the final design
37
direction is selected, the team will remain working on the two alternative design options. Should
one design become very apparent as the best alternative, that design will become the new final
design direction. Delegation of time and efforts has been a 50-50 split between both design
alternatives, but as the project continues, one design alternative will become the main focus in
which case delegation of time and effort will become 90-10 (90% of the time being on the final
design direction and 10% being towards ensuring the correct design direction was chosen).
5.4. Psychrometrics
Mechanical design of HydroTower for optimal plant growth includes humidity and
temperature control of the water and nutrient system. The environmental conditions for plants are
optimal when relative humidity is about 50% and temperature is 70F. 31
5.4.1. Humidification
From a biological standpoint, if humidity is too high, and condensation forms on plant
leaves, the plants become susceptible to fungus and disease.32 Thus, the mechanical design of
HydroTower includes compensation for air flow and ventilation to regulate the humidity within
the HydroTower growing structure. Furthermore, if the relative humidity is too low, plants will
close their stomatas, which are how plants intake CO 2 and release O2. Should the humidity
become too low, a humidifier will turn on via the control system for psychrometrics and will
subsequently add moisture to the air within HydroTower.
Initially, the mechanical designs were going to measure humidity with a hygrometer and
then have the regulation of air flow controlled by fans and a venting system with mechanical
flaps capable of different degrees of opening/closing. However further analysis of alternative
design options showed that a more complex and expensive humidity control system was not
necessary to meet the design requirements. For example, below is a list of the alternative designs
for the humidifiers/dehumidifiers, four humidifying systems researched and then analyzed
included the following.
1) Steam humidifiers which boil water to release steam into the air
2) Impeller humidifiers which move water through a diffuser to make very fine water
droplets in the air
31
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
32
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
38
"Cotton Rope | Twisted & Braided 1/4 - 1 Inch Sizes." KnotandRope.com. N.p., n.d. Web. 5 Dec. 2010.
<www.knotandrope.com/store/pc/Cotton-Rope-c6.htm>.
34
"Wick Humidifier - Google Search." Google. N.p., n.d. Web. 05 Dec. 2010. <http://www.google.com/search?q=wick
humidifier...>
39
12cfm of air flow (cited in bibliography page DC Fan Data Sheet and NMB-Mat DC Axial Fan).
Equation 6.4.1 shows the main equation used to calculate the needed air flow rate while full
calculations are contained in Appendix E. The result of the calculation showed that one fan
capable of 12cfm would be enough to maintain the proper humidity within HydroTower since
the calculated air flow rate was 5.1 cfm based on the previously mentioned conditions.
=
Equation 6.4.1
Variable
Variable Name
Units
Cfm
Gal/min
Providing HydroTower remains with the flood and drain system along with the current
prototype model as the final design direction, HydroTower will implement a wick humidifier
due to the low cost and simplicity of implementing the design both in prototyping and in
manufacturing. The wick humidification system will work well for ensuring that the air within
HydroTower remains at about 50% relative humidity because as the air becomes more humid,
the water requires more energy to evaporate and the same principle applies for dry air (easier to
evaporate water when air is less humid). Thus, the wick humidification system works by natural
evaporation of water from the wick. Specific design of the wick humidifier will occur during
spring semester once the final design direction is known. However, one specific issue with wick
humidification to be addressed during the design phase is that wick humidification will be to
ensure that condensation does not occur within the HydroTower. Thus, as previously mentioned,
the two fans will be installed on each growing level on either side of HydroTower. The wick
humidifier will have a control system based on readings from a hygrometer. For the control
40
system, if the humidity is too high the fan furthest to the water input flow (hence, the fan without
the wick in front of it) will turn on. Should the humidity remain high, both fans will turn on. The
fail-safe method to ensure humidity can be lowered within HydroTower will be looked into
further during the spring semester. The table below shows a more visual summary of how the
fans will turn on and off via the control system and hygrometer readings.
