1

1

2010

Team Foxtrot Flora Vinson, Jason Ressler, Kathryn Chinn, Sandra Nakasone, Dimple Patel

Measuring Flow rate: Discrete vs. Continuous flow meters in a hydrometer

2

Table of Contents

Table of Contents

Abstract………………………………………………………………………………..………..4

Introduction…………………………………………………………………………………….4

Problem Statement……………………………………………………………………………...5

A. Process Scheme………………...……………………………………………………5

Figure 1………………………………………………………………………….6

B. Preliminary Device……………………………………………………………………...7

C. Prototype Device…………..……………………………………………………………8

Figure 2……………………...……………………………………..…………...10

Figure 3………………………………………………………………………….10

Figure 4………………………………………………………………………….11

D. Head Tank and Piping……….…….………………………………….………………...11

E. Solenoid valves……..……………....…………………………………………….…....12

F. Continuous flowmeter……...…………………………………………………………..12

Figure 5………………………………………………………………………….12

G. Discrete flowmeter……………………………………………………………………...13

Figure 6…………………………………………………………………….........13

H. Circuit Board……………………………….……………………………………………14

Figure 7………………………………………………………………………….14

I. 1208LS USB computer control…………….……………..…………..………………...15

J. Computer Programming………………….……………...……………………………...15

K. Materials and Costs…………………....………………..………….…………………...16

Table 1….…...………………………………………………….………………..16

Table 2………..………………………………………………………………....17

L. Results………………………...……………………….…..…………….………………18

Figure 8 …………….......…..………….………….………………………….….19

3

M. Limitations…………………………..…………..……………………………..…….….20

N. Appendix………………………………..…………………………………….……… ..22

Operating Instructions………………………………...……………………….22

Programming……………………………………………………...……………23

O. References………………………………………………………………….….……… 26

4

Abstract

The flow meters This project's primary objective was to compare the efficacies between

two types of flow meters: a continuous flow meter and a discrete flow meter. To pump water

throughout the system, a 12-V pump was used in conjunction with solenoid valves and a ¼-inch

piping system. In the project, the preliminary device was slightly adjusted to create the prototype

device. In the prototype device, a 2-step gear/DC motor system was used to measure the

volumetric flow rate of the continuous flow meter, and an infrared emitter detector was utilized

to measure the volumetric flow rate of the discrete flow meter. In the simulation of the prototype

device, Microsoft Visual programming was used to gauge the volumetric flow rates. Although

the simulation was intended for 1000 seconds, the simulation ran for only 60 seconds, which

yielded a volumetric flow rate of 4.6 ml/sec for the discrete flow meter. Likewise, the head

tank’s reference volumetric flow rate was 6.0 ml/sec. However, because of excess friction and

unsteady motion of the turbine flow meter, results were not obtained for the continuous flow

meter. In future device modifications, a different two-step gear should be implemented in order

to reduce the resistive forces against the turbine flow meter; also, the turbine flow meter should

be made out of clear material in order to ease the use of an infrared emitter detector. Under the

assumption that the device worked, the cost of a large-scale version of the device turned out to be

$5044.24. If a water bottle company used this device, then it would take 5.6 days to offset the

device’s cost, which is an entirely reasonable price and time to pay for an efficient machine.

Introduction

Water is an integral and peripheral part of many industrial operations throughout the

world. In order to properly and efficiently utilize an invaluable source like water, a flow meter

system needs to be implemented to successfully measure key components of the liquid at hand.

For instance, flow meters are used in measuring the rate of flow in fish farms throughout the

world; at the correct speed, water in fish tank can be adjusted such that there is an adequate

dispersion of feed to the fish stock1. In another application, the U.S. Geological Survey (USGS)

measures stream flow of various rivers in North America in order to compile data for studies on

climate change, weather patterns, oceanic flows, water levels, ecosystems, and natural hazards2.

Flow meters are imperative for processing and handling liquids other than water. For

example, in a more local application of flow meters, a tailored flow meter is used in the

processing of the highly viscous orange juice, whose pulp interferes with measurements of sugar

concentration without proper data on flow3. In terms of another liquid like alcohol, the Auper

flow meter was developed in such a way that the turbine within the device helped prevent foam

from developing on top of the beer4.

5

In this project, a prototype device was constructed in order to compare the efficacies

between two types of flow meters: a continuous flow meter and a discrete flow meter. This

comparison will help in providing data for industries (e.g. such as the aforementioned fish farm,

USGS, orange juice factory, and beer company) purchasing the optimal, most accurate flow

meters for handling their specific liquids. Although there are other types of flow meters in

industrial use, the focus of this project was on the discrete flow meter and continuous flow meter

because they were commercially available.

Problem Statement

This project aimed at comparing the efficacies of two flow meters, a continuous flow

meter and a discrete flow meter. An adjoining head tank provided the reference flow rate. To

control water input into the aforementioned devices, a solenoid valve system was implemented

adjacent to the girder containing the aforementioned head tank and two flow meters.

