Team 8 ME Senior Design Danfoss Turbocor : Stator Insertion

1. Team 8 ME Senior DesignDanfossTurbocor: Stator Insertion Gregory Boler Jr. Matt Desautel Ivan Dudyak Kevin Lohman Figure 1: Compressor Housing

2. Overview • DanfossTurbocor Background/Introduction • Product Specification • Design Approach • Initial Expansion Calculations • Experiment 1: Verifying Linear Expansion • Heat Transfer Calculations • Design Concept • Design Details • Cost Analysis • Conclusion • Future Work

3. Cutting Edge Compressors • Outstanding Efficiency • Totally oil-free operation • Extended life with minimal scheduled maintenance • Onboard digital controls and electronics • Exceptionally quiet operation • Compact • Environmentally responsive Figure 2: Turbocor Compressor

4. Introduction • Background • Heating of an aluminum housing to allow thermal expansion of the material • Once expanded a stator is inserted into the housing • The housing cools in ambient conditions locking the stator in place through an interference fit

5. Product Specification • Current method • Large oven requiring extensive floor space • Lengthy heating time ~ 45 minutes • High final temperature ~ 300°F • Four units per cycle • Long cooling time before the technicians can continue assembly ~ 30 minutes Figure 3: Current Oven

6. Product Specification • Current method • Stator inserted at a secondary station after heating cycle • Precise position required for pneumatic actuator • Additional floor space required for the secondary station Figure 4: Stator Insertion Station

7. Product Specification • Engineering Requirements • Reduced heating time, < 8 min. • Lower final temperature • Smaller size • Thermal expansion must allow for 60 microns clearance at maximum material conditions

8. Design Approach Problem Specification Spring Events Preliminary thermal expansion calculations to determine the housing temperature to reach the desired clearance Construction of heating unit proof of concept Experimental measurements of housing expansion in a thermal chamber Final design and prototype of heating unit Calculation of heat input needed to achieve the desired temperature using hot air Experimental testing and design adjustment Design concept and component selection based on analysis Final Product Evaluation

9. Initial Expansion Calculations • Sliding fit at maximum material condition 60 microns clearance Linear Expansion Equation 60 μm 85.86 °C Figure 5: Linear Expansion Relationship

10. Experiment 1: Verifying Linear Expansion Steps: • Heat housing • Take diameter measurements at various temperatures • Plot experimental data versus theoretical data • Data analysis Figure 6: Bore Gauge (http://www.fvfowler.com)

11. Where to measure? Linear expansion equation Dimensionless linear expansion Figure 7: Compressor Housing Cross-Section

12. Figure 8: Experiment 1 Data Analysis

13. Initial Heat Calculations • How much heat input to reach 85 °C? Closed system with no work output 1985.66 kJ 85.86 °C Figure 9: Change in Temp w/ Heat Input

14. Q loss Heat Transfer Analysis 1 • W • Heat input to system 2 from heater • Q21 • Heat transferred from system 2 to system 1 • Q loss • Heat lost from system 2 to outside environment Q21 2 W Figure 10: Heat Transfer System

15. System 1 First Law System 1 1 Q21 System 2 First Law System 2 Q loss 2 W Figure 11: Heat Transfer Systems

16. Coupled System of Ordinary Differential Equations Initial Conditions MATLAB 84.6 °C 7.56 min Figure 12: System Temperature vs. Time

17. The Design Concept • Re-circulating air over a heater coil within an insulated unit to heat housing • Cooling cycle opens lid to hood and activates a blower to circulate ambient air around outside of housing Figure 13: Convection Concept Sketch

18. The Design Concept • Consists of: • An insulated table and hood • Re-circulating fan • Heater • Cooling fan Figure 14: Provisional Design

19. Table Selection • Requirements: • Heating unit • Hot air recirculation • Housing locator • Temperature sensors • Design chosen: • Utilizes an exterior blower • Has built in return ducts for hot air recirculation Figure 15: Lower Design Section

20. Heater Selection • Heater chosen: • MSC 5600 watt electric portable heater 84.6 °C 7.56 min Figure 16: Electric Heater (http://www.mscdirect.com) Figure 4: Housing Temperature vs. Time

21. Hood Selection • Requirements: • To retain heat within unit (insulated) • To allow easy insertion and removal of the part in and out of the machine • An opening lid to allow for a cooling cycle • Design chosen: • Has two doors, one inlet and one exit • Contains a cooling fan Figure 17: Interim hood Design

22. Nozzle Selection • Various nozzles are to be tested on their performance of these goals • Even heat distribution • Turbulent flow • High heat transfer • Testing method • Smoke generator is used to blow smoke through each nozzle into a clear cylinder for observation • Testing will start next week Figure 18: Nozzle A Figure 19: Nozzle B Figure 20: Nozzle C

23. Cost Analysis

24. Conclusion Exploded View Housing Heater Hood Exhaust Fan Table Heater Fan Shroud Nozzle 1 8 7 6 2 5 3 4 Figure 21: Concept Exploded View

25. Planned Future Work • Build and test nozzle designs • Proof of concept testing (Fall Semester) • Begin building prototype (Spring Semester) Figure 22: Electric Heater w/ Shield removed

26. Acknowledgements • Turbocor • Rob Parsons • Dr. Lin Sun • Kevin Gehrke • Famu/FSU College of Engineering • Dr. Juan C. Ordóñez • Dr. Kareem Ahmed • Dr. Rob Hovsapian • Dr. SrinivasKosaraju

27. Questions?

28. References • "Aluminum A356 T6 Properties." N.p., n.d. Web. 15 Nov 2010. <http://www.matweb.com/>. • "Linear Expansion." N.p., n.d. Web. 15 Nov 2010. <http://hyperphysics.phy-astr.gsu.edu>. • Engineering Tool Box. N.p., n.d. Web. 15 Nov 2010. <http://www.engineeringtoolbox.com/>. • Cengel, Turner, Cimbala. Thermal Fluid Sciences. New York: McGraw Hill, 2008