System Reading
Off
On
On
Off
On
On
To be determined in
To be determined in
humidity out of
spring semester
spring semester
or low
range
5.4.2.Temperature
Control of the temperatures of both water and air are necessary to optimize plant growth,
however, hierarchically, the water temperature is more important. Such a decision is based on
the rate of heat dissipation from the water and the rationalization that the air temperatures will be
relative to the ambient air in a room of a residential area. The optimum growing temperature for
most plants is 70F. 35 Using the waste heat from the electrical components has been discussed as
a method to control the heat of the water. However, since the Team is still working towards
finalizing a design direction, specific mechanical design and analysis for the temperature control
system have been placed on hold until a final design direction is chosen.
35
Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed. New York: W.H. Freeman and Worth
Company, 1999.728-730. Print.
41
6. Frame Structure
The responsibility of the frame and structure design of HydroTower is one portion of the
mechanical responsibilities of Team HydroTower and specifically falls to Brian DeKock and
Jacqueline Kirkman. The frame and structure design must fit within the objectives of a modularized
unit which is light weight and easily transported when emptied from plants and water. The frame
structure must also be sturdy enough to be operable under safe conditions. Specific quantities and
objectives on the safety regulations for HydroTower have not yet been quantified but will be
addressed once a final design direction has been chosen. Furthermore, specific requirements on the
weight and transportability of HydroTower are estimated thus far in the design process. This section
addresses the specifications of the frame of HydroTower including the size, safety, mobility,
manufacturability and appearance of HydroTower.
DoItYourself. What is the Standard Door Fram Width? Nov 30, 2010.
<http://www.doityourself.com/stry/what-is-the-standard-door-frame-width>
42
The modular and stackable design provides the user with adaptability and portability such
that a user may choose how many plants are grown and the overall configuration of
HydroTower. For example, a user may purchase the base unit and one growing level, one base
unit and two growing levels. Many possibilities for base unit and growing levels exist, but the
constraints are that at least one base unit and one growing level are necessary for function while
the maximum is two growing levels supported on one base unit.
6.3 Mobility
The HydroTower must be mobile enough to be moved by one average-sized adult person
regardless of gender. Mobility of HydroTower is very important to the overall success of the
project. HydroTower will be purchased as a fully assembled base unit with one growing level.
Additional growing levels may be purchased individually. However, all modular components
must be easily moved from the store to the users residence and must be easily set-up by the
user. Initial market research has confirmed HydroTower will need to produce food for a family
but will need to fit in a corner of a room. The final design of HydroTower will determine the
overall mobility of the product instead of the mobility determining the design since the Team has
chosen overall function as a higher priority than mobility. However, mobility is still a factor in
design decisions and will be used more during second semester and final design selections.
6.4
Ease of Build
The relative ease of producing HydroTower for mass production is a high priority for
both the design and prototype of HydroTower. While the measures of success for HydroTower
43
in May 2011 only define a working prototype, planning for full scale production of HydroTower
is a priority in the design and decision making processes. Hence, the design of HydroTower
must not only meet the direct requirements as established by the group for success, but must also
allow a transfer to an assembly line production method. For example, each HydroTower will be
a modular component off the base unit. Thus, each growing level will be manufactured the same
way. The growing levels of HydroTower will be stackable via interlocking metal rectangular
tubes wherein the tubes for the growing levels fit within the tubes for the base unit. Figure 10
depicts the exploded assembly version of the HydroTower. The design must be easily transferred
to an assembly line and consideration of assembly during final design selection will assist the
Team in knowing what methods to employ for manufacturability.
44
45
6.5
Aesthetics
Part of designing in engineering is to make a product that not only serves its purpose, but
also is pleasing to the eye. Marketing for HydroTower is for in-home and residential usage, thus,
the HydroTower will be placed in the house or apartment and will need to coordinate with
interior dcor. Some brainstorming has concluded HydroTower could be manufactured in
several colors or could have some patterns on the exterior such that users could select the design
which best fits their style and dcor. Aesthetics will be a strong selling point for HydroTower as
a product. Successfully blending function and aesthetics will be a key component in selling the
HydroTower. While function of HydroTower is hierarchically a higher priority than aesthetics, if
HydroTower does not meet the aesthetic appeal to potential customers the overall success of
HydroTower as a product will be lessened.