Nonetheless, as with most practical applications, there were constraints on the materials available

for this project; therefore, a broad-scheme comparison of many flow meters was not possible.

Also, for this project, a 1208LS USB Computer control interface, a circuit board, and Microsoft

Visual™ programming created automated control of the prototype device. Ancillary materials

included infrared emitter detectors adjacent to the discrete flow meter; a two-step gear system for

the continuous flow meter; a DC motor for the continuous flow meter; solenoid valves; an

electric pump; a girder; and a network of ¼-inch clear piping to transport the water from the

solenoid valves to the various tank and flow meters.

A. Process Scheme

A plan of action, as illustrated in Figure 1, served as guideline for the engineering design

team. Fortunately, enough time was allotted to adjust the preliminary design. However,

problems encountered with its materials forced reworking the preliminary design such that

measurements from the continuous flow meter were obtained in a different, albeit easier manner.

Unfortunately, this reparative move did not stymie the subsequent problem encountered with

rotating the continuous flow meter to yield flow rate results. Nonetheless, for future projects, the

somewhat efficient prototype can be improved upon in order to obtain comparative data from

both the continuous and discrete flow meter.

6

Figure 1: Process Scheme of Flow Meter Project

Purpose: To design a device that will compare the efficacies of two different types of flow meters

Brainstorming Session

Original idea: Build a hydrodynamic toy set that will have a turbine flow meter and a tilt scale.

Testing Process

FAIL: Test simulation failed in adding the emitter detectors to the continuous flow meter (i. e. turbine flow meter). Another way of detecting flow changes needed.

Final idea: Only one emitter detector used in the tilt scale (i.e. continuous flow meter). The turbine flow meter was fixed to a two-step gear, DC motor system in order to ease rotation. Microsoft Visual programming redone.

Testing Process

SUCCESS: Tilt scale discretely moved, and turbine flow meter continuously rotated. Comparable results and repeatable simulations were developed.

Brainstorming Session

SUCCESS: Test Simulation succeeded with 1 infrared emitter detector per flow meter.

Completed programming. Rerun the simulation to yield results.

Final Presentation and a report.

FAIL: Turbine flow meter only budged slightly in its rotation. Tilt scale yielded verifiable results.

7

B. Preliminary Device

A two-flow meter device was constructed in order to compare the efficacies of the

continuous flow meter and the discrete flow meter. In order to ease the visualization of these

aforementioned flow meters, the continuous flow meter may be referred to as a “turbine flow

meter,” and the discrete flow meter may be referred to as a “tilt scale.”

As indicated by Figure 1, the preliminary device had a solenoid valve system that was

situated in a bigger, white base. The base also held a twelve-volt water pump that worked at 1.8

amperes. The solenoid valve system was placed adjacent to the girder. The girder held the head

tank at a head of approximately 17.44 inches from the ground, given that the ground was a

reference frame in which the white base was at a position of zero in the zenith direction (given

that the zenith direction was orthogonal to the ground, or the horizontal axis). Moreover, the

girder held the turbine flow meter and the tilt tank at approximately the same height in the zenith

direction; both of these aforementioned flow meters were approximately five inches from the

ground in the zenith direction. For the tilt scale flow meter, an infrared emitter detector system

was situated such that the emitter was parallel to the left side of the triangular prism that makes

up the tilt scale; the detector was parallel to the right side of the triangular prism. Another

infrared emitter detector system was set up such that the emitter was parallel to the left side of

the turbine tank and the detector was parallel to the right side of the turbine tank. Next,

appropriate ¼-inch plastic tubing was used at appropriate lengths in order to connect the water

pump to the top of the head tank, the bottom of the head tank to the two top valves of the

solenoid valve system, one bottom valve to the discrete flow meter, one bottom valve to the

continuous flow meter, the continuous flow meter to the white base, and the discrete flow meter

to the white base.

For the trial simulation, the bottom base was filled half-way to the brim for the

simulations. Filling the bottom tank helped cover the inlet of the electric pump at the bottom of

the system. The water pump in the base powered the movement of the water to the top of the

head tank. This water flowed down the head tank to the two top valves of the solenoid bank

system. The head tank’s volumetric flow rate was measured using a simple stop watch as the

parameters of the head tank were known; the head tank’s volumetric flow rate was used as the

reference flow rate. Then the water flowed from these two top valves from the solenoid valve

bank via ¼-inch plastic tubing that was joined by an L-connector. Then the water flowed

through the solenoid valve bank to either of the bank’s bottom two valves. One of the bottom

valves then pumped the water to either of the flow meters.

