P11251: Side Entry Agitator Test Stand

MSD I: Detailed Level Design Review

https://edge.rit.edu/content/P11251/public/Home

Wednesday, February 16, 2011 @ 4:00-6:00PM

RIT KGCOE: 09-4435

A100 A312

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)

Meeting Agenda

•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-??

Time Frame

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

Customer Requirements

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

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

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

Concept Selection Process

Subsystem SelectionWeek 5Pugh 1

System SelectionWeek 6Pugh 2

System Interface SelectionWeek 7

CAD Modeling

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

System Assembly

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.

Physical Structure Sub-System

Physical Structure

Physical Structure

Physical Structure

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

Physical Structure Feasibility

•FEA analysis on key components

•Assembly meets or exceed FOS of 4.0

Physical Structure Adt. Adjustment

•Tank will need to be raised an additional 8”

Physical Structure BOM

Item Number

Quantity Description Material Net Size Supplier Supplier P/ N

Unit Price

Total Price

P11251- 001 4Linear Plane Bearing Pillow Block attached to motor plate (1/2") Aluminum 2" x 1.7" x 1.25" PBC Linear P08 $70.00 $280.00

P11251- 002 2Linear Plane Bearing Pillow Block for vertical shafts (3/4") Aluminum 1.75" x 2.75" x 2.06" PBC Linear P12 $70.00 $140.00

P11251- 003 2 Vertical Ground Shafts 1566 Steel 30" x .75" McMaster- Carr 6061K545 $24.09 $48.18

P11251- 004 2Bottom shrink fit mount for vertical 3/4" shaft (material for 2 pieces) 6061 4.38" x 1.67" x 4.38" McMaster- Carr 8975K574 $43.53 $87.05

P11251- 005 2Top shrink fit support for 3/4" vertical shaft (material for 2 pieces) 6061 4.38" x 2.35" x 4.38" McMaster- Carr 8975K574 $43.53 $87.05

P11251- 006 4Front blocks to connect shaft support to linear plane bearing 2024 2.82" x 2" x 0.75" McMaster- Carr 8509K77 $30.89 $123.56

P11251- 007 4End support block for front attachment to 1/2" shaft Aluminum 2" x 1.63" x 0.63" PBC Linear NSB08 $30.00 $120.00

P11251- 008 41/2" shaft supporting front of motor and rear of motor 1566 Steel 4" x .5" McMaster- Carr 6061K427 $4.08 $16.32

P11251- 009 4 Shaft clamp for 1/2" shaft 1215 1.125" x .5" x 13/32" McMaster- Carr 6435K14 $1.79 $7.16P11251- 010 2 Lead screw single flange mount 4.38" x 1.67" x 4.38" Nook Industries EZF- 4025 $286.51 $573.02P11251- 011 2 Lead screw 3/4" SS 36" x .75" Nook Industries 11070 $63.69 $127.38

P11251- 012 2Double flange mount for 3/4" lead screw 4.38" x 2.35" x 4.38" Nook Industries EZF- 3025 $409.31 $818.62

1 Misc Machining costs Nook Industries - - - - - $475.00 $475.00P11251- 013 2 Handle for 3/4" lead screw Nook Industries H044 $155.61 $311.22P11251- 014 2 Custom Lead screw nut SS 1.75" x 2.75" x 2.06" McMaster- Carr 9064K75 $153.01 $306.02P11251- 015 1 Acme thread tap HSS 8" x 0.75" McMaster- Carr 25345A21 $133.12 $133.12

P11251- 016 4Slotted shaft end supports for rear of motor mount 2024 2.69" x 1.5" x .63" McMaster- Carr 8509K77 $30.89 $123.56

P11251- 017 4Cross braces for rear motor plate support square tubing (6' section) 1026 1" x 1" x 0.12" McMaster- Carr 6527K31 $6.04 $24.14

P11251- 018 2Horizontal support plate for rear of motor plate 1018 12" x 6" x 0.5" McMaster- Carr 8910K714 $41.02 $82.04

P11251- 019 290 degree channel for support of horizintal support plate (3' section) steel 6" x 1.0" x 0.125" McMaster- Carr 8968K32 $5.96 $11.92

P11251- 020 4Top Support vertical support square tube aluminum 25" x 2" x 4" x 0.125" McMaster- Carr 6546K422 $34.96 $139.84

P11251- 021 6 Top support short angle (8' section) 6063 1.5" x .125" x 9.19" McMaster- Carr 88805K57 $4.16 $24.96

P11251- 022 1 Top support rear support (8' section) 6063 1.5" x 0.125" 36" McMaster- Carr 88805K57 $24.96 $24.96P11251- 023 1 Main Horizontal Plate aluminum 24" x 36" x 0.5" Clinton Aluminum $350.00 $350.00