46
7. Business Analysis
7.1. Market Research
7.1.1.Customer
HydroTower involves minimizing space and maximizing efficiency to grow plants in a
non-commercial environment. The market for this type of product would be anyone who does not
have gardening space to grow vegetables and plants. More specifically, HydroTower is being
targeted at women who have a family at home and need fresh produce for their children. The
table below shows the 2006-2008 statistics from the United States Census Bureau.
Table 11: Census Bureau 2008 population 37
Between the ages of 25 and 39 there are over 30 million women living in the United
States. If only 1% of the population of women in the United States buy at HydroTower within the
first two years over 60,000 units could be sold each year.
Growth in this market could increase as larger questions are raised about the safety of
consumers in commercial food production. Additional growth could be driven by the growing
number of people moving into cities and living in apartments and high rise condominium towers.
HydroTower presents the perfect solution for the consumer who is looking to eat fresh produce
whose quality can be ensured all while reducing the carbon footprint of large scale food
production.
7.1.2.Overview of Market
The current hydroponics market is a growing market as perceptions shift towards the need for
new sources of food production. The hydroponic tomato market alone is predicted to grow by
37
http://factfinder.census.gov/servlet/STTable?_bm=y&-geo_id=01000US& qr_name=ACS_2008_3YR_G00_S0101&ds_name=ACS_2008_3YR_G00_
47
over 50% from 2007 onward. 38 In the past hydroponic gardening has often been associated with
marijuana cultivation. Many people are unaware that hydroponics can be used to grow many
types of herbs and vegetables indoors with incredible efficiency. Some current hydroponic
growers and designs can be seen in the competitor analysis section of this business plan. The
HydroTower creates a distinct and new niche in the market for hydroponic gardening. First by
designing a new type of hydroponic grower with the visual appeal that is unseen in the market of
previous hydroponic gardeners will be attracted to this product. The second part of the market
will attract people who have never been interested in hydroponics due to the maintenance and
complexity of the system. HydroTowers user interface and scheduling system will now make it
easier for an individual to grow many plants comparable to that of a home garden.
Brentlinger, D.J. 2007. NEW TRENDS IN HYDROPONIC CROP PRODUCTION IN THE U.S. Acta Hort. (ISHS) 742:3133. http://www.actahort.org/books/742/742_3.htm
48
purchasing produce. The key tradeoff for consumers to consider will be that growing food in the ir
own homes is higher quality and has a greater sustainable/environmental impact over simply
buying from the grocery store. Additionally the HydroTower presents the opportunity to avoid the
growing number of food and produce recalls that have hit multiple regions of the United States.
7.2.1.Entrepreneurs vision of the company
HydroTowers vision is to Feed people, more efficiently, through hydroponics.
HydroTower will be a standalone unit capable of producing plants for feeding a family of four.
HydroTower will reduce the amount of soil, nutrients and water used in growing plants while also
decreasing the amount of fossil fuels used in transporting produce from the farm to the market.
7.2.2.Design Norms
The HydroTower Team has chosen three specific design norms that will help drive our design
decisions and ensure a quality product. The first design norm is stewardship. The HydroTower
team strives to be good stewards of Gods creation by decreasing costs of transportation, fossil
fuels, current food processes. Sustainability and environmental impact will be some of the largest
issues in the 21st century. The second design norm is transparency. We want to be open and
genuine with our customers about the functionality and usability of this product. The third design
norm is trust. Trust is vital in any relationship between a company and a customer. However the
HydroTower Team takes this very seriously given the past perceptions of hydroponic gardening.
The HydroTower team wants to have customers trust that they can feed families with an efficient
and reliable system.
39
40
Howard M . Hydroponic Food Production. 6thth ed. M ahwah, NJ: NewConcept, 2004. Print.
Dalton, Lon, and Rob Smith. Hydroponic Crop Production. Tauranga, New Zealand: NZ Hydrop onics International, 1999.
Print.
50
of the individual hydroponic gardening industry is based off of the internet according to both
Mud Lake Farms and Horizon Hydroponics. Many individuals have posted their own builds and
recommendations on many websites that cannot be found commercially.
