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P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Final Review

The project at Rochester Institute of Technology involved redesigning a compressor bearing test rig. Action items included lubrication system enhancement, load system redesign, and bearing housing modification. The manufacturing process involved building the table base, test surface, bearing block, and shaft. Final photos and problem tracking were also documented in the project.

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P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Final Review

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  1. P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Final Review Rochester Institute of Technology

  2. Project Team Rochester Institute of Technology

  3. RIT: Researchers: • RIT: Industry Engineers: • Dresser-Rand: Stakeholders • MSDII Team – 14453 • Graduate/Masters Students • William Nowak (Xerox) • Dr. Jason Kolodziej • Assistant Professor • (Primary Customer) • Dr. Stephen Boedo • Associate Professor • (Subject Matter Expert) • James Sorokes • Principal Engineer • Financial Support • Scott Delmotte • Mgr. Project Engineering • Point of Contact ? Rochester Institute of Technology

  4. Final Design Review Agenda • MSD I Action Items • Manufacturing • Problem Tracking • Testing • Results • Conclusions Rochester Institute of Technology

  5. MSD I Action Items: Lubrication • Customer feedback indicated that more oil would be required than could be supplied by the initial design • A gear pump was chosen for its ability to flow a large quantity of oil at high pressure • Pump is capable of 0-150 psi • 1.5 gpm flow possible at 50 psi • A pressure relief valve was included to protect the system for overpressure • Valve is capable of handling up to 170 psi • Oil seals were incorporated into the test block to contain outgoing oil • All components were strengthened in order to maintain a robust design Rochester Institute of Technology

  6. MSD I Action Items: Load System • Due to budgetary constraints our customer requested that we redesign the load system to be single axis-static load • A pivoting lever system was • chosen due to its simplicity • A 10:1 ratio was utilized in • order to fully load the bearing • with only 200 lbs of weights • Loading was done from under the • table to reduce the impact on the • table surface for later development • The design remains robust enough • to adapt to full dynamic loading for • follow-on projects Rochester Institute of Technology

  7. MSD I Action Items: Test Bearing Housing • Conversations with our guide determined that the three piece housing would be too complicated to manufacture • A one piece design was implemented • Test bearing became a press fit design • Oil seals were pressed into the block to control oil flow • A single piece eliminated concerns about stack up issues and provided for more accurate readings • A one piece steel part is more durable with no concern about structural failure Rochester Institute of Technology

  8. Manufacturing • Table Base • Steel tube stock pre-ordered to length • Cleaning • Welding prep • Welded together in machine shop: THANK YOU ROB! • Painted black • Table Test Surface • Hole profiles water-jetted in machine shop • Water-jetted holes hand tapped • Mated to table base Rochester Institute of Technology

  9. Manufacturing • Test Bearing Block • Steel Block milled to size • Surface ground to drawing spec • All bearing hole machining done in lathe: THANK YOU JAN! • Oil feed/return lines, load cell hole, drilled and tapped • Test bearing pressed in • Test Shaft • Machined to size in lathe (THANK YOU ROB!) • Ground to clearance spec Rochester Institute of Technology

  10. Manufacturing • Load System • Pivot Pin Mounts • Cut to size, ground to spec • Holes drilled and tapped • Pivot & Load Pins • Lever Arm • Cut to size, ground to spec • Holes drilled and tapped • Weight strap • Lubrication System • Holes drilled and tapped in table base for locating pump motor, gear pump, filter bracket • Hoses cut to size and crimped, various hose couplings • Oil reservoir Rochester Institute of Technology

  11. Final Build Photos Rochester Institute of Technology

  12. Problem Tracking: • Test Surface machining/finishing: • Table-top was too large to machine without re-indexing • Re-indexing could lead to misalignment • Table-top was machined on the Brinkman Lab water jet • Lubrication System Motor Mount: • Multiple options were available regarding pump motor mounting locations/methods • After a PUGH analysis it was decided to mount the pump to the lower table using the four mounting holes on the motor Rochester Institute of Technology

  13. Problem Tracking: • Lubrication Reservoir Weld-up/Assembly: • Welding thin sheet metal with an arc welder is extremely difficult. Being bad at arc welding only makes it worse • The team worked with Rob in the machine shop to properly weld the tank • The tank was completed enough to make it operational • Bearing-Shaft Clearance: • When pressed into the test-block the internal bore diameter of the bearing decreased, causing negative clearance between it and the shaft • The team worked with Rob to measure the bore and adjust the shaft outside diameter to accommodate the change Rochester Institute of Technology

  14. Problem Tracking: • Hydraulic Hose Crimping: • The machine shop did not have the proper crimping tools for the hydraulic fittings and most companies would only crimp the fittings of their specific manufacturer • After calling many local businesses “Empire Radiator Service” on Dewey Ave. was the only company that would crimp our generic fittings • Motor/Motor-Controller Overloading: • The total amount of torque required to drive the shaft was greater than the motor was rated for due to calculation discrepancies • After a PUGH analysis it was decided to use a belt drive to decrease the torque load on the motor Rochester Institute of Technology

  15. Problem Tracking: • Motor-Controller Overloading: • Constant overloading and an ‘aggressive’ settings setup lead to the first motor controller being destroyed. • John Wellin donated a larger motor controller for the group to use • A mount was fabricated to mount the controller to the original motor mount holes in the table, eliminating the need for further table modification 2005 – 2014 Rest In Peace Rochester Institute of Technology

  16. Lessons Learned • Project Management • Work prioritization • Milestones • Teamwork • Effective Communication • Balancing Schedules • Work delegation • Accountability • Complete Design Process • System breakdown • Customer Needs → Concept Generation/Selection • System → Subsystem → Detailed • Manufacturability • Ask questions • Problem Tracking • On-the-fly problem solving, solution implementation • Anticipate Complications Rochester Institute of Technology

  17. Questions Rochester Institute of Technology

  18. BACK-UP Slides Rochester Institute of Technology

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