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Design Team 4: Norfolk Southern Cracked Spike Detector

Design Team 4: Norfolk Southern Cracked Spike Detector. Chad Church: Manager Ron Fox: Webmaster John Vogel: Document Prep Geoff Brigham: Presentation Prep Matt Hamm: Lab Coordinator Professor Deller: Facilitator Hayden Newell: Sponsor from Norfolk Southern. Agenda.

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Design Team 4: Norfolk Southern Cracked Spike Detector

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  1. Design Team 4:Norfolk Southern Cracked Spike Detector Chad Church: Manager Ron Fox: Webmaster John Vogel: Document Prep Geoff Brigham: Presentation Prep Matt Hamm: Lab Coordinator Professor Deller: Facilitator Hayden Newell: Sponsor from Norfolk Southern

  2. Agenda • The Problem and Design Requirements • Method Background • Eddy Currents • Acoustic • Ultrasonic Testing • Design Specifications • Conceptual Designs • Proposed Design Solution • Risk Analysis • Resources and Budget • Summary

  3. The Problem & Design Requirements • Norfolk Southern has over 22,000 miles of track • 286,000 lb freight cars and locomotives exceed 30k psi on spikes • Broken spikes must be driven through the tie • Associated damage of $200,000 in 2001 • An ultrasonic prototype is desired to detect a cracked or broken spike • Ergonomic and lightweight • Rechargeable with long battery run time • Readable in bright sunlight • All weather device • Optional: automatically mark bad spike Randy’s Spike Breakage

  4. Method BackgroundEddy Currents • Aluminum aircraft parts • Electromagnetic wave • Exponential Drop-off • Goal: 5 inches • Electrical Conductivity: 0.1 • Magnetic Permeability: 1000 times the permeability of free space • Solve for the frequency…

  5. Method BackgroundEddy Currents • Frequency = 0.157 Hz • Not Practical • How Do they do it with aircraft parts?

  6. Method BackgroundAcoustic Testing • Hit it with a hammer • Fourier transform • Processing issues? • Damping?

  7. Method BackgroundUltrasonic Testing • Special case of acoustic • 2 – 10 MHz • Internal reflection • Finding an edge • Calculating the time • Rail Testing • 169mm = 6.5 in

  8. Design Specifications • Necessities • Ultrasound waves • Analyze the data received from the spike • Compact Design • Couplant Application • Power Constraints • Other Additions • Simple display of results • Marking defective spikes • Cost

  9. Proposed Design Solution • Ultrasound transducer • Bottom of pole • Fault detector • Red/Green LED • Buzzer • Top of pole • Orange marker • Easily replaceable • Signal Processing • Band-pass filter • Threshold detector • Couplant • Bottom of transducer • Rubber material with gel solution

  10. Risk Analysis • Risk to Railroad • 6 Sigma research with proposed solutions • Randy’s Spike Breakage • Build Risk • Proper testing materials • Battery • Budget • Weather

  11. Resources and Budget • LEDs • Resistors Capacitors • Rubber pad • Ultrasonic Gel • Electromagnetic Transducer • Programmable Memory device (IC) • Clock (IC) • Circuit Board • Spool of wire • Triggers (switches) • Spray paint • PVC piping

  12. Summary • Design and prototype a device to detect cracked and broken spikes • Research different methods of non destructive testing • Organize the design specifications • Create a conceptual design • Propose a design to complete all specifications and requirements • Analyze possible risks • Create a list of required resources within the budget

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