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P11251: Side Entry Agitator Test Stand

P11251: Side Entry Agitator Test Stand. https://edge.rit.edu/content/P11251/public/Home. 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

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  1. P11251: Side Entry Agitator Test Stand https://edge.rit.edu/content/P11251/public/Home MSD I: Detailed Level Design Review Wednesday, February 16, 2011 @ 4:00-6:00PM RIT KGCOE: 09-4435 A100 A312

  2. 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)

  3. 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-??

  4. 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. A100 A312 Side Entry Agitator Top Entry Application

  5. Customer Requirements Four Most Important Customer Needs: • Fluid Tight Seal • Calibration Incorporation • Tangential Fluid Forces • Fluid Thrust Force

  6. 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

  7. Impeller Assumptions 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

  8. Concept Selection Process Subsystem Selection Week 5 Pugh 1 System Selection Week 6 Pugh 2 System Interface Selection Week 7 CAD Modeling

  9. 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

  10. System Assembly

  11. 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.

  12. Physical Structure Sub-System

  13. Physical Structure

  14. Physical Structure

  15. Physical Structure

  16. 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

  17. Physical Structure Feasibility • FEA analysis on key components • Assembly meets or exceed FOS of 4.0

  18. Physical Structure Adt. Adjustment • Tank will need to be raised an additional 8”

  19. Physical Structure BOM

  20. Sealing System Sub-System Tank Wall Tank Flange Gasket Rubber Bellows Mechanical Seal Support Rod Mount Gasket Seal Flange Support Rod

  21. 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. * http://www.chemseals.com/msvgp.pdf

  22. Sealing System - BOM

  23. 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

  24. 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

  25. 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

  26. 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

  27. 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.

  28. Shaft, Motor, & Impeller Integration Subsystem BOM

  29. Axial and Tangential Fluid Force Feasibility Load Cell Mount Plate Support Pin Motor Mount Plate

  30. 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

  31. 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

  32. Motor Mount Plate Feasibility

  33. Motor Mount Plate Feasibility Force Vectors Maximum Stress: 7474.0 psi Maximum Displacement: 0.0014in

  34. Load Cell Mount Plate Feasibility

  35. Support Pin Feasibility

  36. 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)

  37. Axial and Tangential Fluid Force BOM • Advantages: • All items chosen are in stock

  38. Torque and RPM Measurement Subsystem

  39. 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

  40. 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

  41. 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

  42. 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

  43. System BOM Budget System BOM: https://edge.rit.edu/content/P11251/public/Detailed%20Design%20Review?rev=0

  44. Updated Risk Assessment (FMEA)

  45. 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)

  46. Preliminary Test Plan • Key Objectives: • Test Strategy • Test Schedule • Control Features • Responsibilities • Deliverables

  47. GANTT MSD II Preliminary Schedule Project Plan: https://edge.rit.edu/content/P11251/public/Team%20Project%20Plan

  48. Questions/Comments/Concerns

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