P11251- 024 4Top support Cross brace angle (4' section) 6061 1.5" x 0.125" x 23.62" McMaster- Carr 8982K134 $7.35 $29.38

P11251- 025 1 Main Base Plate Ground Steel 48" x 24" x 1.0" Steel Plate $600.00 $600.00

P11251- 038 2Set screws for slotted shaft end supports (packs of 10) nylon tipped SS 1/4"- 20 x 1" McMaster- Carr 90291A542 $8.06 $16.12

1 Hardware McMaster- Carr $150.00 $150.00P11251- 039 1 HRC25A- 500R Curved linear rail SS 500mm x 90 degrees THK HRC25A- 500R $1,300.00 $1,300.00P11251- 040 1 HRC25A- 750R Curved Linear Rail SS 750mm x 90 degrees THK HRC25A- 750R $1,400.00 $1,400.00

Total $7,930.62

Sealing System Sub-System

Tank Flange

Gasket

Support Rod

Tank Wall

Rubber Bellows

Support Rod Mount

Mechanical Seal

Seal FlangeGasket

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

Sealing System - BOM

Shaft, Motor, & Impeller Integration

PRO/E System Model

Stepped Shaft

(2) Piece Coupling5HP AC Motor

Ø.75” for Impeller Integration

Ø1.375 Shaft

(Matched Output Shaft)

RIGID Shaft CouplingAcceptable Motor

Bearings & Construction

G McCarthy & Manuf. CAD Models

System Overview

•Motor

•Shaft

•Rigid Coupling

•VFD (Dan)

•Integration w/: Seal, Physical Stand, DAQ, & Force Measurement

Shaft, Motor, & Impeller Integration

WEG: 00512ET3E215TC-W22

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

Manuf. CAD Model

Shaft, Motor, & Impeller Integration

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

Precision Machined Shaft

FOS Calculation

ηMod-Goodman= 1.8 (Bending & Torsion)ηAxial Thrust= 17.1 (Impeller Thrust Load)ηNatural Freq = Acceptable (1st NF of Shaft)

G. McCarthy 2.13.11

Machinist: TBD

Shaft, Motor, & Impeller Integration

McMaster-Carr: 60845K941a.k.a.: Ruland Manufacturing: SPX-22-22-SS

FOS Calculation

ηMax Torque = 13.1*ηAxial Loading = 17.5*ηRPM/Speed = 3.3*

*Based on Manuf. Supplied Data

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 ClampingTol: +/- .002” on Bore

•Excellent Corrosion Resistance •One of few Rated on all (3) FOS levels

Manuf. CAD Model

Shaft, Motor, & Impeller IntegrationReferences & Justification

Preliminary: HP/Tq, Thrust, & FF Requirements

Preliminary Stepped Shaft Calculation

(Solid Ø.75” Shaft fails under bending)

Not Shown: Hand Calculations, Supplier Data Sheets, Matl Prop, Additional FBD’s, etc.

Shaft FBD

Stepped Shaft P1 of 3

•Review of all this Data was necessary to make safe selection

Shaft, Motor, & Impeller IntegrationSubsystem BOM

Axial and Tangential Fluid Force Feasibility

Motor Mount Plate

Load Cell Mount Plate

Support Pin

Load Cell FeasibilityAssumptions

• 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

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

Motor Mount Plate Feasibility

Motor Mount Plate Feasibility

Maximum Stress: 7474.0 psi Force Vectors

Maximum Displacement: 0.0014in

Load Cell Mount Plate Feasibility

Support Pin Feasibility

Support Pin Feasibility

Minimum Design Criteria

Factor of Safety Stress Concentration

4 2.8

Minimum Diameter in Shear (in) 0.118 0.263

Minimum Diameter in Bending Stress (in) 0.577 0.513

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)

Axial and Tangential Fluid Force BOM

Advantages:• All items chosen are in stock

Torque and RPM Measurement Subsystem

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

Data Acquisition

List Price: $1,149.00

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

Data Acquisition

List Price: $379.00

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

Data Acquisition

List Price: $699.00

•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

Labview Data Processing

System BOM Budget

Subsystem CostShaft, Motor, and Impeller Integration $1,672.23Sealing System $625.20Load Cells: Thurst and Fluid Force Measurement $5,152.24LABVIEW, Motor Tq, & RPM $2,227.00Physical Stand Structure $7,581.86

Total Cost $17,258.53Initial Budget $5,000.00

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

Updated Risk Assessment (FMEA)

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)

Preliminary Test Plan

Key Objectives:

• Test Strategy• Test Schedule• Control Features• Responsibilities• Deliverables

GANTT MSD II Preliminary Schedule

Project Plan: https://edge.rit.edu/content/P11251/public/Team%20Project%20Plan

Questions/Comments/Concerns