8

Next, for the discrete flow meter, the one-inch thick triangular prism that makes up the

tilt tank was filled to the brim; when a mass of water that filled the tilt tank equaled the weight of

its metal counter weight (which held the tilt tank at a slight angle above the horizontal axis), then

the tilt scale rotated 180 degrees such that it moved from the positive to the negative zenith

direction (from 90 degrees to -90 degrees in the zenith direction if 90 degrees was measured

counterclockwise from the horizontal direction). The infrared emitter detector system was set up

such that the emitter emitted infrared light to the detector, which was on the right side of the tilt

flow; at the initial position, this beam of infrared light was interrupted. However, every time the

tilt flow completed a rotation and spilled its liquid contents to the tank below, the infrared light

beam was no longer interrupted by the plastic of the tilt scale. Therefore, the programming

language recorded the number of times the electronic beam was fully detected by the emitter

over a set time interval in order to correspond the number of tilt tank volumes filled to the time

interval. Essentially, by corresponding the number of electron beams formed to a set number of

volumes filled and dumped over a given time interval, a volumetric flow rate was established.

This discrete flow meter simulation was completed after the continuous flow simulation.

Switching from the continuous flow simulation to the discrete flow simulation was completed by

a command in the programming language and by a shunt valve in the solenoid valve system.

Originally, in the preliminary device (which is not pictured but is essentially the same as that of

Figure 1 but without a DC motor and a two-step gear system), an infrared emitter detector was

set up along the continuous flow meter. However, when the team attempted a simulation, the

continuous flow meter’s inner turbine rotated at a speed much higher than the upper limit of the

infrared emitter detector system. This problem was agitated by the fact that an electron beam was

formed every time a blade unblocked the emission of light from the emitter to the detector. This

phenomena did not occur with the discrete flow meter because the continuous flow meter’s

turbine tank did not necessarily have to fill up its tank in order to unblock the light emission.

Moreover, as indicated by Figure 3, the shaft of the turbine’s rotor inadvertently blocked some of

the infrared light’s emission such that the detector detected no light at all or a diffuse amount of

light when full detection was expected. Therefore, because of these aforementioned problems,

the preliminary device was adjusted to fix the continuous flow meter.

C. Prototype Device

In the project, the preliminary device was slightly adjusted to create the prototype device.

As indicated by Figure 2, prototype device still implemented a girder that held the head tank, the

discrete flow meter, and the continuous flow meter. The twelve-volt pump was still used to pump

the water to the head tank. The water that flowed down the length of the head tank then entered

the solenoid valve system through the top two valves and into the bottom two valves. One of the

bottom two valves provided water to the continuous flow meter. The other bottom valve

provided flow to the discrete flow meter. All of the excess or “measured” water from the discrete

flow meter and the continuous flow meter eventually poured into the white based.

9

However, the prototype device was markedly different from the preliminary device with

respect to the configuration of the continuous flow meter. As mentioned before, the continuous

flow meter’s rotor was moving at a high velocity in a turbulent fashion. Therefore, its adjacent

infrared emitter detector could not accurately gauge the number of times its light emission was

interrupted by the flow meter’s blades. Moreover, the plastic material of the turbine flow meter

created an unintended obstruction for the light emission even when the blades were displaced.

Therefore, to amend the aforementioned problems with the continuous flow meter, the

prototype device needed to implement a system such that it would be able to better control the

otherwise turbulent motion of the turbine flow meter. Therefore, a two-step gear/DC motor

system was utilized on the continuous flow meter to not only slow down the rotation of the

continuous flow meter’s rotor blades, but to also create a more steady motion. This controlled

motion would mean that the time interval for the light emission detected by the infrared emitter

detector would approach a steady value. In this two-step gear system, a DC motor (which was

obtained from a previous design project) was placed parallel to the white base (or orthogonal to

the sides of the turbine flow meter). The large gear was placed on top of the face of the DC

motor; the large ear was then placed orthogonal to the vertically standing small gear. In order to

provide the correct amount of torque to the turbine flow meter, the small gear was placed parallel

to the side of the flow meter such that the blade rotation was also parallel to the small gear.

Therefore, the vertical rotation of the rotor would translate into the vertical rotation of the small

gear, which would translate into the horizontal rotation of the large gear and the adjacent DC

motor. The aggregate resistances of the two gears and the DC motor would help stymie and

control the otherwise turbulent motion of the continuous flow meter. The Microsoft Visual

programming would record the voltage readings by the DC motor (which corresponded to the

number of large gear rotations and hence turbine blade rotations). Then number of rotations over

a given time interval would be related to the volume of the turbine flow meter in order to a yield

a volumetric flow rate.

As obvious in the design modification, the idea of implementing an infrared emitter

detector system was abandoned because of the turbine’s obstructive plastic material and the still

somewhat rapid motion of the turbine’s blades. In an ideal system, both the continuous flow

meter and the discrete flow meter would implement the same measurement instruments in order

to reduce any unnecessary discrepancy.

10

Figure 2: Photograph of the prototype device

Figure 3: Sketch of the turbine flow meter5

11

Figure 4: Prototype Stand with Discrete Flow meter and Continuous Flow meter

Key: Brown-solenoid valves; light grey base-base; light grey pipes-1/4’’ tubing; charcoal black-

head tank; rounded green structure-continuous flow meter; thin green structure (triangular

prism)-discrete flow meter.