7.3.3.Regulatory Restrictions
There are currently no direct regulatory restrictions pertaining to hydroponic growing.
Any regulatory restrictions in place will be on safety features of the HydroTower. The safety
concern and regulation will be in design that combines water and electrical connections. These
regulations are set by the UL, FCC, and CE. Organic farming in the HydroTower will be under
the direction of the organic growing standards set by the United States government. There are
additional local and federal regulations on the cultivation of marijuana that can be grown through
hydroponics. However these ordinances and laws pertain only to the use of marijuana and not to
the use of hydroponic gardening.
41
Smith, Amy. 7 Rules of Design for Low-Tech Engineering. N.p., Oct. 2009. Web. 29 Nov. 2010.
http://www.popularmechanics.com/technology/engineering/gonzo/4273680
51
quality hydroponic and organic hydroponic fruits and vegetables are selling at more than 15% 50% higher than traditional fruits and vegetables. 42
42
Brentlinger, D.J. 2007. NEW TRENDS IN HYDROPONIC CROP PRODUCTION IN THE U.S. Acta Hort. (ISHS) 742:3133. <http://www.actahort.org/books/742/742_3.htm>
52
inexpensive microcontrollers while still maintaining the requirements as established by the Team
to control automation and standard parts that can be easily manufactured and mass produced.
7.4.4.SWOT Analysis
Strengths: Expanding market with many new ideas on hydroponic gardening. People are
more likely to try out ideas and product which are showing up multiple places in different forms.
Weaknesses: Quality reference research material lacking, not organic, untested ideas for
automation.
Opportunities: Many small and startup companies in the industry. This competition will
keep the HydroTower team thinking and working towards the best possible solution.
Threats: Large corporation industrial designs
43
"RotoGro 240 Rotating Garden." HHydro.com. N.p., n.d. Web. 5 Dec. 2010. <http://www.hhydro.com/RotoGro-240-RotatingGarden.html>.
53
The second established competitor is the Desktop Hydroponic System. The Desktop
Hydroponic System is a compact planter that grows small herbs on desk using sunlight or the
artificial light from an office. This product has a strong visual appeal and a low cost of $40. The
weaknesses of the Desktop Hydroponic System are that it has no additional light source and is not
big enough to feed a family. Growing options are limited. 44
The AeroGarden Pro 200 Indoor Tabletop Vegetable Garden is a fully automated system
that is capable of growing multiple types of herbs and vegetables. For $200 the indoor garden
provides everything that is needed to start growing. The weaknesses of this product are that it
lacks growing spaces and still does not have a strong visual appeal. 45
"ThinkGeek :: Power Plant Herb Garden." ThinkGeek. N.p., n.d. Web. 05 Dec. 2010.
<http://www.thinkgeek.com/homeoffice/kitchen/b7d7/?cp g=cj&ref=&CJURL>.
45
"The Indoor Tabletop Vegetable Garden." Hammacher Schlemmer. N.p., n.d. Web. 05 Dec. 2010.
<http://www.hammacher.com/publish/75426.asp#?cm_mmc=CJ-_-2617611-_-3682082-_-Save up to 70% on
Electronics>.
54
7.5.2.Potential Competitors
Biosphere home farming concept generates food and cooking gas, while filtering water.
The concept supplements a familys nutritional needs by generating several hundred calories a
day in the form of fish, root vegetables, grasses, plants and algae. Unlike conventional
hydroponic nurseries this system incorporates a methane digester than produces heat and gas to
power lights, similarly algae produces hydrogen and the root plants produces oxygen, which is
fed back to fish. CO2 is pumped into the plants. It is a closed loop interdependent system. The
system uses waste water and non-consumable household matter and delivers food in return. 46
The strength of this idea is that it is backed by Phillips which is a large company. However the
system is larger than most needs for a family.
46
"Biosphere Home Farming by Philips." Yanko Design. N.p., n.d. Web. 05 Dec. 2010.
