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Two inlet nozzles works

October 14, 2019 — BarryK

I posted yesterday that the inlet design was not spreading the water wide enough:

https://bkhome.org/news/201910/inlet-pipe-design-not-satisfactory.html

I have jury-rigged a setup with two nozzles. Externally, from the linline-filter there is a T-junction and two 4 litres/hour drippers, then 4mm trickle pipe taped onto the distiller:

img1

...the 4mm pipes are taped on the up-flow-side of the aluminium channel, so as to flow horizontally somewhat before seeping underneath the channel.

This looks good. I managed  to take the photo at an angle where you can just see how the water has progressed down the cloth. It is covering the width of the cloth. Interesting, it looks like the left-hand outlet has a very slightly higher flow rate.

Next step, redesign the inlet to have two pipes. 

Tags: nomad

Inlet pipe design not satisfactory

October 13, 2019 — BarryK

Today I setup a test of the inlet pipe in the solar water distiller prototype #3:

img1

...from the water container, there is an inline filter, then the flow-reducer as described in an earlier post:

https://bkhome.org/news/201906/testing-pope-4-litre-per-hour-dripper.html

Then there is a 13mm-to-4mm trickle-pipe reducer, and silicone tube into the distiller. Water comes out of the top-side of the aluminium square-section channel, so flows along the top before working its way underneath the channel and down the wicking cloth.

The design was a punt. I thought that the spreading effect would work, but didn't know how much. In the photo, the water has trickled down about halfway in the centre, and if you squint at the photo, you might just make out the spread. It is good, but not wide enough to reach the sides of the cloth.

So, need to rethink the design. Two holes would probably do it, but the problem is to get equal water flow through them. I don't want to put any trickle parts inside the distiller, as the temperature might get up to 65 degrees C and the plastic might soften. Thinking to have two flow-reducers externally. 

EDIT 2019-10-14:
Problem solved, see post:

https://bkhome.org/news/201910/two-inlet-nozzles-works.html 

Tags: nomad

Assembling inlet of water distiller

October 08, 2019 — BarryK

Continuing construction of solar water distiller prototype #3, previous post here:

http://bkhome.org/news/201910/constructing-water-distiller-inlet.html

Holes needed to be drilled to mount the inlet pipe. The small holes are 4mm diameter, the large one is 6mm:

img1

...there was a bit of messing around deciding exactly where the holes will be drilled. Exact measurements will be in the final DIY page. I assembled the central glass with silicone mat and wicking cloth, then placed the inlet pipe on top, to find out where those holes needed to be.

I didn't really want to glue anything together, as the aim is that the distiller can be totally pulled apart. However, the mat sits on the glass and want the edges folded up so as to contain the water. The top up-slope end of the mat is a problem, want it to stick up about 90 degrees from the plane of the mat. I used Selleys 401 silicone sealant to adhere the mat to the glass and achieve the top lip.

Here is the inlet pipe assembled:

img2

...using the black towel used in prototype #2, which has a 6.3mm aluminium rod inserted along the top of the towel. The towel is cotton, from Kmart, it is plain black, no embossing. The aluminium rod is from Bunnings.

The rod was AU$2,32:

https://www.bunnings.com.au/metal-mate-6-3mm-x-1m-aluminium-solid-rod_p1130541

The towel was AU$6:

https://www.kmart.com.au/product/malmo-cotton-bath-towel---black/2332350

The great thing about the towel is that it already has a folded-over-end through which the aluminium rod fits snuggly:

img3

As you can see in the second-last photo, the silicone mat top-end lip is not sticking up at 90 degrees, more like 45 degrees. So what I did was fold it right over 180 degrees and apply silicone sealant:

img4

...left that overnight. Yes, that did the trick, it sprang back to about vertical:

img5

The next exercise will be to construct the distilled-water runoff. That is tricky, as distilled water will be running down both top and bottom glass sheets. I have considered various ways to construct it, and trying to do it without any more gluing.

