CP5070-2022-2B05-Group 3-Asraf-Blog 7 (Project Development)
Hello everyone, welcome back to my final blog of the semester. It has been a wonderful semester so far, with its fair share of ups and downs. However, I am thankful that I didn't have to go through it alone, as I had a great team to work with.
In this blog, I am excited to showcase my final product, the Fume Extractor. I hope you all enjoy it!
1. Our Chemical DeviceThe objective of this device is to prevent inhalation of toxic fumes during soldering which can cause occupational asthma or worsen existing asthmatic conditions; as well as cause eye and respiratory tract irritation.
Students and lecturers are commonly exposed to these toxic gas when they do soldering during their practical lessons or projects. In order to reduce the toxicity of the fumes, we decided to create a fume extractor that utilizes a fan using negative draft to pull fumes and dust particles in to a contained filtration system. This process removes hazardous particles from the air.
The front side of the prototype is the sensor with a "window" at the side. The purpose of the "window" is to absorb the soldering fumes and thus the fan will blow it out into the atmosphere after filtering it.
On the back of the device, there is a fan that has a filter installed on top of it to filter out the soldering fumes particles. It is angled in such a way as to prevent the fumes from blowing to any individual that is facing in front of the fan.
At the side of it is the wirings of the servo, sensor, and Arduino board that is covered with a transparent cover of our team logo.
The purpose of the servo is an indication to let the users know that toxic fumes are being detected hence the device is operating.
The flag at the side is attached to the servo. When it senses fumes, the fan will turn on and the flag will raise up. However, when there are no fumes, the fan is off and the flag is raised down.
By using this chemical device, it will reduce the number of hazards and dangers that students and lecturers encounter while doing these tasks.. As such, this device promotes workplace health and safety(WSH).
2. Team Planning, Allocation & Execution
Name
Goh Kai Xuan Valarie
Mohamed Asraf Bin Abdul Rahman
Nur Insyirah Binte Azmi
Eshvin Kaur Chahal
Roles
CEO
COO
CFO
CSO
Allocated Task
Fabrication and coding (Combine both code)
Design of prototype and coding (Exhaust Fan
& Servo)
Buying of material, assembly of prototype
Clean-up of fabrication and design of logo
and flag
https://docs.google.com/document/d/1H2DveFn8CgWA7ZPPibyiQWK3pxH3ua7u/edit?usp=sharing&ouid=105837281852398648383&rtpof=true&sd=true
https://1drv.ms/x/s!AhjPYx8EpT1vuSJVsVF4Gsz8rxl_?e=zbUfpTHAHAH3. Design & Build Process
Section 1: Plan of model and coding for exhaust fan and servo (Done by Asraf)
In this way, I was accountable for planning the smoke extractor outline and doing the coding for the exhaust fan and servo. To begin with, I'll explain about the design of the smoke extractor outline.
The first thing I did is to measure the component of the exhaust fan, arduino board, smoke sensor and miniature servo 9g.
Device Name
Device Picture
Measuremnt
Exhaust Fan
80mm x 80mm x 10mm
Arduino Board
70mm x 60mm x 12mm
MQ2 Smoke LPG CO Sensor Module
Circumferance: 21mm
Micro Servo 9g
22.5mm x 12mm x 26mm
When the measurements for the devices is finished, I relegate my group to do a model of our plan utilizing cardboard to save time with printing and laser cutting.
Front View
Top View
Side View
The overall dimensions for
the prototype frame.
Length: 200mm
Width: 80mm
Height: 80mm
After obtaining the final dimension for the prototype using cardboard, I transfer everything to Fusion software. Starting with the foundation, I gradually work my way through the design process. As depicted on the right, the frame's foundation can be observed.
On the right-hand side, the image illustrates the positioning of the exhaust fan and the entry point for the Arduino and servo. The most challenging aspect is deciding on the screw hole's dimensions and precise location, which should align with the exhaust fan.
The image displayed on the right-hand side portrays the placement of the exhaust fan and the access point for the Arduino and servo. The most challenging aspect of this task is to determine the appropriate hole size for the screw and its precise placement, which should correspond with the exhaust fan. Surprisingly, aligning the hole with the fan turned out to be less complicated than expected.
I had to attempt 3D printing twice to ensure the screw fit correctly. During the initial attempt, the hole was precisely measured at 3.8mm, which was the same size as the screw. However, when I tried to test the screw's fit, only one screw would fit, and the remaining three would not. This could have been due to various factors, but two possibilities come to mind:
1. The screw size may not have been consistent throughout the manufacturing process.
2. Depending on the printer used, some prints may have a variation of +-2mm.
As a result, I decided to increase the size of the hole to 4mm and reprint. After the reprinting process was completed, all four screws fit perfectly..
