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P11251: Side Entry Agitator Test Stand. MSD I: Detailed Level Design Review. Wednesday, February 16, 2011 @ 4:00-6:00PM RIT KGCOE: 09-4435. A100. A312. Project Team/Attendees. Project Sponsor : Richard O. Kehn - "ROK"

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P11251: Side Entry Agitator Test Stand

MSD I: Detailed Level Design Review

Wednesday, February 16, 2011 @ 4:00-6:00PM

RIT KGCOE: 09-4435




Project Team/Attendees

Project Sponsor : Richard O. Kehn - "ROK"

Senior Technologist - Mixing

SPX Flow Technology

MSD I, Team Guide: William J. Nowak Principal Engineer,

BGO/XIG/XRCW/OSL/Media & Mechatronic Systems Xerox Corporation

Team P11251: Kurt Lutz: P.M./(Measurement System w/ Integration)

Dennis Beatty: (Fluid-Tight Sealing Structure)

Joseph Bunjevac: (Physical Structure w/ Adjustability) Daniel Geiyer: (Measurement System w/ Integration)

Gregory McCarthy: Scribe/(Motor/Shaft/Coupling Integration)


Meeting Agenda

Time Frame

  • Project Background & Description 4:00-4:05
  • Customer Requirements 4:05-4:10
  • Engineering Specifications – Revised 4:10-4:15
  • Impeller Assumptions 4:15-4:25
  • Concept Selection Process 4:25-4:30
  • System Assembly 4:30-4:35
  • Feasibility Chart 4:35-4:40
  • Detailed Sub-System & Feasibility Analysis 4:40-5:35
    • Physical Structure
    • Sealing System
    • Shaft, Motor, & Impeller Integration
    • Measurement System w/ Hardware Integration
      • Load Cells: Thrust & FF Measurement
      • LabVIEW, Motor Torque & RPM
  • System BOM Budget 5:35-5:40
  • Updated Risk Assessment 5:40-5:45
  • Preliminary Test Plan 5:45-5:55
  • GANTT MSD II Schedule 5:55-6:00
  • Questions, Comments, & Concerns… 6:00-??

Project Background & Description

Mission Statement: To create a side entry agitator test stand that allows the user to measure and calculate axial and tangential components of fluid forces, torque, and impeller speed on the motor, impeller, and shaft, incorporating a wide range of adjustable parameters.



Side Entry Agitator

Top Entry Application


Customer Requirements

Four Most Important Customer Needs:

  • Fluid Tight Seal
  • Calibration Incorporation
  • Tangential Fluid Forces
  • Fluid Thrust Force

Engineering Specifications: Revised

  • Engineering metrics were re-evaluated after design review and further communication with sponsor and/or component vendors.
  • Maximum RPM under load increased to 1200 RPM.
  • Wall voltage increased to 208-230 Volts
  • Motor HP Increased

Impeller Assumptions


  • 20% of Total Power is Lost During Power Transmission
  • Provided Formula is accurate: SHP, Torque, Thrust, & Fluid Force
  • Provided Power Factors are accurate
  • Water as Working Fluid (SG)
  • Max Speed of Selected Impellers does not exceed 1200RPM
  • Will need to check max values of any other impellers to ensure comfortable FOS

Design Criteria

  • Max Torque: 283.5 in-lbs
  • Max Thrust: 108.9 lbs
  • Max FF: 51.5 lbs
  • Max Impeller Weight: 3.5 lbs

Concept Selection Process

Subsystem Selection

Week 5

Pugh 1

System Selection

Week 6

Pugh 2

System Interface Selection

Week 7

CAD Modeling


System Inter-connectedness Flowchart

  • Simple flowchart indicating the connectedness of the subsystems and components within the unit.
  • Green: Motor/Shaft/Coupling
  • Blue: Sealing System
  • Red: Physical Stand
  • Purple: Tang. And Axial Force Measurement
  • Orange: Torque/RPM Measurement, DAQ

Feasibility Checklist

  • Feasibility checklist items were taken from the risk analysis. These items are most likely to cause future complications.
  • Simple checklist to validate whether proposed design will work.
  • Allows comparing before part is in-hand and then re-validating after part in obtained or the component is built.

Physical Structure Feasibility

Key Points

1) Lead screws support weight

2) Full range of travel

3) System will not bind

  • Max lead screw load = 3840 lbs
  • Additional travel built into system
  • Linear shaft assembly interchangeable with lead screw assembly

Physical Structure Feasibility

  • FEA analysis on key components
  • Assembly meets or exceed FOS of 4.0

Physical Structure Adt. Adjustment

  • Tank will need to be raised an additional 8”

Sealing System Sub-System

Tank Wall

Tank Flange


Rubber Bellows

Mechanical Seal

Support Rod Mount


Seal Flange

Support Rod


Sealing System Feasibility

  • Allowable leakage rate is reached. Literature* shows a 1:800 leak ratio for mechanical seals compared to stuffing box.
  • Power loss is the main reason for use of a mechanical seal over stuffing box with a loss ratio of 1:6.
  • The rubber bellows have not been spec’d currently, theory shows full range of movement is possible, but true range of motion is not known until a sample in in hand.