Tags: nomad

Constructing water distiller inlet

October 04, 2019 — BarryK

Continuing the construction of solar water distiller prototype #3, here is the previous post:

http://bkhome.org/news/201909/cutting-inner-slots-and-runoff-holes.html

In the prototypes #1 and #2, the water inlet was an aluminium tube running horizontally across the top, with two or more tiny holes in it, through which the water trickled. I had difficulty with getting an exact flow rate, and experimented with an external flow reducer, see here:

http://bkhome.org/news//201906/testing-pope-4-litre-per-hour-dripper.html

I am using this external flow-control system for prototype #3. Inside the water distiller, there will just be one hole that the water comes out from, and it is intended to spread out so that it flows down the entire width of the wicking cloth.

There have been several iterations of the inlet pipe, and even got to the point of buying some parts then changing my mind, hence wasting money.

Until recently, it was going to be a 12mm OD aluminium round pipe, with 12mm holes drilled in the wood frame on both sides to hold it. However, the inner sheet of glass, on which the wicking cloth lies, will also have a silicone mat between glass and cloth -- that mat will have folded-up lips on the sides, to form a sloping tray, to keep the water contained.
The 12mm pipe resting on top of the wicking cloth will compromise the lips of the silicone mat at the sides. hence had to rethink the design.

What I decided on is to use 12x12x1.5mm aluminium channel, length slightly less than the inner width of the distiller, with brass rods extending into the wood frame to hold it in place. This creates a gap on the sides for the silicone mat lip.

First step, buy the channel, AU$5.81:

https://www.bunnings.com.au/metal-mate-12-x-12-x-1-5mm-1m-aluminium-channel_p1079307

I decided to use standard 4mm trickle fittings for the inlet piping. I already have 13mm trickle/drip fittings, a inline filter and the flow-control construction described in the above link. Hence, need to reduce to 4mm and bought this, a 13mm to 4mm adaptor, AU$3.64:

https://www.bunnings.com.au/ladco-13mm-end-flow-irrigation-poly_p3110770

I could have used cheap 4mm trickle irrigation pipe, however decided to go for silicone tube. Main reasons, it is translucent so can see the water inside, secondly it is highly UV-resistant. I went for silicone tube 3mm ID and 6mm OD, so the wall thickness is 1.5mm. Earlier this year I had purchased silicone tube from China, via eBay, to suit the 13mm trickle fittings, with a 1mm wall thickness, but I found that it kinks very easily. Smaller diameter tube is less likely to kink, but decided to play safe and go for the thicker wall.

I thought to also use this 3mm ID tube for the outlet of the distilled water, however, was concerned that the surface tension of water might impede the flow through such a small diameter tube. So for outlet, chose 4mm ID and 7mm OD, 1.5mm wall thickness.

The silicone tube can be purchased from China cheaply, for example:

https://www.ebay.com.au/itm/Food-Grade-Clear-Silicone-Tube-Beer-Brew-HIGH-TEMP-Flexible-Hose-Pipe-Many-Sizes/223569644388

However, I wanted it NOW, so purchased from a local supplier, here in Perth, Western Australia. A very premium price. The company also has an eBay store and they send by Toll Express:

https://www.ebay.com.au/itm/Silicone-Rubber-Tubing-Silicon-Tube-Hose-Medical-Food-Grade-ID-from-0-5mm-to11mm/121841722645

When the DIY plans get published, it will be recommended to save some money and buy from China, if there is no cheap local supplier. The price will be AU$4.44 for 3mm ID 6mm OD, and AU$4.76 for the 4mm ID 7mm OD, 1 metre lengths.

The channel is cut to length 554mm, so as to fit inside the wood frame with slight gaps both sides of a couple of millimetres. A 4.5mm hole is cut in the middle, and a slot cut on the right side 6mm wide and 9mm deep. Like this:

img1

...you might not be able to make it out in the photo, but I gouged lines on the top and bottom insides, as the channel is to be filled with silicone sealant, and the gouges will help it to grip to the channel.

I purchased 4mm 90 degree elbow spur-fittings, supplied in a 10-pack, AU$4.20:

https://www.bunnings.com.au/pope-4mm-barbed-elbow-10-pack_p3121007

I cut the spur off one end of an elbow and attached the 3mm ID silicone tube to the other end. I pushed it into the hole, like this:

img2

On the right side, the silicone tube is pushed slightly into the slot. The reason for this is there will also be a brass rod sticking out from the end, and there needs to be a slight separation between the two holes that will be cut in the wood frame. Snapshot:

img3

...I cut off two short pieces of silicone tube and placed them on the left side -- when the brass rod gets positioned, it will be resting on top of the silicone tube, same situation at left and right sides.