<http://www.yankodesign.com/2009/03/17/the-ultimate-recycle-bin-nourishes-as-well/>.
47
"Kitchen Nano Garden." Fast Co. Design. N.p., n.d. Web. 5 Dec. 2010. <www.fastcodesign.com/idea-2010/kitchen-nanogarden>.
55
56
8. Business Financials
HydroTower has been identified as a potential marketing and business opportunity. The business
financials section contains estimates on costs and revenue possible for HydroTower. Professor
Medema of the Business Department at Calvin assisted the HydroTower Team in beginning an
analysis on HydroTower. However, due to the issues faced in selecting a final design direction, much
of the financial analysis will occur during Engr. 340.
The current outlook for HydroTower is to sell modularized levels, the first of which would be the
base unit. Subsequent stackable units could be purchased and attached to the base unit. HydroTower
will also sell refills of the nutrient concentration bottles.
0
0
0
3.79
0
0
0
0
0
3.79
0
0
Description
Provided free to Team by Engr WoodShop
Provided free to Team by Engr WoodShop
Provided free to Team by Engr WoodShop
Provided free to Team by Biology Dept
Provided free to Team by Biology Dept
3.79
repair, replacement and initial purchasing costs. The depreciation expense fluctuates because the
initial purchasing cost and interest is compiled throughout the next two years. The equipment
purchase for the second year and the third are much lower but still exist because the growth of the
company. Interest rates are based on a pessimistic view of the economy. Error! Reference
source not found.The cash flow analysis is solely a prediction and only used as a way to assess
the start up of a potential business. More cash flow analysis will be done in the second semester
when more information can be obtained. In conclusion, based on the assumed number of units
sold, the business will break even around the end of year two and turn a large profit at the end of
year three.
Table 13: Variable and fixed costs estimations for HydroTower
Fixed Costs
Rent on Facility
Renting Equipment for Manufacturing
Taxes
Salaries (manager, 4 employees at 40,000/employee)
Labor of Design (200 hours)
Amount
100,000
200,000
50,000
290000
20000
660,000
15
50
100
30
25
10
10
30
20
75000
250000
500000
150000
125000
50000
50000
150000
100000
1450000
2,110,000
422
58
potential to be profitable. The purpose of the cash flow analysis is to analyze the costs and profit
if a business were formed to design and sell this product to the market.
For this class, the team will be designing a prototype useable in urban residential housing
areas. The cost for the prototype and the final design is expected to differ. During the
prototyping, multiple design considerations cause cost to increase. Designs are perused but later
deemed infeasible. In addition, several components were salvaged from spare parts in the
engineering building to keep the final cost within budget.
59
9. Management
9.1. Project
Since the Team is comprised of two mechanical and three electrical engineering students,
work was delegated to each member according to the strengths each member provides the Team.
Table 9.1.1 shows the work delegated to each Team member. While multiple members of the
Team work together, one member is designated as a Tech-Lead and is thus responsible for the
overall organization of their specific task area.
Table 14: Tech-Lead positions for the HydroTower Team
Task
Business
Big Idea Project
Elevator Pitch
Engineering Business Plan
PPFS
Project Requirements
Research
Feasibility
Design
PCB
Power System
User Interface
Automatic Plant Care Program
Air Quality Controls
Water Quality Controls
Structure Design
Air Flow
Water Piping
Heating/Cooling
Chemical Distribution
Tech Lead
Nathan
Brandon
Jacqueline
Brenton
Brian
Jacqueline
Brandon
Brandon
Nathan
Brenton
Brenton
Nathan
Brian
Jacqueline
Brian
Brian
Jacqueline
Brian DeKock was placed in charge of the overall structure and manufacturing of
prototypes. Brian has the most knowledge and passion for building in the
woodshop and finding ways to implement designs using scraps from the wood
and metal shop. Brian was also placed in charge of the heating/cooling system as
well as the water piping. Each of the heating, cooling and piping systems involve
60
integration of components into a prototype system. Thus, Brian was the best fit
for each of his task delegations.