The left-side of the image indicates the location of the MQ2 Smoke LPG CO Sensor Module. On the right-hand side, a hexagonal grid is currently being printed to safeguard users from touching the exhaust fan blade. It is designed to be small enough to prevent fingers or hands from passing through, while also allowing fumes to pass through. This ensures that safety is not compromised.
On the side where the Arduino board and servo are located, I constructed a hexagonal grid comparable to the one on the front. The only variation is that the hole is larger to accommodate the plug. However, after printing, I discovered that the hole was not large enough to accommodate the plug. To save time and 3D printing material, I decided to remove a few of the hexagonal grids that were large enough to allow the plug to fit through. I followed the same process for the servo located at the top.
The side with the exhaust fan is completely enclosed. Initially, I planned to install the same hexagonal grid on this side, similar to the other side and the front of the device. However, this approach posed a problem as it allowed fumes to escape. Therefore, the optimal solution was to fully enclose this side to prevent any fumes from escaping.
At this stage, I am converting the design from a PDF format to Fusion for including our team name, logo, and individual names, all of which will be laser-cut.
The final component of the Fusion design is the flag, which will be affixed to the side of the device, indicating that the soldering process is in progress. This is how the completed design will appear in Fusion, once everything is finished.
This is how the final design will appear in Fusion, once all the components are finished.
Prototype Frame Drawing
Final Prototype Frame
The Process Of Being Made
Moving forward, let me discuss the coding process. Initially, I started with the exhaust fan code. Although it was a bit perplexing, I found a helpful YouTube video featuring an Indian girl who demonstrated a smoke sensor with a buzzer. While her code featured a buzzer as output, mine was designed for an exhaust fan instead.
Original Code
Edited Code
Electronic Layout
The most challenging aspect of writing the code for the exhaust fan was determining the appropriate sensor value. Since I didn't have any soldering tools on hand, I had to improvise and try burning wood, plastic, and even cigarettes to determine the values for different types of fumes. My father, who smokes, was able to assist me, and it took us about two hours to gather the necessary data.
Here are the sensor values that I came up with:
If the sensor value falls between 191 and 200, the fan fluctuates to the surrounding air.
If the sensor value is below 285, it's detecting light smoke from a cigarette.
If the sensor value is below 295, it's detecting heavy smoke from a cigarette.
If the sensor value is below 447.5, it's detecting solder fumes.
Thicker smoke from a cigarette with different sensor value against time.
If the sensor value is below 200, the fan runs for 30 seconds.
If the sensor value is below 250, the fan runs for 14 seconds.
This data provided some interesting insights and taught me two important things:
1. The thickness of the fumes affects the sensor value that triggers the exhaust fan.
2. The time the exhaust fan stays on after detecting thicker fumes also depends on the thickness of the fumes.
I will now discuss the coding process for the servo. Interestingly, I used the wrong type of servo at the beginning - I mistakenly used a micro 360 degree continuous rotation servo. For the code, I utilized the example provided in the software and made a few modifications. However, upon testing, I found it strange and wondered, "why is the servo not staying put when fumes are detected and going back to its original position when there are no fumes?" This is when I realized my mistake and that I should have used the micro servo 9g instead. As soon as I obtained the correct servo, I promptly adjusted the code and reconnected all the necessary components.
Code
Electronic Layout
Hero Shot
Part 2: Fabrication and coding combine 2 code into 1 (Done by Valarie)Part 3 Buying of material, assembly of prototype (Done by Insyirah)Part 4: Clean-up of fabrication and design of logo and flag (Done by Eshvin)
Build Process
4. Problems & Solutions
Problems
Solution
The
hole for MQ2 Smoke LPG CO Sensor Module was too tight
The 3D frame for the MQ2 Smoke LPG CO Sensor Module slot needs to be sanded repeatedly until it fits perfectly. To avoid the need for reprinting, I intentionally made the slot slightly smaller than the size of the module. However, if the slot is too tight, we can sand it off to adjust the size, but this process can be time-consuming.
The
side with the hexagonal grid was too small for the wire to fit through
To make it less noticeable from a distance, we trimmed off part of the hexagonal shape and sanded it until it became smooth.
Exhaust
fan placement – Originally, we wanted to put it inside
The exhaust fan was initially intended to be placed inside the frame to avoid any protrusion upwards which would look unsightly. However, during the fitting process, we realized that the inner height was not taken into consideration, and as a result, we had to place the fan outside. Surprisingly, the final result turned out great because the whole print was black, and our black exhaust fan created an illusion that it was part of a single piece.
Servo
– We assumed that our exhaust fan was a mechanism
Initially, we believed that our exhaust fan was a mechanism, based on our research online and consultation with seniors. However, Mr. Ting clarified that it was not a mechanism. This presented a challenge as we needed to find a way to incorporate a servo into the prototype without altering the design.