D. Head Tanking and Piping

Piping in the device was used to connect the head tank with the solenoid valves and flow

devices. The piping was done with ¼” diameter polyethylene pipes. Polyethylene pipes were

chosen for the piping of the project due to its flexibility, light weight, and easiness to handle.

Also, polyethylene tubes are resistant to a wide range of fluids, and they are very durable for

long-term use. Furthermore, they were cut to specific lengths to increase efficiency of the overall

project.

12

E. Solenoid Valves

The solenoid valve bank used in the project controlled the flow of the water from the tank

to the continuous and discrete flow devices. The solenoid valves work by converting electrical

energy into magnetic energy that allows an inlet pipe to transport fluid to different outlet valves.

The air bank was controlled by the program written in Visual Basics which commanded the

specific valves to open and close when water was wanted to flow into the continuous or discrete

flow meter devices.

F. Continuous Flow Meter

As indicated by Figure 5, the continuous flow meter used was provided in the hydrodynamic

deluxe set. It is a simple turbine velocity flow meter which provides continuous flow made of a

hard clear plastic material. The solenoid valves send water from the head tank to the turbine to

measure the flow rate coming out of it. The turbine flow meter was made out of opaque plastic;

it was composed of a rotor, a shaft, and blades.

A DC motor connected to a 2 step gear was intended to be used for calculating the

continuous flow from the turbine velocity flow meter. A DC motor runs on direct current

electricity and simple electromagnetism. A magnetic field is generated by a conductor carrying

current which is then later moved into an external magnetic field experiencing the same force as

the conductor and the strength of the external magnetic field. A DC motor reinforces the

interaction of a conductor and a magnetic field to produce a rotational motion17

. The DC motor

reads off the voltage changes of the revolution of the gears, supplying data to the computer

program for the calculation of the flow. Various limitations were encountered while using this

method.

Figure 5: Continuous Flow Meter

13

G. Discrete Flow Meter

The discrete flow meter, also known as the tilt tank, was used was provided in the

hydrodynamic deluxe set. As shown in Figure 6, the tilt tank has a triangular shape which

dumps the fluid when full. The solenoid valves feed water through the pipes and slowly water

drops into the triangular shaped tank and when the tank becomes heavier than the opposite side,

it tilts dumping the water back to the plastic bucket. The discrete flow rate was calculated by

knowing the number of dumps though a certain time rage and multiplying it by the volume of the

tilt tank.

The infrared emitter and detector were placed across the metal weight balancing the

discrete tank. They function by being placed directly facing each other within a short distance.

The emitter and detector send infrared wavelengths to each other whenever there’s an

obstruction in between them which then sends a voltage reading to the computer program.

Furthermore, the computer program collects the data and notifies when there was a voltage

change, which helps identify how many times the discrete tank tilts for volumetric rate.

Figure 6: Discrete Flow Meter

14

H. Circuit board

An H-bridge circuit board was used for the project in order to guide electrical current that

will power the water pump providing water to the head tank fifteen inches above the base of the

device. It also helped record the voltage readings from the DC motor as well as the number of

emissions from the infrared emitter detector. The H-bridge circuit has the unique ability of

applying a voltage across a load in any of two directions.

In this project, the H-bridge circuit had six components. Pins are connected to Toshiba

TA8409S/SG Driver chips, which are sensitive to excess current. Also, there are two components

that act as outputs to the individual stepper motors. Next, there are two sets of terminals for data

acquisition (DAQ), or Digital I/O Input, which is dictated by the microcontroller. The circuit is

powered by two power inputs of five volts. The exact configuration of the various components of

the circuit board is illustrated in Figure 5:

Figure 7: Components of the Circuit Board

LED lights LED lights

Power Input (5V) DAQ pins

21-24

DAQ pins

25-38

DAQ pin 29

Infrared

emitter/detector

DC Motor/Power

pump

15

I. 1208LS USB computer control

The 1208LS USB computer control is a low-speed device supported by Microsoft

Windows compatible with 1.1 USB ports and 2.0 USB ports. Essentially, the USB-1208LS

computer control device provides commands for the water pump which dictate the flow of the

water to the head tank; the computer control device also provided voltage readings from the DC

motor and the number of emissions from the infrared emitter detector.

The USB-1208LS features eight analog inputs, two 10-bit analog outputs, 16 digital I/O

connections, and one 32-bit external event counter8. The USB-1208LS does not need any

external power since it is powered by the +5 volt USB supply from the computer8. Essentially,

the USB-1208LS computer control device provides commands for the power pump at the base of

the device.

After the USB 1208LS was calibrated, wires were used to connect the control interface to

the circuit board and the solar cell panels. The first eight analog input connectors were used to

obtain data from the solar cell panels. Pins 1 and 2 are connected to the DC motor and the power

pump, and pins 7 and 8 are connected to the infrared emitter detector

The I/O connections in the controller were used to send information to the circuit board.

These connections are also called DAQ pins, for Data Acquisition. Pins 21 through 24 are

connected to the circuit board via small wires to the left most I/O ports and pins 25 through 28

are connected to the right most ports. This connection feeds information to the circuit board

which later sends the command to the power pump at the base of the device.

