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Detailed Design Review Project Team 13453

Detailed Design Review Project Team 13453. Brandon Niescier Erin Sullivan Mike Gorevski Sean Deshaies. Agenda. Team and Project Overview (2 min) Customer Needs and Specifications Review (3 min) Hardware Design (40 min) Test Fixture Design (40 min) Test Plans (5 min) Q&A.

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Detailed Design Review Project Team 13453

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  1. Detailed Design ReviewProject Team 13453 Brandon Niescier Erin Sullivan Mike Gorevski Sean Deshaies

  2. Agenda • Team and Project Overview (2 min) • Customer Needs and Specifications Review (3 min) • Hardware Design (40 min) • Test Fixture Design (40 min) • Test Plans (5 min) • Q&A

  3. Team and Project Members TEAM: Project Manager: Sean Deshaies (ME) Project Engineers: Brandon Niescier (ME) Erin Sullivan (EE) Mike Gorevski (EE) CUSTOMER: Dr. Jason Kolodziej, ME Department, RIT SUPPORT: Project Guide: Bill Nowak (Xerox) Faculty Champion: Dr. Jason Kolodziej(RIT) Sponsors: Scott Delmotte (D-R)

  4. Project Description and Objective The purpose of this project is to monitor the health of the main crank bearing on RIT’s Dresser-Rand ESH-1 compressor. This will be done through recording vibration measurements via wireless sensor technology.

  5. Customer Needs

  6. Customer Specifications

  7. System Block Diagram Rotational System

  8. Accelerometer PCB Series 660 Low voltage was critical Met customer spec for measurement range Verified by meeting with PCB

  9. Epoxy • Tra-Con Tra-Cast 3103 • Consulted with PCB • Is what their customers use

  10. Accelerometer Mounting Accelerometer will be potted to the shaft using epoxy Keyway chosen as mounting location

  11. Accelerometer Mounting

  12. Accelerometer Mounting Frequency Curves

  13. TelosB Wireless Module • Low power research development • Wireless sensor networks • Data collection and programming via USB • Integrated on board antenna • Compact

  14. Enclosure Options • Option 1: Commercial Off-The Shelf • Cheap and readily available • Close fit difficult to attain • Option 2: Custom Design • Can produce an enclosure to the exact dimensions needed for a close fit • Difficulty in obtaining desired construction for a reasonable cost • Requires large minimum orders

  15. Enclosure Bud Industries CU-1931-MB ABS plastic construction Inside Dimensions: 2.9”x1.9”x0.93” Wireless Module Dimensions: 2.55”x1.24”x0.75”

  16. Wireless Module Mounting

  17. Enclosure Mounting • The enclosure will be mounted to the flywheel • Limited space on shaft • Shaft mount would require milling a flat • Large, flat space on flywheel spokes

  18. Enclosure Mounting

  19. Vibration Analysis

  20. Vibration Analysis

  21. Centrifugal Force and Bolt Stress

  22. Battery Life Formula Used: • These calculations were made using the specs of an Energizer Ultimate Lithium Ion AA Battery which has a capacity rating of 3,100 mAh.

  23. Wiring Diagrams

  24. Programming the Module

  25. System Block Diagram Stationary Wired System

  26. Stationary Accelerometer PCB 607A11 “Swiveler” Needed to withstand harsh conditions Voltage use not a concern Stud mounted Exceeded customer spec for measurement range Recommended by PCB

  27. Mounting Drill 0.21” Dia. 0.31” deep Tap ¼’-28 UNF-2A 0.25” deep

  28. Wiring Through Housing

  29. Wiring Through Housing

  30. Wiring Diagrams

  31. System Block Diagram Stationary Wireless System

  32. Faraday Cage • A Faraday cageis an enclosure formed by conducting material. Such an enclosure blocks external static and non-static electric fields.

  33. Research Done • Faraday cage prevents transmission from inside cast • External antenna required for transmission (defeats purpose of wireless transmission) • Other methods out there, but still in development stages (not feasible)

  34. BOM

  35. Risk Assessment

  36. Risk Assessment

  37. Test Rig • In order to analyze our solutions for monitoring bearing health, a model test facility will be constructed • 1:1 scale for shaft diameter and rotational speed • Bearing configuration will not be identical to actual compressor for the sake of simplicity

  38. Test Rig Model

  39. Test Rig Model

  40. Assembly Drawing 6 5 3 4 2 1 7

  41. Torque and Critical Speed

  42. Motor Brushless 24VDC Motor with planetary gearbox NEMA Size 11 14: 1 gear reduction 55 oz-in rated torque 714 rpm max speed

  43. Encoder Photocraft HS20BQZ-720/8-30 FB2 Use requested by customer Industrial grade Optical, hollow shaft encoder Flexible tether used to assist in alignment

  44. Motor Controller Anaheim Automation MDC100 050101 Adjusts the rotational speed internally or externally Readily available from and recommended by customer

  45. Power Supply Motor maximum power consumption: 212W Encoder power consumption: 1.2W 24VDC 350W power supply

  46. Test Rig Wiring Diagram

  47. Bearings • 2” ID Ball Bearings from Xerox Fuser • Readily available from guide • Housings will need to be made • Original plan was mounted ball bearings • Rolling resistance was too high

  48. Bearing Fits • Timken Engineering Manual • Light Loading • Rotating shaft, Stationary housing • Bearing-Shaft Interface • Interference fit (0.0004in to 0.0008in) • Bearing-Housing Interface • Loose fit (0.0005in clearance)

  49. Bill of Materials

  50. Accelerometer Test Plan • Accelerometer mounting • Verifying mounting with epoxy (Tra-Con Tra-Cast 3103) does not alter readings

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