I used some silicone sealant to fix the tube in place, and left overnight to set. The above photo shows the sealant applied, and the photo was taken the next day. I am using Selleys 401 acetic cure silicone, because it is rated food-safe and has superior bonding to silicone and glass, this one at AU$19.65:

https://www.bunnings.com.au/selleys-310g-401-rtv-engineering-grade-silicone_p1231042

Brass rod is available via eBay, however also sold at many local hobby shops. I purchased K&S brand (made in USA) 1 foot length 5/32 inch diameter (305mm, 3.97mm) brass rod from PerthRC hobby shop, Lord Street, Perth, for AU$4.49:

http://www.perthrc.com.au/brass-rod-solid-5-32x12-1-pieces-per-card.html

Cut it in half, gouged with a file edge, and placed into the channel, sticking out about 10mm each end from the channel, embedded in silicone sealant. Used various tools and implements to hold the rods in place and left overnight. Here is a view of the left side:

img4

...you can see that the rod is at the same height as the channel. To help fix it in place more securely, I wanted the sealant to have a convex surface, so as to completely encircle the rods. So, the following day, used a small piece of cardboard as a spreader for the final application of sealant:

img5

The sealant was applied along the entire length of the channel, then dragged the piece of cardboard along the entire length to form a nice slightly-convex surface.

Finally, here are views at the right side:

img6
img7

There is one important detail. Notice the outlet hole, where the 4mm plastic elbow is pressed through the channel. It is on the up-slope side, not facing down-slope. So, there will be a slope, about 30 degrees, and the hole seems to be on the wrong side. This is part of the plan. The water will trickle out and run along the up-slope side of the channel and work its way underneath through the wicking cloth. This mechanism is intended to help the water to spread out the width of the distiller. This is so far entirely theoretical!

The next step will be to drill holes into the wood frame so as to mount this assembly. 

Tags: nomad

Router frame wobble fixed

October 03, 2019 — BarryK

I posted about the ill-fitting frame in my el-cheapo 30 bucks trimmer router:

http://bkhome.org/news/201909/cutting-grooves-with-new-router.html

Here is a closeup showing the cause of the wobble:

img1

...you can see the plastic "bridge", that prevents the lower-end of the frame from closing tightly to the body. You may also be able to make out where it cracked when I tightened the knob too much.

Today decided to try an experiment: cut off the bridge. Simple exercise, with a hacksaw blade cut the section of plastic that holds the two sides apart, cutting a slot as wide as possible. Photo:

img2

...magic, problem fixed! Yep, a simple bit of surgery and the frame now tightens up top and bottom, no wobble, grips the body tightly.

So, two surgical operations have been performed on the frame, front and back, and now I can recommend this cheap router. 

Tags: nomad

Cutting inner slots and runoff holes

September 28, 2019 — BarryK

Continuing with construction of solar water distiller prototype #3. Here is the previous post:

http://bkhome.org/news/201909/cutting-frame-for-prototype-3.html

Today have cut the inner slots and holes for the runoff tube. The runoff tube is 16mm outside-diameter aluminium, and I posted previously how a 10mm wide slot was cut in it. One end of the tube has to be blocked off, so I purchased a rubber stopper from Clark Rubber:

https://www.clarkrubber.com.au/rubber-stopper

I chose the 24x16x13mm stopper, and cut off the narrow end and pushed it into the end of the tube:

img1

...I managed to push it in a bit more than shown in the photo, until it was just about flush with the end of the tube.

Cutting the inside slots taught me more about router bits! I used the 4mm straight single-flute bit, and as I was moving the router along, suddenly realised that it was cutting much deeper. The single flute causes more vibration, and although I thought that I had tightened the chuck very well, the bit was gradually working its way out.

What a lesson that was. Fortunately, I spotted what was happening and readjusted the depth of the bit in the chuck, and tightened it up as much as I could.

But then I observed something else: the 4mm bit was cutting a fractionally-over-4mm wide groove. Before, when cutting the outside grooves, I used a Diablo 3.2mm (1/8 inch) straight dual-flute bit, then later ran through the grooves with the 4mm single-flute bit to widen the grooves. That resulted in a pretty well spot-on 4mm width, that the glass fitted into very snuggly.