J. Computer Programming

The program that directed the USB computer control was Microsoft Visual, a

programming language by Microsoft. This program was used instead of the recommended

previously used C# programming because of the former’s easier modus operandi.

Microsoft Visual programming (VPL) is based on a system of inputs and outputs and

logical data flow and variables that affect the inputs and outputs6. The Microsoft Visual

programming used references from the VPL user guide6. In this system, the Microsoft Visual

programming provided instructions to the USB computer control to initiate the water pump in the

base of the system to provide flow to the head tank.

Once the water reached the solenoid valve system, the programming instructed the valve

to direct the flow to the continuous flow meter and then to the discrete flow meter.

Desynchronized flows were used in order to minimize possible errors in the simulation of the

device and to maximize the focus of the user per flow system. The program created was only

partially automated and meant to be commanded manually for flow rate measure. A computer

16

user press the button whenever the valves from the solenoid bank needed to be open and closed.

In addition, the program received data from the emitter and detector placed by the discrete flow

meter. It recorded data whenever the obstruction in between them moved creating a voltage

reading. Whenever the voltage increase or decrease from its calibrated 0 reading, the program

would read a 1; then when the voltage went back to its original reading the program read a 0.

This data was later graphed and used for manually calculating how many times the tank dumped

water back to the bucket throughout a specific time period.

K. Materials and Cost Analysis

The following budget provides an overall cost analysis of the project. The more

expensive materials, like the 1208LS USB control and the circuit board, were provided by the

instructor. In addition, most of the other costly materials such as the solenoid valves bank, the

hydrodynamic deluxe set and the emitter and detector were borrowed from the UF Civil

Engineering Department. Ancillary items like wires and pipes added negligibly to the overall

cost.

Table 1: Cost of the Prototype Device

Part Cost

Hydrodynamic Deluxe Set1 $84.95

Solenoid Valves Bank2 $123.74

Connectors3 $1.50x4 $6.00

Polypipes4 4ft ($3.50/20ft) $0.70

Infrared Emitter and Phototransistor Detector5

$3.49x2

$6.98

Wiring6 (about 10 ft) $2.49

Circuit Board7 $2.99

DAQ/1208LS USB control8 $129.00

Batteries9 $4.49x3 $13.47

Mini DC Motor10

$4.95

TOTAL $375.27

17

Table 2: Cost of the Large Scale

Part Cost

Head Tank11

(1500 gallon) $1,339.56

Hydro Turbine13

(continuous flow) 4-250gpm $2,209.00

Water Tank12

(discrete flow) 50 gal $119.70

Water Pump14

$699.99

Pipes16

(15ft) $19.50

Emitter Detector $3.49

Solenoid Valves Bank15

(3 port) $653.00

TOTAL $5044.24

Overall, as indicated by Table 1, the prototype device cost was approximately $375.27.

For its complex design and complicated nature, it resulted to be an economical project. In order

to replicate the prototype model into a large scale industry size, the cost will be 13.6 times more

of the small scale design. The predicted cost of a large-scale flow meter was found to be

$5044.24. However, the cost of a large-scale flow meter was calculated under the assumptions

that the costs of manual labor in maintaining the equipment and running the program and the

device’s electricity consumption and other maintenance costs would be too variable to be taken

into consideration.

According to literature found online, a water production filtration device in industry

produces approximately 1 gallon of water per minute depending on the head of the device. So,

when comparing the large scale data to these values, it is found that the 1500 gallon head tank

will take about 25 hours to empty. The flow rate of the large scale head tank will be 100 gallons

per day. Given this value, in order to measure the time it would take to offset the cost of the large

scale device, it was assumed that a standard water bottle company like Aquafina © would be

used as an illustrative example. Here, approximately 2110 Aquafina water bottles (at 1 liter per

bottle, $2.39 liters per bottle) would have to be sold to offset the cost of the large-scale device

(under the assumption that the entire cost of the bottle goes into paying off the large-scale

equipment and not to taxes, employment, profits, etc.). Therefore, given the volumetric flow rate

of the large-scale device and at a rate of 379 bottles manufactured in a given day, it would take

approximately 5.6 days, or 133.8 hours, to produce and sell the necessary amount of bottles to

offset the equipment cost. Given that most water bottle companies run year-round, this time

frame is negligible. Therefore, under the assumption that the large-scale version of the prototype

device would work in an industrial setting, the real-life implementation of the prototype device is

entirely reasonable and practical.

18

L. Results

The programming and the device underwent several simulations. However, data was only

gathered for one of the simulations. Unfortunately, throughout the process of gathering data and

testing, the solenoid valve bank appeared to have burned, not being able to close or open the

valves when commanded. The only data that could be obtain with some confidence was the

number of infrared emissions for the discrete flow meter, as indicated by Figure 8.

Unfortunately, the continuous flow meter encountered several problems with its motion of

rotation, which was the antithesis of the problems it encountered in the preliminary device.

