Detailed Design ReviewProject Team 13453

Brandon NiescierErin Sullivan

Mike GorevskiSean 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

Team and Project MembersTEAM: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)

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.

Customer Needs

Customer Need #

Importance Description

CN1 9 Single axis accelerometer mounted to crankshaft (Rotates)CN2 9 Single axis accelerometer mounted inside housing (Stationary)CN4 9 Continuous sensor operationCN8 9 Reliability and accuracy of measurements

CN12 9 Must fit inside of compressorCN13 9 Must fit on shaftCN7 3 Robust design of wireless technology for harsh environmentCN9 3 Interface wth DAQCN3 3 Minimal user intervention CN6 3 Wireless transmission of signal

CN11 3 User manual/Important informationCN5 1 Low cost

CN10 1 Scalable to higher temperature (Internal environment)

Customer Specifications

Engr. Spec. #

Importance Source Specification (description) Unit of Measure

Marginal Value

Ideal Value

Comments/Status

ES1 9 CN1/CN2 Acceleration Range (g) g 20 50ES2 9 CN1/CN2 Acceleration Sensitivity (mV/g) mV/g 100 100ES4 9 CN6 Range of Wireless Transmission Distance (ft) ft 0.5 10ES8 9 CN7 Operational Maximum Temperature (degrees F) F 185 200

ES10 9 CN12 Size of Sensor and Wireless Technology (in^3) in^3 - - As small as possibleES7 3 CN3 Maintenance Intervention Rate (Interventions/time) inv/t 1 inv/month 0ES9 3 Implied Power Consumption of System (W) W 65.2m 63μ

ES11 3 CN3/CN4 Lifespan of Technology (years) years 5 ForeverES12 1 CN5 Total Cost ($) $ 5000 0 Sensor Cost $500-$1500

Rotational System

660 Series PCB

Accelerometer

TelosB Wireless

Transmission Module

TelosB Wireless Receiver Module

Lab PC and LabView

System Block Diagram

Accelerometer

• PCB Series 660• Low voltage was critical• Met customer spec for

measurement range• Verified by meeting with PCB

Epoxy

• Tra-Con Tra-Cast 3103• Consulted with PCB

– Is what their customers use

Accelerometer Mounting

• Accelerometer will be potted to the shaft using epoxy

• Keyway chosen as mounting location

Accelerometer Mounting

Accelerometer Mounting Frequency Curves

TelosB Wireless Module

• Low power research development

• Wireless sensor networks

• Data collection and programming via USB

• Integrated on board antenna

• Compact

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

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”

Wireless Module Mounting

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

Enclosure Mounting

Vibration Analysis

Flywheel Vibration

Mass of Flywheel (m) 261.2 lbm

Eccentricity (e) 0.006 inFrequency (ω) 6 HzModulus of Elasticity (E) 29000000 psi

Area moment of Inertia (I) 2.807 in4

Shaft Length (L) 21 in

Spring Constant (k) 421913.8 lbf/in

Natural Frequency (ωn) 10.4781 Hz

**x(t) and y(t) are solved using MatlabAssumptions:

Rigid FlywheelMassless ShaftNo DampeningSimply Supported Shaft

Vibration Analysis

Centrifugal Force and Bolt Stress

Battery Life

MCU ON, Radio RXMCU ON, Radio TX

MCU ON, Radio OFFMCU Idle, Radio OFF

MCU StandbyAccelerometer

134.78 hours147.62 hours

1,291.62 hours2,583.33 hours147,619 hours4,133.33 hours

23 mA21 mA

2,400 µA1,200 µA

21 µA0.75 mA

142.20 hours158.97 hours

1,722.22 hours56,880.73 hours607,843 hours

-

21.8 mA19.5 mA1,800 µA54.5 µA5.1 µA

-

Nominal MaximumCurrent Draw Battery Life Current Draw 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.

Wiring Diagrams

Programming the Module

• Open source operating system

• Designed for low-power wireless devices

Stationary Wired System

607A11 PCB Acceleromet

erSignal

ConditionerPreexisting

DAQ System

System Block Diagram

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

Mounting

Drill 0.21” Dia. 0.31” deepTap ¼’-28 UNF-2A 0.25” deep

Wiring Through Housing

Wiring Through Housing

Wiring Diagrams

Stationary Wireless System

660 Series PCB

Accelerometer

TelosB Wireless Transmis

sion Module

TelosB Wireless Receiver Module

Lab PC and

LabView

System Block Diagram

Faraday Cage

• A Faraday cage is an enclosure formed by conducting material. Such an enclosure blocks external static and non-static electric fields.

