Construction Process

Completed CAD drawings can be found here

 

The model has been constructed.

 

 

Presentations Pictures

Plan of Procedures

The lists shown below lay out the different materials, supplies, tools, and parts needed to completely construct the tank design which has been created through the process of this project. Visuals are included to ensure accuracy, and step-by-step instructions lay out the process by which the product should be constructed to ensure the highest quality of the final solution. The procedures laid out below are solely for the construction of the tank, which will eventually be integrated with the water flow system constructed by Mr. Trimble to complete the tank. All parts of the tank are illustrated below and will be detailed in the charts.

Supplies
Number	Supply	Quantity	Amt.	Notes
S1	Marine Grade Sealant	2	10 oz	Joins acrylic to each other

The materials that are purchased for the tank will need alteration to best fit the needs and size of the tank. The following tools will be used to process the materials into the final product. All tools will be supplied by the school and used under the proper conditions to ensure the safety of the user, others in the room, as well as for the best results of the product.

Tools
#	Tool	Use
T1	Power Drill	To cut holes in PVC, to attach pipe holders
T2	Table Saw	To cut materials
T3	Yard Stick	To use for measurements
T4	Drill Bit	To cut holes in PVC
T5	Marker	To use to mark measurements
T6	Pencil	To use to mark measurements
T7	Hole Saw	To cut hole for PVC in acrylic

Everything listed below is needed within some aspect of the tank. The majority of the tank is made of acrylic which is why that is the largest part of the list, everything else is needed in the details of the tank to ensure proper function of the system as a whole.

Materials
#	Supply	Qty	Size	Notes
M1	Acrylic Walls	4	23.75” x 6.75” x .25”	Outer walls of the tank
M2	Acrylic Partitions	4	10.56” x 6.75” x .25”	Inner partitions of tank, cut angle
M3	Acrylic Bottom	1	24” x 24” x .25”	Entire bottom of the tank
M4	2” PVC	1	8”	To be drilled according to drawings

Construction Procedures

PART 1: The Bottom

1.      Take one 24” x 24” x .25” piece of acrylic and lay it flat on a smooth surface.

2.      Using a yard stick (T3) and a marker (T5) mark the exact center of the acrylic.

3.      Use the hole saw (T7) to cut a 2.875” hole out of the center of the acrylic.

PART 2: The Outer Walls

1.      Take one 24” x 24” x .25” piece of acrylic and lay it flat on the table saw (T2).

2.      Using the table saw (T2) cut the piece to fit the 6.75” x 23.75” dimensions.

3.      Two walls should come from one piece of acrylic.

PART 3: The Inner Walls

1.      Take the acrylic remaining from the outer walls and cut out two pieces measuring 10.56” x 6.75”.

2.      Using the yard stick (T3) measure one inch down on one side of the newly cut piece.

3.      Cut from this measure up to the opposite top corner using the table saw (T2). See below picture for reference.

PART 4: The PVC Tube

1.      Take an 8” section of 2” PVC and lay it on a flat surface, securing it to ensure it does not roll.

2.      Using the power drill (T1) and drill bit (T4) drill a .125” hole into the PVC 2” down from the top.

3.      Repeat, making three more holes each spaces .125” apart.

4.      Using the power drill (T1) and drill bit (T4) make a 1” slit 1” down from the top.

5.      Repeat steps 1-4 on each quadrant of the pipe.

 

 Assembly Procedures

1.      Take the tank bottom (M3) and the outer walls (M1) and apply the acrylic solvent solution (S1) around the edges of the bottom.

2.      Set the walls (M1) in place on the bottom (M3) and allow the solvent to set and dry.

3.      Slide the PVC pipe (M4) into place and use the PVC-Acrylic Adhesive (S2) to adhere it into the tank.

4.      Once the pipe is dried and in place, use the acrylic solvent solution (S1) again to place the inner partitions (M2) into place and let them dry.