In Figure 8, the number of emissions for the discrete flow rate were measured across the

time span of one minute. Here, the value of 0 corresponded to the obstruction of the infrared

emitter detector; the value of 1 corresponded to a complete emission of an infrared light beam.

There were twenty four light emissions made in the time span of one minute. The time interval

between each light emission was variable because the counter balance on the tilt scale rocked the

discrete flow meter a bit before the complete dump of its contents.

Given that the volume of the discrete tank (which was shaped like a triangular prism) was

14 ml, the discrete flow rate was round to be 4.6 ml/sec given that the number of dumps or

infrared light emissions were twenty over a 1-minute time interval. Also, because the discrete

flow meter and the head tank had a constant head loss of 44.3 cm, the head tank's volumetric

flow rate was round to be approximately 6 ml/sec. Moreover, the head tank was found to have

experienced a fully developed turbulent flow as its Reynold’s number was 19452.

Figure 8: Emissions for Discrete Flow Meter

0

0.2

0.4

0.6

0.8

1

1.2

0 10 20 30 40 50 60

Emis

sio

ns

Time (sec)

Discrete Flow Rate

19

Some of the calculations done for this project was using the continuity equation to find the

velocity of the water. By knowing the head tank water flow rate, experimentally determined to

be 6mL/sec , and the diameter of the poly ethylene pipes (1/4”) the velocity was determined

using the equation:

The roughness coefficient of the pipes was calculated by using the Bernoulli equation. By

knowing the distance between the two points calculated (0.337m). Later, the Reynolds number

was calculated using all the values obtained.

The Reynolds number was calculated using the water viscosity value at room temperature. The

Reynolds number for the water flow from the head tank is 19452.2, meaning the water flow is

turbulent.

20

M. Limitations

Moreover, the tilt tank's discrete motion was inaccurate, leading to errors in the emitter

accuracy. For instance, the time interval between each of the emissions was variable. This event

occured because the counter balance on the tilt tank rocked the meter's motion slightly before it

released its contents to the base. This rocking motion would have not only created variable time

intervals as apparent in Figure 8, but also, it would lead to more unobstructed infrared light

emissions. This event would have led to an inaccurately higher volumetric flow rate for the

discrete flow meter. Therefore, a future improvement would be to implement a steadier

counterbalance.

Also, the programming Microsoft Visual was not fully automated as the programming only

measured voltage of the DC motor and the emitter counters over time; the only automated

components were the transitions between the head tank flow, the discrete meter flow, and the

continuous meter flow. Therefore, a future improvement would involve full automation of the

programming language in order to reduce the amount of possible human error involved with

running simulations.

Unfortunately, the trial simulations of the device were unsuccessful. Specifically, during

some of the simulations, the solenoid valves experienced some leakage. After some time, the

solenoid valves actually experienced some major burning and had to be cleaned out and repaired

before another simulation, albeit unsuccessful, was attempted. Therefore, data was only obtained

for the discrete flow meter. The simulation could not repeated for the discrete flow meter; repeat

trials would have led to a greater accuracy in the volumetric flow rate calculations. Also, the time

interval that hte discrete flow meter was stymied because the solenoid valves started to burn; a

longer time interval would have tested the durability of the tilt tank. In the future, a newer

version of the solenoid bank system should be used in order to prevent leakage and burning.

Also, the continuous flow meter, even after the design modifications from the

preliminary design, proved to be unsuccessful in all of the attempted simulations. Specifically,

because of the two-step gear/DC-motor system was implemented, a significant amount of

resistance and friction were stymied the motion of the continuous flow meter system. Unlike the

highly turbulent motion of the continuous flow meter in the preliminary design, the prototype

design proved to experience extremely slow, incomplete motion. Therefore, in future model

improvements, the gear ratio should be reversed such that the large gear is placed on the

continuous flow meter and the small gear is placed on the DC motor; this change may reduce the

friction enough such that the motion of the continuous flow meter would be steadier.

Nonetheless, the prototype design seemed successful because the discrete flow meter's

volumetric flow rate of 4.6 ml/sec was somewhat similar to the volumetric flow rate of 6 ml/sec

for the head tank. It was postulated that the continuous flow meter would have performed better

21

than the discrete flow meter because the flow is seemingly uninterrupted. However, the results

prove to be inconclusive in such a comparison. Nonetheless, after the implementation of the

aforementioned improvements, this prototype design could be ideal for an industrial setting.

22

N. Appendix

Operating Instructions

To operate the device for an entire day, the user needs to manually initiate computer commands

to start and stop the pre-determined program. The intermediate steps of the program are entirely

automated in order to ease operational use for users who are not familiar with the Microsoft

Visual programming:

1. Copy the programming code into the Microsoft Visual software (programming code

available in appendix).

2. Fill the bottom tray with an optimal amount of water so as to neither limit the water

supply nor as to cause the spillage.

3. Connect the plastic tubing to the appropriate sites on the head tank, the discrete flow

meter, the continuous flow meter, and the solenoid valve bank system according to

the diagram provided in Figure 4.