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)

BOM

Bill of MaterialsVendor Part Number Vendor Item Quantity Unit Cost Total Cost Lead Time

66213LPZ2 PCB Embeddable Accelerometer w/ 1ft cable 2 $117.00 $234.00 2 weeks607A11 PCB ICP Accelerometer w/ 10ft cable 1 $208.80 $208.80 In Stock

TPR2400CA MEMSIC TelosB Wireless Module 3 $99.00 $297.00 20 days70147996 Allied Electronics Enclosure 1 $4.40 $4.40 In Stock6907K12 McMaster Carr Cable Gland 1 $8.18 $8.18 In StockHEADS10 Futurlec Male Header Pins-10 pack 1 $0.90 $0.90 In Stock

FHEADS10 Futurlec Female Header Pins 10 $0.16 $1.60 In Stock70113956 Allied Electronics 3M Scotch-Weld Epoxy Potting Compound 1 $20.40 $20.40 In Stock70039961 Allied Electronics 3M EPX Applicator 1 $74.21 $74.21 In Stock

N/A N/A 1-Channel ICP Signal Conditioner 1 $355.00 $355.00 In StockN/A RIT Machine Shop 1/4"-20x1/2" Socket Head Cap Screw 2 $0.12 $0.24 In StockN/A Supplied by Team Member StyroFoam Block 1 $5.00 $5.00 In Stock

Total Cost (Actual) $849.49

Total Cost (List) $1,209.73

Risk Assessment

Risk ManagementRisk # Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner

R1 Noise in the Wireless Signal Poor Data Quality Surrounding Environment 9 5 45 Use Filters Mike

R2 Trip Hazard for Wires Fall Injuries and Damage to the System Cables and wires in walk ways 5 7 35 Route wires away from walkways Brandon

R4 Insufficient Battery Life Increased User Intervention Power Consumption Too High 5 5 25Calculate and Minimize Power

Composition and Consider Battery Choice

Mike

R17Accelerometer does not Communicate Properly

with TranscieverData is Corrupted or Not Transmitted Coding Errors 3 7 21 Consult with Expert in Proper Coding

Language Erin

R18 Bearing Fits are not Tight Enough Bearings will not work properly Machining Error 5 3 15 Work with Machine Shop Assistants Brandon

Risk AssessmentRisk Management

Risk # Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner

R5 Compressor is Not Operational Cannot Validate Solutions Other Parties Use the

Compressor 3 3 9 Create Test Rig Sean

R6 Working With Compressor Injury to team or others Pinch points and moving

componets on compressor 1 9 9Use caution when working with

compressor and work with power off

Mike

R8 Accelerometer Falls Off- Inside Housing

Damage to Accelerometer and to the Compressor Improperly Mounted 1 9 9 Ensure Proper Installation

Method Brandon

R9Damage to

Compressor During Install

Broken Compressor and Project Failure Improper Installation 1 9 9 Thoroughly Plan Installation

with Input From D-R Brandon

R10 Components Not Received on Time Project Delayed Long Lead Time for Parts 3 3 9

Order Parts Early and Order Spares of Critical Parts with Long

Lead TimesBrandon

R11 Sensors Break On Installation Need to Buy New Sensors Improper Installation 1 7 7 Verify Installation Strategy with

PCB Sean

R12 Injury While Machining Parts Team Member Hurt Disregard to Safety

Precautions 1 7 7 Proper Training and Supervision in Use of Machine Operation Mech Es

R13 Accelerometer Fails to Satisfy Needs Data is Not Measured Correctly Uncertainty in Operating

Conditions 1 5 5 Verify Accelerometer Choices with PCB Erin

R14 Accelerometer Falls Off- Outside Housing Damage to Accelerometer Improperly Mounted 1 5 5 Ensure Proper Installation

Method Brandon

R15 Shaft is Unbalanced Induced Vibrations in SystemWeight of Technology Mounted on Shaft and

Flywheel1 1 1

Do Calculations and if Necessary Apply Counter Weights to

Balance Shaft and/or FlywheelBrandon

R16Wireless Signal

Affected By Shaft Rotation

Data is Not Transmitted Correctly Doppler Effect 1 1 1 Consult Experts in Wireless Transmission Erin

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

Test Rig Model

Test Rig Model

Assembly Drawing

12

34

5 6

7

Torque and Critical Speed

Material Steel

Density 0.282 lbm/in3

Diameter 2.75 inAngular Acceleration 12.57 rad/s2

Area Moment of Inertia 2.807 in4

Modulus of Elasticity 2.90E+07 lbf/in2

Shaft Length (in) Weight (lbf) Mass Moment of Inertia (lbm-in2) Torque (lbf-in) Natural Frequency (Hz) Critical Speed (rpm)3 5.025 4.750 0.155 105498 1007431