We are talking about sub-millimetre difference here, but it is still significant. I put the wider cut of the single-flute bit being due to the vibration as it cuts one side then the other.

I did receive advice that dual-flute bits are better, now I know from experience. Though they are expensive. Here is the Diablo 1/8 inch bit:

https://www.bunnings.com.au/diablo-1-8-x-3-8-dual-flute-straight-router-bit_p6370474

...unfortunately, there isn't a 4mm (5/32 inch) dual-flute bit. Not at Bunnings anyway.

The steps that I followed today, was to firstly drill the round holes to hold the runoff pipe. I did that before cutting the slots.

I will post a diagram showing exact measurements when the final DIY page is uploaded. Basically, there is a 16mm hole cut 10mm deep on the left side, and cut right through on the right side. To do this, I purchased a set of spade drill bits, at only AU$7.98:

https://www.bunnings.com.au/craftright-10-piece-spade-drill-bit-set_p6360080

...require the 16mm bit, and later on the 12mm bit, so it was cheaper just to buy the set.

After drilling the holes, the router was then setup and the slots cut, 630mm long, well slightly over, as the glass is 630mm long.

Finally, a check to see that it goes together. Here is the inner sheet of glass and runoff tube inserted:

img3

...just eyeballing it, I think that if I ever make another runoff tube, I will make the slot slightly narrower, down from 10mm to 8mm. But 10mm is OK. The important thing is that the runoff should not be able to splash out -- the design is such that there won't be any splashing anyway. 

Tags: nomad

Miscellaneous mumblings

September 26, 2019 — BarryK

Before executing the next step in construction of the solar water distiller, I am waiting on arrival of a silicone mat. It is 600x800mm and will go inside the distiller, between the glass and wicking-cloth. I think that it is 1mm thick, but wanted to wait until it arrives, to confirm, as it will have an affect on the internal layout. Ordered from here:

https://www.ebay.com.au/itm/Non-Stick-Silicone-Rolling-Baking-Mat-Sheet-Pastry-Fondant-Icing-Cake-Pizza-Tool/143332064871

Ordered on the 19th, it is now the 26th. It is supposed to be shipped from NSW Australia. However, yesterday I checked the tracking number, and found that it is being shipped by "Winit". That is a Chinese transport company. There is tracking information, but it is evasive, does not identify any locations.

I found this comment on a forum:

https://community.ebay.com.au/t5/Buying/False-Seller-Item-Location-Massive-Problem/td-p/2136889

Quoting:

I am sick and tired of buying off sellers in AU stores that list there items location as in Australia when in fact the item location is overseas and so is the seller and you end up with a very lengthy postage wait or not item at all or you end up with a WINIT tracking number that means squat to anyone as it does not track anything outside of China.

I want to see eBay crack down on these sellers for false advertising a location of their items when you are trying to buy from within Australia only thinking you have brought local only to find out the seller falsely listed the items location.

I am dealing with one right now and seller has avoided the questions I have put to him/her of the real location of the item I brought after getting that WINIT tracking number the seller finally answered with an outright lie "It Come USA" clear not good with English at all and the item is clearly coming from China.

The eBay page states this:

Postage:
FREE Standard Postage
Item location:
NSW, Australia

I wonder when it will arrive?

Continuing the mumblings and grumblings, If you have sent me an email in the last few weeks, with a question or problem, and I haven't replied, my apologies. The to-do list has grown rather long.  Besides, I take time out from EasyOS development and do other things for awhile. 

EDIT 2019-09-26:
For the record, here are two other eBay vendors selling the 60x80cm silicone mat, and claiming AU stock and shipping by Australia Post:

https://www.ebay.com.au/itm/XL-LARGE-Silicone-Rolling-Cake-Dough-Mat-Pastry-Clay-Fondant-Baking-Sheet/401686088813

https://www.ebay.com.au/itm/XL-LARGE-Silicone-Rolling-Cake-Dough-Mat-Pastry-Clay-Fondant-Baking-Tool-Mat-Pad/173883836414 

EDIT 2019-09-27:
It arrived today! Delivered by Australia Post. So how come it had a Winit tracking number?
 


Tags: nomad