4. Press the command “START” in the Microsoft Visual software in order to run a

simulation in which each flow meter will run in a desynchronized manner for a 1000

seconds.

5. Press the command “STOP” in the Microsoft Visual software in order to prevent a

repeat simulation.

23

Microsoft Visual Programming

The following information includes the programming code for the software Microsoft Visual.

The programming was implemented to provide instructions on the desired, desynchronized

functioning of the discrete and continuous flow meters. Three timers were used in order to

simulate three distinct program intervals: water flow from the tank to the solenoid valves to the

head tank to the continuous flow meter, water flow from the tank to the solenoid valves to the

head tank to the discrete flow meter, and interim period in which the solenoid valve system shuts

off flow to the continuous flow meter in order to provide adequate water flow to the discrete

flow meter.

Imports System.IO

Imports System.Text

Public Class Form1

Dim CurrentPos As Byte = 2, Count As Integer, CountDownEnable As Byte = 0

Private DaqBoard As MccDaq.MccBoard = New MccDaq.MccBoard(0)

Private RangeSelected As MccDaq.Range

Const PortNumA As MccDaq.DigitalPortType =

MccDaq.DigitalPortType.FirstPortA

Const Direction As MccDaq.DigitalPortDirection =

MccDaq.DigitalPortDirection.DigitalOut

Dim ULStat As MccDaq.ErrorInfo

Private Sub Form1_Load(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles MyBase.Load

ULStat = DaqBoard.DConfigPort(PortNumA, Direction)

Timer3.Interval = 1000

Label2.Text = 0

End Sub

Private Sub Timer1_Tick(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles Timer1.Tick

ULStat = DaqBoard.DBitOut(PortNumA, CurrentPos, 1)

If Discrete.Checked = False Then

CurrentPos = 2

Else

CurrentPos = 0

End If

ULStat = DaqBoard.DBitOut(PortNumA, CurrentPos, 0)

If Discrete.Checked = False Then

CurrentPos = 0

Else

CurrentPos = 2

End If

End Sub

Private Sub Quit_Click(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles Quit.Click

Timer1.Enabled = False

24

Timer2.Enabled = False

Timer3.Enabled = False

If Discrete.Checked = True Then

Discrete.Checked = False

End If

ULStat = DaqBoard.DBitOut(PortNumA, CurrentPos, 0)

CurrentPos = 0

CurrentPos = 2

End Sub

Dim Chan As Byte

Dim i As Integer

Dim DataValue As Single

Dim MessageBox As Label

Dim options As MccDaq.VInOptions

Dim objStreamWriter As StreamWriter

Private Sub Timer2_Tick(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles Timer2.Tick

Chan = 0

options = MccDaq.VInOptions.Default

ULStat = DaqBoard.VIn(Chan, RangeSelected, DataValue, options)

voltage0.Text = DataValue.ToString()

Chan = 1

options = MccDaq.VInOptions.Default

ULStat = DaqBoard.VIn(Chan, RangeSelected, DataValue, options)

i = 0

If DataValue > 0.09 Then

i = i + 1

End If

Dump.Text = i.ToString()

objStreamWriter = New

StreamWriter("C:\Users\flora\Desktop\DesignProject4\test.txt", True, _

Encoding.Unicode)

objStreamWriter.WriteLine(Dump.Text + "," + Label2.Text)

objStreamWriter.Close()

End Sub

Private Sub Timer3_Tick(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles Timer3.Tick

Timer3.Interval = 1000

Label2.Text = Label2.Text + 1

End Sub

Private Sub Start_Click_1(ByVal sender As System.Object, ByVal e As

System.EventArgs) Handles Start.Click

Timer1.Enabled = True

Timer2.Enabled = True

Timer3.Enabled = True

25

End Sub

End Class

26

O. References

1. "F i s h Fa rm Su pp l y. " F low M et er a nd O xy g en E q u ip m en t . N .p . , n .d .

W eb . 17 Dec 2 01 0 .

< h t tp : / / w w w. f i sh f a r m su pp l y. ca / mm5 /m er ch an t .mv c? Sc r een =CT G Y &

St o r e_C od e=FFS &C at ego r y_ C od e = f l ow Ox ygen > .

2. "U . S . G eo l o gi ca l Su r v ey: S c i en ce fo r a Ch an g i n g Wo r l d . " Wa t er

S c i en ce fo r Scho o l s . N . p . , n . d . W eb . 17 D ec 20 10 .

< h t tp : / / ga . w a t e r . usgs . go v / edu / m easu r e f l ow .h tml > .

3. "F l o w T ech no lo g y In c . " A p pl i ca t io n No t e : Fo od I nd us t r y . N .p . , n .d .

W eb . 17 Dec 2 01 0 .

< h t tp : / / w w w. f t i m ete r s . com /p df s / app l i ca t i on _n o t e s / an 65 111 _ fo od _b e

v e r age_ j u i ce . pd f > .