The simplest solution I could think of was to use the servo as an indicator to show whether the fan was on or off. We attached a flag to the servo and placed it at the side of the prototype, and it worked perfectly.
5. Project Design Files As Downloadable Files
6. Learning ReflectionThis CA prototype was an opportunity for us to apply the skills we acquired this semester, such as using Fusion 360 to design our prototype, Arduino to program the code, laser cutting to cut out parts, and 3D printing to create the final product. Although it was a challenging project, we enjoyed the process and tested our skills.
Initially, we had a different idea for the prototype, but we switched to a simpler design. 3D printing and Arduino programming were the most challenging aspects of the project. To avoid wasting time and material, we split the printing process into two parts. With no prior experience in Arduino programming, we searched for solutions on YouTube, and it was difficult to combine the two codes.
Despite the difficulties, we learned to persevere, sacrifice sleep, and work together as a team. The final product was compact and functional, and we gained valuable experience. If we were to improve the prototype, we would do it again, with more efficiency.
Ultimately, we believe that the process is more important than the outcome, and we had fun, grew as a team, and developed new skills.
|
Name |
Goh Kai Xuan Valarie |
Mohamed Asraf Bin Abdul Rahman |
Nur Insyirah Binte Azmi |
Eshvin Kaur Chahal |
|
Roles |
CEO |
COO |
CFO |
CSO |
|
|
|
|
|
|
|
Allocated Task |
Fabrication and coding (Combine both code) |
Design of prototype and coding (Exhaust Fan & Servo) |
Buying of material, assembly of prototype |
Clean-up of fabrication and design of logo and flag |
Section 1: Plan of model and coding for exhaust fan and servo (Done by Asraf)
In this way, I was accountable for planning the smoke extractor outline and doing the coding for the exhaust fan and servo. To begin with, I'll explain about the design of the smoke extractor outline.
The first thing I did is to measure the component of the exhaust fan, arduino board, smoke sensor and miniature servo 9g.
|
Device Name |
Device Picture |
Measuremnt |
|
Exhaust Fan |
|
80mm x 80mm x 10mm |
|
Arduino Board |
|
70mm x 60mm x 12mm |
|
MQ2 Smoke LPG CO Sensor Module |
|
Circumferance: 21mm |
|
Micro Servo 9g |
|
22.5mm x 12mm x 26mm |
When the measurements for the devices is finished, I relegate my group to do a model of our plan utilizing cardboard to save time with printing and laser cutting.
|
Front View |
|
|
Top View |
|
|
Side View |
|
The overall dimensions for
the prototype frame.
Length: 200mm
Width: 80mm
Height: 80mm
|
After obtaining the final dimension for the prototype using cardboard, I transfer everything to Fusion software. Starting with the foundation, I gradually work my way through the design process. As depicted on the right, the frame's foundation can be observed. |
|
|
On the right-hand side, the image illustrates the positioning of the exhaust fan and the entry point for the Arduino and servo. The most challenging aspect is deciding on the screw hole's dimensions and precise location, which should align with the exhaust fan. |
|
|
The image displayed on the right-hand side portrays the placement of the exhaust fan and the access point for the Arduino and servo. The most challenging aspect of this task is to determine the appropriate hole size for the screw and its precise placement, which should correspond with the exhaust fan. Surprisingly, aligning the hole with the fan turned out to be less complicated than expected. I had to attempt 3D printing twice to ensure the screw fit correctly. During the initial attempt, the hole was precisely measured at 3.8mm, which was the same size as the screw. However, when I tried to test the screw's fit, only one screw would fit, and the remaining three would not. This could have been due to various factors, but two possibilities come to mind: 1. The screw size may not have been consistent throughout the manufacturing process. 2. Depending on the printer used, some prints may have a variation of +-2mm. As a result, I decided to increase the size of the hole to 4mm and reprint. After the reprinting process was completed, all four screws fit perfectly.. |
|
|
The left-side of the image indicates the location of the MQ2 Smoke LPG CO Sensor Module. On the right-hand side, a hexagonal grid is currently being printed to safeguard users from touching the exhaust fan blade. It is designed to be small enough to prevent fingers or hands from passing through, while also allowing fumes to pass through. This ensures that safety is not compromised. |
|
|
On the side where the Arduino board and servo are located, I constructed a hexagonal grid comparable to the one on the front. The only variation is that the hole is larger to accommodate the plug. However, after printing, I discovered that the hole was not large enough to accommodate the plug. To save time and 3D printing material, I decided to remove a few of the hexagonal grids that were large enough to allow the plug to fit through. I followed the same process for the servo located at the top. |
|
|
The side with the exhaust fan is completely enclosed. Initially, I planned to install the same hexagonal grid on this side, similar to the other side and the front of the device. However, this approach posed a problem as it allowed fumes to escape. Therefore, the optimal solution was to fully enclose this side to prevent any fumes from escaping. |
|
|
At this stage, I am converting the design from a PDF format to Fusion for including our team name, logo, and individual names, all of which will be laser-cut. |
|
|
The final component of the Fusion design is the flag, which will be affixed to the side of the device, indicating that the soldering process is in progress. This is how the completed design will appear in Fusion, once everything is finished. |
|
|
This is how the final design will appear in Fusion, once all the components are finished. |
|
Final Prototype Frame
The Process Of Being Made
Moving forward, let me discuss the coding process. Initially, I started with the exhaust fan code. Although it was a bit perplexing, I found a helpful YouTube video featuring an Indian girl who demonstrated a smoke sensor with a buzzer. While her code featured a buzzer as output, mine was designed for an exhaust fan instead.