5.      When all the joints are secure, use the silicone sealant (S3) to make a final seal on all joints.

6.      Integrate with the water flow system.

Marking Period 2 Calendar of Work and Due Dates

Due Dates:

11/27 - calendar of dates due

12/2 - developmental work/plan of procedures

12/16 - press release

12/18 - initial construction analysis

1/15 - outline for formal presentation

1/16 - formal presentations begin

1/20 - final construction analysis

1/23 - mentor contacts

4 days after presentation - presentation reflection

Working Plan*:

11/26 - develop schedule of work for the marking period

11/27 - work on plan of procedures; figure out what supplies and materials to be used

12/2 - finish POP and developmental work

12/3 - find distributors of materials needed 

12/4 - create list of possible places to buy items

12/5 - contact mentor to find possible suppliers

12/6 - begin working on the press release

12/9 - continue press release

12/10 - continue writing up material purchases

12/11 - begin construction of tank

12/12 - continue tank construction

12/13 - let mentor know about press release; test tank construction

12/16 - finalize and turn in press release

12/17 - work on building tank

12/18 - work on building tank

12/19 - ensure everything is working properly in the tank

12/20 - collaborate with Mr. Trimble to ensure proper connections

12/23 - contact mentor to update on tank construction

12/27 - work on building tank

12/30 - test the tank so far; continue building

12/31 - work on building tank

1/1 - work on building tank

1/2 - work on building tank

1/3 - work on building tank

1/6 - test tank

1/7 - work on building tank

1/8 - work on building tank

1/9 - work on building tank

1/10 - ensure Mr. Trimble's parts properly match my own

1/13 - read over rubric for formal presentation; ensure all needed aspects are completed

1/14 - construct the outline for the formal presentation

1/15 - finalize and work through the formal presentation outline

1/16 - formal presentations

1/17 - formal presentations continue

1/20 - first possible day to turn in presentation reflection; formal presentations

1/21 - formal presentations; work on midterm

1/22 - work on midterm

1/23 - work on midterm

1/24 - work on midterm

1/27 - midterm due

 *subject to change

Testing Procedures

The purpose of completing this project, for our team, is not only to help horseshoe crabs as an entire species, but we are also building this tank for the Seniors in the Class of 2015 and beyond to use in MAST's Oceanography course. A successful tank will be able to raise at least 20% of the 100 horseshoe crabs which will be placed in the tank, while also benefitting the scientific community by advancing our knowledge of the species. A complete system - which includes Mr. Trimble's water and nutrient systems - will be constructed and implemented, and if the entire system can constantly and consistently maintain flow of the necessary nutrients and water while also maintaining a stable connection throughout the tank the solution will be considered a success. (more information can be found about the functions of the tank here)

Throughout the process of this project the design of the tank will undergo many tests to ensure the best product is created. Starting at the beginning the four alternate designs will be compared to find the best solution. From this decision there will be tests comparing materials, water volume sizes, substrate choices, system integration with Mr. Trimble's systems, as well as the final test of the solution once construction has taken place and the tank is ready to be used. Most of these tests will be performed by myself along with the rest of the team, but along the line my mentors will be assisting in the tests and the final solution will be tested during implementation of the tank by the Oceanography class next year. In general, these tests will take place in the Systems Engineering II classroom with exceptions being any time emails are sent and the final solution which will happen in the NOAA lab on Sandy Hook.

Testing Type: Comparison
Testing Stage: Preliminary
State of Solution: Alternate Solutions
Condition of Testing Stage: Preconstruction on paper
Tools and Equipment: the drawings of solutions

Testing Procedures:
1. Lay out the four designs
2. Using the specifications, compare the designs
3. Decide which solution best fulfills the specifications


Testing Type: Exploratory
Testing Stage: Preliminary
State of Solution: Paper drawing
Condition of Testing Stage: Preconstruction on paper
Tools and Equipment: drawing, mentor, future user

Testing Procedures:
1. Set up a meeting with the Oceanography teacher at MAST
2. Show her the drawing of current solution
3. Ensure design incorporates all necessary design aspects and fulfills the needs of the project
4. Make changes as necessary


Testing Type: Validation
Testing Stage: Preliminary
State of Solution: Dimension Specific Drawing
Condition of Testing Stage: Preconstruction on paper
Tools and Equipment: drawing, Mr. Trimble's drawing, Mr. Trimble

Testing Procedures:
1. Meet with Mr. Trimble and compare drawings
2. Ensure the measurements of the two drawings completely integrate
3. Alter as needed


Testing Type: Exploratory
Testing Stage: Secondary
State of Solution: Drawings and Research
Condition of Testing Stage: Materials
Tools and Equipment: Notes on materials, possibly samples of materials

Testing Procedures:
1. Compare possible materials among each other
2. Using information gathered, decide which materials would best accomplish the needs of the tank to ensure stability and usability


Testing Type: Assessment
Testing Stage: Secondary
State of Solution: CAD Drawing
Condition of Testing Stage: Preconstruction
Tools and Equipment: CAD Drawings, project specifications

Testing Procedures:
1. Compare the current solution with the specifications of the project
2. Going down the list, look at the details of the tank to make sure each specification is fulfilled


Testing Type: Assessment
Testing Stage: Tertiary
State of Solution: Post Construction Non-implemented
Condition of Testing Stage: Dry and Empty
Tools and Equipment: constructed tank, specifications, weights, water

Testing Procedures:
1. Examine the constructed tank to ensure the pieces are sturdy
2. Test all joints for leaks
3. Apply pressure to ensure the joints will hold under the pressure of the water, sand, and crabs.