4. "F l o w m et e r Di r ec to r y. " M ea su r in g D ra f t B eer . N .p . , n .d . W eb . 1 7

D ec 20 10 .

< h t tp : / / w w w . f l ow met e rd i r ec to r y. co m / f l o wm et e r_ a r t c_0 202 0 50 1 . h t ml

> .

5. "H yd r o d yn am i c Bu i l d i n g S e t s . " B r id g e S t r ee t T o ys . N . p . , n . d . Web .

1 7 D ec 2 01 0 .

< h t tp : / / w w w. br id ges t ree t to ys . com /w a yt w or k / i m ages /H Y DR O _ BO O K

. p df > .

6. "V P L In t r o du c t io n . " M i cr os o f t Co rp ora t i on . N . p . , n . d . Web . 17 D ec

2 0 10 . <h t t p : / / ms dn . mi c ro so f t . com / en -u s / l i b r a r y/ b b 4 83 088 . as px > .

7. Educational Science Kits and Toys. Retrieved December, 7 2010.

<http://www.discoverthis.com/hydrodynamic-factory-deluxe.html>

8. Pneumatic Valves. EBay. Retrieved December 7, 2010. <http://cgi.ebay.com/6-

Humphrey-HW240-4E2-L-Solenoid-Air-Valve-Bank-

H240M6AW/140481513114?pt=Pneumatic_Hydraulic_Valves_Parts&hash=item20b559

c69a#ht_1628wt_905>

9. Lowe’s Companies, Inc. Retrieved December 7, 2010.

<http://www.lowes.com/pd_65118-104-

LFA16_4294822030+5003694+4294963669_12_?productId=3134881&Ns=p_product_p

rd_lis_ord_nbr|0||p_product_quantity_sold|1&pl=1&currentURL=/pl_Brass_4294822030

%2B5003694%2B4294963669_12_%3FNs%3Dp_product_prd_lis_ord_nbr|0||p_product

_quantity_sold|1%26page%3D2&facetInfo=$1%20-%20$5|Brass>

10. Lowe’s Companies, Inc. Retrieved December 7, 2010.

<http://www.lowes.com/pd_15775-104-

SVEB20_4294822036_4294937087_?productId=3130957&Ns=p_product_prd_lis_ord_

nbr|0||p_product_quantity_sold|1&pl=1&currentURL=/pl_TubingHoses_4294822036_42

94937087_%3FNs%3Dp_product_prd_lis_ord_nbr|0||p_product_quantity_sold|1>

11. Radio Shack Corporation. Retrieved December 7, 2010.

<http://www.radioshack.com/product/index.jsp?productId=2049723>

27

12. Hook up Wires from Alan’s Electronic Store. Retrieved December 7, 2010. <http://alan-

parekh.vstore.ca/stair-light-hook-wire-feet-p-5.html>

13. Circuit board. RadioShack Corporation. Retrieved December 7, 2010.

<http://www.radioshack.com/product/index.jsp?productId=2102846&CAWELAID=1075

94612>

14. USB1208. Measurement Computing Corporation. Retrieved December 7, 2010.

http://www.mccdaq.com/usb-data-acquisition/USB-1208-Series.aspx

15. Radio Shack Corporation. Retrieved December 7, 2010.

<http://www.radioshack.com/product/index.jsp?productId=3897297>

16. Powerizer. DC Motors. Retrieved December 8, 2010.

<http://www.batteryspace.com/dcmotors.aspx>

17. US Plastic Corp. Retreived December, 16 2010.

<http://www.usplastic.com/catalog/item.aspx?sku=11319>.

18. Heat and Plumb. Retrieved December 16, 2010.

<http://www.heatandplumb.com/acatalog/Polytank_50_Gallon_Water_Tank_PT2_925m

m_x_600mm_x_570mm.html>.

19. Power Production Management. Retrieved December 16, 2010.

<http://onlinesolarsupply.com/shop/article_PPM02-

AEE%2BHarris%2BHydroelectric%2B017-01032/Harris-PM-2-Nozzle-Micro-Hydro-

Turbine-017-01032.html?pse=coa>.

20. Water Pumps Direct. Retrieved December 16, 2010.

<http://www.waterpumpsdirect.com/BE-HP-2055HM/p5127.html>.

21. Industrial Automation. Retrieved December 16, 2010.

<http://www.valvestore.com/products.asp?dept=1276>.

22. Pipe and Gas Journal. Retrieved December 17, 2010. <

http://pipelineandgasjournal.com/large-diameter-plastic-pipe-mains-are-helping-gas-

distribution>

23. DC Motors Principles of Operation. Retrieved December 17, 2010. <

http://www.solarbotics.net/starting/200111_dcmotor/200111_dcmotor2.html>

24. "A q u a f i na W at e r . " H o m e D el i v e r y Fo od s . N . p . , n . d . Web . 1 7 D ec

2 0 10 . <h t t p : / / w w w.h om ed e l i v e r yf o o d s . co m/ aq u a f in a - w at e r . h tm l > .