|
Original Code |
 |
|
Edited Code |
|
|
Electronic Layout |
 |
The most challenging aspect of writing the code for the exhaust fan was determining the appropriate sensor value. Since I didn't have any soldering tools on hand, I had to improvise and try burning wood, plastic, and even cigarettes to determine the values for different types of fumes. My father, who smokes, was able to assist me, and it took us about two hours to gather the necessary data.
Here are the sensor values that I came up with:
If the sensor value falls between 191 and 200, the fan fluctuates to the surrounding air.
If the sensor value is below 285, it's detecting light smoke from a cigarette.
If the sensor value is below 295, it's detecting heavy smoke from a cigarette.
If the sensor value is below 447.5, it's detecting solder fumes.
Thicker smoke from a cigarette with different sensor value against time.
If the sensor value is below 200, the fan runs for 30 seconds.
If the sensor value is below 250, the fan runs for 14 seconds.
This data provided some interesting insights and taught me two important things:
1. The thickness of the fumes affects the sensor value that triggers the exhaust fan.
2. The time the exhaust fan stays on after detecting thicker fumes also depends on the thickness of the fumes.
I will now discuss the coding process for the servo. Interestingly, I used the wrong type of servo at the beginning - I mistakenly used a micro 360 degree continuous rotation servo. For the code, I utilized the example provided in the software and made a few modifications. However, upon testing, I found it strange and wondered, "why is the servo not staying put when fumes are detected and going back to its original position when there are no fumes?" This is when I realized my mistake and that I should have used the micro servo 9g instead. As soon as I obtained the correct servo, I promptly adjusted the code and reconnected all the necessary components.
|
Code |
|
|
Electronic Layout |
|
|
Problems |
Solution |
|
The
hole for MQ2 Smoke LPG CO Sensor Module was too tight |
The 3D frame for the MQ2 Smoke LPG CO Sensor Module slot needs to be sanded repeatedly until it fits perfectly. To avoid the need for reprinting, I intentionally made the slot slightly smaller than the size of the module. However, if the slot is too tight, we can sand it off to adjust the size, but this process can be time-consuming. |
|
The
side with the hexagonal grid was too small for the wire to fit through |
To make it less noticeable from a distance, we trimmed off part of the hexagonal shape and sanded it until it became smooth. |
|
Exhaust
fan placement – Originally, we wanted to put it inside |
The exhaust fan was initially intended to be placed inside the frame to avoid any protrusion upwards which would look unsightly. However, during the fitting process, we realized that the inner height was not taken into consideration, and as a result, we had to place the fan outside. Surprisingly, the final result turned out great because the whole print was black, and our black exhaust fan created an illusion that it was part of a single piece. |
|
Servo
– We assumed that our exhaust fan was a mechanism |
Initially, we believed that our exhaust fan was a mechanism, based on our research online and consultation with seniors. However, Mr. Ting clarified that it was not a mechanism. This presented a challenge as we needed to find a way to incorporate a servo into the prototype without altering the design. The simplest solution I could think of was to use the servo as an indicator to show whether the fan was on or off. We attached a flag to the servo and placed it at the side of the prototype, and it worked perfectly. |
This CA prototype was an opportunity for us to apply the skills we acquired this semester, such as using Fusion 360 to design our prototype, Arduino to program the code, laser cutting to cut out parts, and 3D printing to create the final product. Although it was a challenging project, we enjoyed the process and tested our skills.
Initially, we had a different idea for the prototype, but we switched to a simpler design. 3D printing and Arduino programming were the most challenging aspects of the project. To avoid wasting time and material, we split the printing process into two parts. With no prior experience in Arduino programming, we searched for solutions on YouTube, and it was difficult to combine the two codes.
Despite the difficulties, we learned to persevere, sacrifice sleep, and work together as a team. The final product was compact and functional, and we gained valuable experience. If we were to improve the prototype, we would do it again, with more efficiency.
Ultimately, we believe that the process is more important than the outcome, and we had fun, grew as a team, and developed new skills.
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