Testing Type: Validation
Testing Stage: Final
State of Solution: Completed
Condition of Testing Stage: Implemented, containing crabs, water and sand
Tools and Equipment: full tank, all materials

Testing Procedures:
1. Completely implement all variables in the tank
2. Observe how the crabs begin to integrate into their new environment
3. Decide if the tank is working as needed, if not halt all processes and return the crabs to their holding tank

Survey for Assessment:
1. Do the 100 crabs fit comfortably?
2. Are scientists benefitting from the use of the tank?
3. Is the environment of the tank similar to the current state of the natural environment of the horseshoe crabs?
4. Is the tank holding stably?
5. Is the water connection water tight and properly fitted?
6. Is the water flowing constantly?
7. Are any of the parts being negatively effected by the salt water?
8. Are the horseshoe crabs healthy?
9. How clean is the tank overall?

Developmental Work

 2D VIEW

 



3D VIEW



 EXPLODED VIEW

Rationale

The four tank designs talked about below were all created for the purpose of raising horseshoe crabs in a lab environment. These designs focus on the main structure and functionality of the tank, but all must properly integrate with the water flow system Mr. Trimble is creating. All tanks are expected to perform at a certain level and through the process laid out here the flaws and strong points of each design will be analyzed and used to determine the best tank. For these designs to work they will need to be beneficial to the survival rate of the crabs as well as the study of the species for human purposes. Efficiency will be achieved when excessive amount of water or additional nutrients will not be necessary. By raising a significant number of crabs without a high amount of waste of water or other resources we will know the tank works well and efficiently. As per the design of the project, our tank must work off of a closed system of water flow to eliminate the potential for contamination, but there must also be aspects of the tank which will cause constant flow of the water within the system while also taking into account the potential for things like water leakage or over filtration. The system will be considered a failure if there is no benefit to either the horseshoe crabs or the scientists studying them while they are in captivity.

Design 1: Cylindrical Tank
Being the first design I created, this tank is naturally the simplest design of the four. There is a very basic connection to the water filtration system in the sides of the tank and a large observation window in the front of the tank which would be used to watch the activity of the crabs throughout the day. This tank appropriately takes into account the need for constant submergence by the young horseshoe crabs. The simplicity of the design is easy to replicate, the only complications coming from the transition between solid fiberglass and plastic/acrylic to make the observation window. Since this design is one of the larger tanks, the cost of the fiberglass along with the piece of plastic or  acrylic would have to be taken into account along with any tools needed to created the desired shape and connections to ensure a stable and water tight product. If created properly the horseshoe crabs will benefit from having a stable and controlled environment where they will be taken care of during one of their more vulnerable life stages. The scientists will benefit from a proper product by being able to watch the horseshoe crabs in their daily life.

Due to the shape of the tank there is certainly a level of stability not achieved in a shape with more joints and corners. Having a cylindrical shape means having only one seam at the bottom of the tank and along the edges of the observation window, which can become completely water tight with the proper adhesive. Though maintaining structural integrity under the pressure of water is necessary in this project, that is one of the only aspects this tank has that greatly benefits both the horseshoe crabs and the users. The tank only barely resembles the natural environment of the horseshoe crabs and may not properly prepare them for release post-captivity.

Design 2: Shore Tank
With a better understanding of the natural environment of the horseshoe crabs, my next tank design was created. This design was the first design to take into account the natural slope and other aspects of the environment of the juvenile horseshoe crab. There is a section of dry, open sand at the top of the tank onto which the crabs can crawl if desired. This mimicked shore area would also allow my team to imitate the tides of the area where the horseshoe crabs will eventually be released. Again, this tank has a very basic connection to the water flow system, but this is something that could be easily altered as the most important parts of this design are the structural aspects like the sloping bottom. By including the sloped bottom of the tank, the horseshoe crabs become more accessible because with a shallower depth the scientists who will be working with the crabs will be able to reach in to grab the juveniles without submerging their entire arm. Due to the simple box shape the walls of the tank take on the design is easy to reproduce, the only confounding factor being the odd slope of the bottom (this is dealt with in Solution 3: Sloped Tank). The costs considered with this tank will need to be simply the materials (acrylic and adhesive) and tools (such as saws) needed for creating the tank. Overall, this tank will be a better option for raising the horseshoe crabs than the previous design would have allowed, because there is a better representation of the natural environment as well as a more ergonomic design for the scientists who will be using the tank for studying the species.