Brenton Eelkema was in charge of developing the business overview and WBS
creation. In addition he worked to build and measure preliminary experiments in
hydroponics. Brenton took Brandons place as the representative of HydroTower
in the Elevator Pitch, a competition put on by the Business Department and
Entrepreneurship Club at Calvin. HydroTower took third place out of 12
competitors, earning $300 for the Teams budget.
Jacqueline Kirkman was delegated the air flow system and the chemical
distribution system. Jacqueline has the most experience of the group members in
chemical systems and was thus the logical choice. Psychrometrics and air
ventilation were also assigned to Jacquelines responsibilities. Jacqueline has
further acquired the position of Project Manager due to her organizational and
detail-oriented management skills, thus other tasks are delegated to Jacqueline
which fall under team management but are not specifically listed here.
Nathan Meyer was delegated to manage the software design and implementation.
Nathan is also responsible for the design of the nutrient control logic. Nathan
presented to the Big Idea Contest judges since HydroTower was selected in the
final four applicants. The Big Idea Contest was a competition hosted by the
Enterprise Center at Calvin; HydroTower made it to the final four but did not win
the grand prize of $200. Nathan has been assigned to maintain the team website
and update it as content becomes available.
Brandon Vonk has the responsibility of designing the power systems and printed
circuit boards (PCBs) along with the lighting system for HydroTower. Brandon
has the most experience with PCBs and thoroughly enjoys working wit h power
systems, making him the best choice. Brandon has also been delegated the
responsibility of maintaining an updated team budget.
61
62
9.3. Budget
Brandon Vonk is responsible for maintaining an updated budget for the team.
Maintaining the budget requires updating both the working budget and the projections for the
budget in MS Excel. Completing the necessary order forms when necessary is also contained
within the responsibilities for maintaining the proper budget. Current expenses and more cost
details are contained in Section 8.
9.4. Website
Nathan Meyer is responsible for both updating and maintaining the team website. Nathan
is the most familiar with programming and the DreamWeaver software and was thus the most
logical choice for the overall upkeep of the website.
9.6. Resources
Listed below are the key resources contributing to the success of Team 2.
Professor David Dornbos, taught the Team how to mix Hoaglands solution and
gave access to the Biology departments plant laboratory and gave Team 02
seeds to begin experimenting hydroponic growth. Has been a continuous
resource for knowledge about plant growth and optimization.
Professor Uko Zylstra, connected the Team with Mud Lake Farms (Kris and
Steve Haitsma).
Steve & Kris Van Haitsma, owners of Mud Lake Farm, provided the Team with
information about hydroponic growth and gave the Team a tour of Mud Lake
Farm hydroponic floating system.
David Plant, Werecon: Advanced Water Treatment, assisting the team in research
of electrodal analysis of the water supply and providing more alternative
solutions to nutrient system design.
Tim Theriault, Team Industrial Consultant, provided valuable advice to the team
regarding project scope and timeline goals.
64
10.2.
10.3.
48
"ASM E IShow - Programs." American Society Of M echanical Engineers - ASM E.ORG. N.p., n.d. Web. 05 Dec. 2010.
<http://www.asme.org/Co mmunities/Innovates/Programs/Innovation_Showcase_IShow.cfm>.
49
"IEEE Engineering in M edicine and Biology Society Undergraduate Student Design Competition." IEEE. N.p., n.d. Web. 05
Dec. 2010. <http://www.ieee.org/membership_services/membership/students/awards/eng_medicine_undergrad_
design.html>.
50
"Presidents' Change the World Competition." IEEE. N.p., n.d. Web. 05 Dec. 2010. <http://www.ieee.org/membership_
services/membership/students/competitions/change_the_world/index.html>.
65
11. Conclusions
Overall, Engr. 339/340 and the PPFS concluded that HydroTower: Gardening Solutions as both a
project and product are feasible based upon proven technologies, analysis and testing of current
prototype designs. We have achieved many milestones throughout the course of this semester such as
building a prototype, selecting and obtaining LEDs, upload of the team website, basic analysis of air
flow design, and selection of frame structure as a of a rectangular modular unit.