3.5 5.862 5.542 0.180 77509 7401534 6.700 6.333 0.206 59343 566680

4.5 7.537 7.125 0.232 46888 4477475 8.375 7.917 0.258 37979 362675

5.5 9.212 8.708 0.283 31388 2997316 10.050 9.500 0.309 26374 251858

6.5 10.887 10.292 0.335 22473 2146017 11.725 11.084 0.361 19377 185038

7.5 12.562 11.875 0.386 16880 1611898 13.400 12.667 0.412 14836 141670

8.5 14.237 13.459 0.438 13142 1254939 15.075 14.250 0.464 11722 111937

9.5 15.912 15.042 0.489 10521 10046410 16.750 15.834 0.515 9495 90669

10.5 17.587 16.625 0.541 8612 8223911 18.425 17.417 0.567 7847 74933

11.5 19.262 18.209 0.592 7179 6855912 20.100 19.000 0.618 6594 62964

Motor

• Brushless 24VDC Motor with planetary gearbox

• NEMA Size 11• 14: 1 gear reduction• 55 oz-in rated torque• 714 rpm max speed

Encoder

• Photocraft HS20BQZ-720/8-30 FB2

• Use requested by customer• Industrial grade• Optical, hollow shaft encoder• Flexible tether used to assist in

alignment

Motor Controller

• Anaheim Automation MDC100 050101

• Adjusts the rotational speed internally or externally

• Readily available from and recommended by customer

Power Supply

• Motor maximum power consumption: 212W

• Encoder power consumption: 1.2W

• 24VDC 350W power supply

Test Rig Wiring Diagram

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

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)

Bill of Materials

Test Rig Bill of MaterialsVendor Part Number Vendor Item Quantity Unit Cost Total Cost Lead Time

BLWRPG112S-24V-10000-R14 Anaheim Automation Brushless DC Gearmotor 1 $163.00 $163.00 In StockCPL-BKL25-32-6-6 Anaheim Automation Flexible Coupling 1 $32.00 $32.00 4 weeks

8920K821 McMaster Carr 1018 Steel Rod 2.75"x12" 1 $58.30 $58.30 In StockB000H9L3FU Amazon Supply 6061-T6 Angle 6"x6"x.375"- 12" L 1 $42.65 $42.65 In Stock

SE-350-24 Powergate LLC 350W 24V Power Supply 1 $45.90 $45.90 In StockB000H9JXWK Amazon Supply 6061-T6 Bar 24"x3"x1.5" 1 $61.40 $61.40 In Stock

HS20BQZ-720/8-30 FB2 Photocraft Optical Encoder w/ Mounting Bracket 1 $180.62 $180.62 1-3 daysMB-ST.375 Photocraft 3/8" Stub Shaft 1 $10.56 $10.56 In StockMB-ST.312 Photocraft 5/16" Stub Shaft 1 $10.56 $10.56 In Stock

13637 Bolt Depot M3x12mm Socket Head Cap Screw 4 $0.09 $0.36 In Stock6508 Bolt Depot M4x14mm Socket Head Cap Screw 4 $0.11 $0.44 In StockN/A Anaheim Automation Motor Controller 1 $161.00 $161.00 In StockN/A Supplied by Guide Ball Bearing 2 $20.00 $40.00 In StockN/A RIT Machine Shop 1/4"-20x1" Socket Head Cap Screw 12 $0.12 $1.44 In StockN/A RIT Machine Shop 3/8"-16x2" Socket Head Cap Screw 1 $0.42 $0.42 In StockN/A RIT Machine Shop 3/8"x16 Nut 1 $0.06 $0.06 In StockN/A RIT Machine Shop 1/4"-20x1/2" Socket Head Cap Screw 2 $0.09 $0.18 In StockN/A RIT Machine Shop 1/4" Washer 2 $0.05 $0.10 In StockN/A Supplied by Guide Aluminum Plate (15"x15"x0.75") 1 $125.00 $125.00 In StockN/A RIT ME Dept. Assorted Wire N/A $5.00 $5.00 In StockN/A RIT ME Dept. AC Plug with cord N/A $1.50 $1.50 In StockN/A RIT ME Dept. Assorted Wire Connectors N/A $2.00 $2.00 In StockN/A Supplied by Guide Base Plate N/A $857.00 $857.00 In Stock

Total Cost (Actual) $605.79

Total Cost (List) $1,799.49

Accelerometer Test Plan

• Accelerometer mounting– Verifying mounting with epoxy (Tra-Con Tra-Cast

3103) does not alter readings

Wireless Test Plan

• Battery Life– How long do transceivers work without changing

batteries?• Transmission Distance

– How far apart can transmitter and receiver work?• Data Comparison

– Does wireless transmission distort the data?

Post Installation Test Plan

• Accelerometer Response– Check that accelerometers record vibrations

Total Expenses

$5,000 (Initial Budget)

-$849.49(Project) -$605.79 (Test Rig)$3544.72 Remaining

Gantt Chart - MSD II

Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10Task Name S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F SDivide work for paper Work on paper Unify work on paper Design Poster Machine parts Code for transcievers Assemble test rig Execute test plans Revise design if necessary Prepare compressor for accelerometer installation Install components on compressor Troubleshoot installation

Questions