I find with this design that there is a better representation of the natural environment of the horseshoe crabs which makes this design a better choice than the previous tank. However, over time and after creating further designs I have found some flaws in this design. First off, the large portion of dry sand at the top of the tank, which is a focal point of this design, would be virtually useless during the age range the crabs will be in captivity. Generally, horseshoe crabs only make use of the intertidal zone when they are mating and laying eggs which is something the young crabs will not be doing. Even though the crabs will not make use of the dry sand, the availability makes the possibility of tide simulation feasible. Another obstacle faced with this tank as well as in the next three designs is the tendency of sand to settle; this will be a problem with the sloped bottom of the tanks where we expect the sand at the top of the slope to seek the lower parts of the slope.

Design 3: Sloped Tank
As a continuation and alteration of the previous solution, my third design came into being. This tank is a combination of the previous tank and the tanks which they are currently using in NOAA, as this is where the tanks will be used. There is a central drainage pipe where the excess water will flow through into the filters to then be put back into the tanks. I continued with the idea of the sloped bottom in this tank, however I altered the idea so the slope is less dramatic and easier to create and then reproduce. The slope will again allow for those using the tank for scientific purposes to have easy access to the crabs without needing to fully submerge their arm. This design, however, has the entire area of the tank floor submerged instead of keeping a section dry. By including this change there will be more area for the crabs to live in while keeping the benefit of a better simulated habitat.

Since this design was created as an alteration of the previous design, the changes made allow the tank to better fit into the NOAA environment while maintaining a simpler and more easily reproduced shape. The tank still has a good simulation of the natural environment while also incorporating a simpler and more reliable system for water flow. The potential problem with the water drainage in this tank is the possibility of horseshoe crabs (if they were to swim) getting caught in the drain. The drainage system also may not fully cause the water towards the bottom of the tank to filter and drain.

Design 4: Compartmentalized Tank
The final solution that has been made for this project is a tank which could be looked at as a combination of designs one and three. The basic shape of the first tank design was kept, but modified to better fit our needs. Center drainage and sloped bottom of design three was kept and combined with the shape of the first tank. Each compartment of this tank is meant to hold 20 of the 100 horseshoe crabs and the tank as a whole will hold all 100. This tank will save lab space as well as provide the horseshoe crabs with the best simulated habitat we can create. In the center drainage pipe there is one large slit where we want the water level to be maintained along with a series of small holes which will allow the water towards the bottom of the tank to trickle out and be filtered. As a safety, the top of the pipe will be open in case of overflow. On top of reach partition, small pipe holders are in place to hold the pipes of the water flow system. We tried to keep the design as simple as possible while also taking into account all the needs of the tank to work properly and also the needs of the horseshoe crabs.

This tank is the most designed tank with the most thought put into the structure. There are certain aspects of this design, such as the sloped bottom and the trapezoidal shape of the walls which add a bit of difficulty to the design. However, these things are necessary for the proper function of the tank. By using this tank, the space within the lab will be saved or better utilized and the partitions within this tank allow for a few different variable to be tested among the separate sections of crabs.

	Design One	Design Two	Design Three	Design Four
Has space to raise 100 crabs	4	3	4	5
Has potential to raise survival rate	4	4	4	4
Is beneficial to studying the species	2	3	4	4
Replicates the natural environment	1	3	4	4
Is stable under pressure	4	3	3	4
Properly connects with water systems	1	3	3	4
Able to survive constant exposure to salt water and live crabs	3	3	4	4
Water/leak proof	2	3	4	4
Is replicateable	3	2	4	3
Total	25	28	34	36

*on a scale of 1-5

After taking into account each specific need the tank needs to fulfill and comparing the tanks to each other, I have found that the compartmentalized tank will work the best in raising the young horseshoe crabs by mimicking their environment properly, but the design is also ergonomic for human use in a lab. Design four best allows for comfortable living conditions for the crabs, while also giving the NOAA scientists a tank which they may use to study the species and possible help further save them. This tank, though maybe the hardest to construct is thoroughly thought out and "safeties" within the design have been created to ensure constant, up to par function of the tank. This is, therefor, the best option for us to move forward with.

(to see the tank designs follow this link: http://habitatforhorseshoecrabs.blogspot.com/2013/09/alternative-solutions.html)