Although some aspects of the final design have yet to be fully addressed, they will be attended to
next semester. This includes nutrient system, rectangular prototype, final design components, and the
finalized business plan. The team as identified a few concerns which one being the cost of the
HydroTower in a new and competitive market, another is the integration of computer/electrical and
mechanical systems, but realizing these risks will prove to help the design process and help in the
decision making process. The project is on schedule and the HydroTower team is confident that is
can complete the final design on time and according to design specifications.
For the second part of our project the HydroTower team plans to accelerate the development of
our design. We are confident that we will be able to move forward at a greater pace due to the
development of our team and the creation of a framework that will enable us to move on from our
mistakes and repeat our successes. The HydroTower team will continue to work through January in
order to hopefully finalize design requirements and ensure that financial and planning projections are
met.
We will continue our work in the second semester in order to insure that requirements and
deadlines are met promptly. We will no longer have the option to make major design changes that
could fundamentally effect how our product works. Again, fundamental decisions will need to be
made on the nutrient system in order to ensure a viable product.
The HydroTower team hopes that these decisions will help to create a high quality Senior Design
project and overall excellent project.
66
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69
70
71
72
73
74
75
76
77
78
79
Assumptions:
Compressed liquid water
Enclosed space
Heat loss only from water to air (enclosed) by natural convection
<Could add heat loss from sides>
2.0 Inputs
Pressure:
P
P_sat_T_ambient
14.696 psia
0.1779594 psia
Temperature:
Water In
Water Out
Ambient
<assumed>
<calculated from T_ambient>
70 F
21.11 C
65 F
<assumed>
<calculated>
<assumed>
50 F
10 C
<assumed>
<calculated>
stPSAT
0.01505109 m
15.0510933 L
<calculated>
<calculated>
<calculated>
0.5 %
80
Characteristic Length
L_c
kinematic viscosity
Prandtl Number
Pr
gravity
Volume Expansion Coeff
Thermal Diffusivity
Specific Heat
Cp
m_dot_a
m_dot_w
0.348895 Btu/hr-ft-F
1
k*Nu/ L_c
3.976078 ft^2
62.30856 ft^3/lbm
2.25 ft
0.000681 lbm/ft-s
0.121445
32.2 ft/s2
0.014286 1/F
0.005607
0.998662 Btu/lbm-F
12
cfm
1
gal/min
2.31E-03 lbm/s
<calculated>
stCDL
<calculated>
<assumed>
<calculated>
stVCL
stVISL
<assumed>
<calculated>
<calculated>
stCPL
81
3.0 Calculations
Notes:
Procedure
Find heat given off by water in 1 level (can be scaled up later)
Assume CV is closed, thus no airflow
Find condensation tempurature
Find min flow rate to stop condensation
If too dry:
Air humidity will be controlled "automatically" by a wick humidifier
more humid, harder to evaporate the water
less humid, easier to evaporate water
wick will be placed in front of the fan blowing air into the CV
fan will be a CPU fan
Calculations:
Rayleigh Number for enclosure:
Ra_L = Pr * g * (T_water - T_ambient) * rho * L_c^3 * Pr/ v^2
Ra_L = 032 * 1.4E-02 *50.0 - 70.0 * 2.25^3 *0.12 / 0.00^2
2.74E+07 [N/A]
Nusselt Number
Note: If #NUM! is shown, value out of range
Nu = 0.195* Ra_L^(1/4)
For: 10^4 < Ra_L < (4*10^5)
Nu = 0.195* 27447275.0^(1/4)
14.1 [N/A]
Nu = 0.068* Ra_L^(1/3)
For: (4*10^5) < Ra_L < (10^7)
Nu = 0.068* 27447275.0^(1/3)
20.5 [N/A]
Heat Transfer
Note: Negative Q is defined as heat loss. Positive Q is defined as heat absorbed.
Q_dot = k*Nu*A_s* (T_1 - T_2) / L_c
82
Enthalpy of Water
h_w_1
38.09155 Btu/lbm
h_w_2
33.09723 Btu/lbm
Enthalpy of Air
h_a_1
h_a_2
omega_1
omega_2
0.07647 lbm/ft3
83
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