Shaft, Motor, & Impeller Integration

PRO/E System Model

Acceptable Motor Bearings & Construction

RIGID Shaft Coupling

System Overview

  • Motor
  • Shaft
  • Rigid Coupling
  • VFD (Dan)
  • Integration w/: Seal, Physical Stand, DAQ, & Force Measurement

Ø1.375 Shaft

(Matched Output Shaft)

Ø.75” for Impeller Integration

5HP AC Motor

(2) Piece Coupling

Stepped Shaft

G McCarthy & Manuf. CAD Models


Shaft, Motor, & Impeller Integration

WEG: 00512ET3E215TC-W22

Manuf. CAD Model

ηAXIAL= 2.52*

ηRADIAL= 13.45*

IP55: “Dust Protected” & “Water Jet” Resistant

  • NEMA C-Face Mount
  • Sealed Construction
  • Industrial Applications

*Based on Max Published Load Values from Motor Manuf. in combination w/ calculated forces on the shaft


Shaft, Motor, & Impeller Integration

Precision Machined Shaft

G. McCarthy 2.13.11

MATL: 316 SS

Initial Dia: Ø1.375” X 7” LG

Final Dia: Ø0.75” X 14” LG

Total Length: 24”

  • Allows simple integration w/ motor output shaft

+/- .005” Total Runout

FOS Calculation

ηMod-Goodman= 1.8 (Bending & Torsion)

ηAxial Thrust= 17.1 (Impeller Thrust Load)

ηNatural Freq = Acceptable (1st NF of Shaft)

Machinist: TBD


Shaft, Motor, & Impeller Integration

McMaster-Carr: 60845K941

a.k.a.: Ruland Manufacturing: SPX-22-22-SS

Type: 2 Piece Split Collar

BoreA Dia: Ø1.375”

BoreB Dia: Ø1.375”

Outside Dia: Ø2.50”

Length: 3.875”

(8) 5/16-24” SS SHCS for Clamping

Tol: +/- .002” on Bore

  • Excellent Corrosion Resistance
  • One of few Rated on all (3) FOS levels

Manuf. CAD Model

FOS Calculation

ηMax Torque = 13.1*

ηAxial Loading = 17.5*

ηRPM/Speed = 3.3*

*Based on Manuf. Supplied Data


Shaft, Motor, & Impeller Integration

References & Justification

Shaft FBD

Preliminary: HP/Tq, Thrust, & FF Requirements

Stepped Shaft P1 of 3

Preliminary Stepped Shaft Calculation

(Solid Ø.75” Shaft fails under bending)

  • Review of all this Data was necessary to make safe selection

Not Shown: Hand Calculations, Supplier Data Sheets, Matl Prop, Additional FBD’s, etc.


Axial and Tangential Fluid Force Feasibility

Load Cell Mount Plate

Support Pin

Motor Mount Plate


Load Cell Feasibility

  • Assumptions
    • Neglect friction between bushings and support pins
    • Neglect reaction forces at load cells in X and Y directions
    • Neglect static loads
    • Load Cell compression is positive

Load Cell Feasibility

  • Assumptions
    • Extreme conditions
    • Maximum Compressive Load 325 lbs
  • Load Cell Specifications
    • Model: LCF400
    • Manufacturer: FUTEK
    • Rated Capacity: 1000 lbs
    • Resolution 1.0 lbs
    • Features: highly resistive to shear

Motor Mount Plate Feasibility

Force Vectors

Maximum Stress: 7474.0 psi

Maximum Displacement: 0.0014in


Support Pin Feasibility

  • Assumptions:
    • All forces acting in the worst case scenario
    • Loads applied 6.000 in from shaft step (3.000 in max)
    • Fillet radius 0.010 in
    • Pin Location R 5.500 in (True R 8.000 in)

Axial and Tangential Fluid Force BOM

  • Advantages:
    • All items chosen are in stock

Data Acquisition

National Instruments 9237:

  • 24-bit resolution, ±25 mV/V analog inputs with RJ50 connectors
  • 4 simultaneously sampled analog inputs; 50 kS/s maximum sampling rate
  • Programmable half- and full-bridge completion; up to 10 V internal excitation
  • 1 – 18V excitation
  • Smart-sensor (TEDS) compatible
  • Provides required signal conditioning for un-amplified load cells

List Price: $1,149.00


Data Acquisition

National Instruments 9201:

  • 8 analog inputs, ±10 V input range
  • 500 kS/s aggregate sampling rate
  • 12-bit resolution, single-ended inputs, screw terminal or D-Sub connectors
  • Hot-swappable operation; overvoltage protection; isolation
  • NIST-traceable calibration

List Price: $379.00


Data Acquisition

National Instruments cDAQ-9174:

  • Choose from more than 50 hot-swappable I/O modules with integrated signal conditioning
  • Four general-purpose 32-bit counter/timers built into chassis (access through digital module)
  • Run up to seven hardware-timed analog I/O, digital I/O, or counter/timer operations simultaneously
  • Stream continuous waveform measurements with patented NI Signal Streaming technology

List Price: $699.00


Labview Data Processing

  • Determine real time torque output from motor from VFD data
  • Collect data from load cells
  • Program algorithm to separate force measurements into tangential and axial components
  • Determine direction of tangential forces
  • Provide text file with data for easy importation into Matlab and/or Excel

System BOM Budget

System BOM:


Risk Assessment/ FMEA Revised

  • Risk Items With The Highest Importance (≥6)
    • Motor cannot handle the loads experienced during testing (9)
    • Translation system does not lock into position (6)
    • Motor cannot attain maximum speed range (6)
    • Axial and tangential measurement devices are not sensitive to change (6)
    • Load cells cannot measure the entire range of loads experienced during testing (6)
    • Cannot construct Side Entry Horizontal Agitator Test Stand within allocated time period (6)

Preliminary Test Plan

  • Key Objectives:
    • Test Strategy
    • Test Schedule
    • Control Features
    • Responsibilities
    • Deliverables

GANTT MSD II Preliminary Schedule

Project Plan: