P11251: Side Entry Agitator Test Stand REVISION A: For Reading/Review ONLY (No Formal Presentation Given) MSD I: System Level Design Review

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 Mission Statement Project Description Review of Customer Needs/Specs Review of Pairwise, Engineering Metrics, HoQ, Pareto Concept Sub-System Breakdown Initial Concept Generation & Selection Physical Structure Shaft/Motor/Impeller Integration Sealing System Measurement System w/ Hardware Integration Preliminary Risk Assessment/FMEA Project Schedule Review (GANTT) Questions/Comments/Concerns Estimated Time 12: :40 12: :45 12:45 - 1:50 12: :55 12:55 - 1:00 1:00 - 1:40 1:00 - 1:10 1:10 - 1:20 1:20 - 1:30 1:30 - 1:40 1:40 - 1:50 1:50 - 1:55 1:55 - 2:00

Mission Statement 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.

Project Description Shaft protrudes through the side wall of the tank very large, under floor tanks where little headroom is available less costly than top entry mixers requires less motor torque to agitate the fluid three to five times the amount of power as a top entry mixer Rely heavily on impeller selection different diameters, physical sizes and blade profiles Previously developed top entry test-rig they currently have no way to benchmark these same impellers for side entry agitation Create a test-rig that allows reliable measurement through a range of adjustability (Impellers/Speeds/etc.) similar concepts to the top entry test rig different array of: bending moments, torque and fluid forces Very beneficial to our customer benchmark existing and future impeller designs for side entry applications.

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

Pairwise Comparison

Graphical Representation of Pairwise Comparison

Engineering Metrics

House of Quality

Pareto Analysis of Eng. Metrics

Power Law Distribution By designing for only 40% of the Engineering Metrics, We’ll gain 65% of the advantages of designing for all the Engineering Metrics Top (5) Most Important Engineering Metrics Tangential Force Measurement Thrust Force Measurement Shaft Rotational Speed Torque Measurement Ease of Calibration Time of Calibration

Concept Sub-System Breakdown

Physical Structure Sub-System Stand Adjustability Vertical and horizontal adjustment Depth into tank Angle left and right Angle up and down

Physical Structure: Concept Drawings

Physical Structure: PUGH Matrix Height Adjustment Weight Concept Ball Screw Scissors Jack Linear Rail Columns Customer Needs Calibration Repeatability 4101 Test Stand Independent 4000 Height Adjustment 3000 Time for Setup 1000 Appearance 1000 Additional Criteria Cost 4 Ease of Fabrication 4111 Complexity 2111 Stand Size 2001 Potential for Slop 4111 Increments of adjustment 3000 TOTAL

Physical Structure: PUGH Matrix Horizontal Adjustment Weight Concepts Rails Ball Screw Ground Rods Plate with Pins Floating Plate with magnetic locking Customer Needs Calibration 500 Repeatability 4 Test Stand Independent Horizontal Adjustment Time for Setup 1111 Appearance 1000 Additional Criteria Cost 4 1 Ease of Fabrication Complexity 2000 Stand Size Potential for Slop 4 Increments of adjustment TOTAL

Physical Structure: PUGH Matrix Depth Adjustment Weight Concepts Move Impeller on shaft Rails Ball Screw Plate with Pins Floating Plate with magnetic lock Customer Needs Calibration Repeatability 400 Test Stand Independent Distance Into Tank Time for Setup 1011 Appearance Additional Criteria Cost 4100 Ease of Fabrication Complexity 2100 Stand Size Potential for Slop 4 0 Increments of adjustment TOTAL

Physical Structure: PUGH Matrix Vertical Angle Adjustment Weight Concepts Wedge Screw Rotary Disc Curved Track Gear Adjustment Tilt Table Columns Cable Suspension Customer Needs Calibration Repeatability Test Stand Independent Vertical Angle Time for Setup Appearance Additional Criteria Cost Ease of Fabrication Complexity Stand Size Potential for Slop Increments of adjustment TOTAL

Physical Structure: PUGH Matrix Horizontal Angle Adjustment Weight Concepts Curved Track Rotary Table Swivel Plate Cable Suspension Floating plate with magnetic lock Customer Needs Calibration 50 Repeatability 40 Test Stand Independent Horizontal Angle 3100 Time for Setup 100 Appearance Additional Criteria Cost Ease of Fabrication 4000 Complexity 200 Stand Size 20 1 Potential for Slop 40 Increments of adjustment TOTAL

Physical Structure: PUGH Matrix System Design Weight Concepts Rails with servos and screw with a tilt and rotary plate Ground rods instead of rails with locks Stand with Vertical Angle ajustment 'floating' on base plate Plate with pre-drilled holes for positioning motor with tilt plate Suspend motor by inverting Rail concept Four columns with ball screws with curved track. No depth Pre-drilled plate concept with a mounting rail with 1" adjustability Custom plate per setup Ball joint on plate. Ground rod with ball screw for all movement. Swivel plate Linear rail for vertical, horizontal, depth with rotary table Customer Needs Calibration Repeatability Test Stand Independent Height Adjustment Horizontal Angle Vertical Angle Distance Into Tank Time for Setup Appearance Additional Criteria Cost Ease of Fabrication Complexity Stand Size Potential for Slop Allows full range of motion Increments of adjustment TOTAL

Physical Structure: Concept Selection Key Advantages Removes need for tilt plate Reduces potential issue with structure height No limit to step increments on any axis Possibility for fully automated positioning via stepper motors

Shaft, Motor, & Impeller Integration Sub-System Explanation of this sub-system & components: Shaft: Transmits torque & angular velocity via the motor & impeller Coupler: Transmits power between the motor output shaft & shaft Motor: Provides Mechanical Energy to the system Impeller: “Work” horse of the system: agitates the fluid to be mixed ShaftImpellerCouplingMotor Tank Wall Fluid Agitation

SMI: System Diagram w/ Impellers Given Impeller Dia.: 4.5 – 10” Off Wall Distance: TYP. 0.5D <0.4D, Flow Drops Off >0.5D, Minimal Additional Flow, Adds Cost for Minimal flow benefit MATL: 316 S.S. 6”Ø: 2” 10Ø: 3”

SMI: Shaft Design Selection Shaft Length, (From Tank Wall) = APROX – 5”

SMI: Shaft Design Selection PUGH Best Choice: Solid, Continuously Long Shaft

SMI: Shaft Design Prelim. Equations Static Cantilever Beam Analysis Mod-Goodman Shaft Analysis Natural Frequency Ck

SMI: Shaft to Shaft Coupling Set Screw Disc Gear All must have high torsional strength, for accurate fluid force & thrust measurement Minimize parallel mis-alignment (RIGID) for accurate fluid force & thrust measurement Provide a secure connection between the (2) elements Long lasting and minimal maintenance/overhaul required Manuf: LoveJoy Req’s: 1) Required Max Torque 2) Motor Speed/HP Req. 3) Shaft/Motor Shaft Dia. Thru-Bolt

SMI: Shaft Coupling PUGH Best Choice: Thru Bolt or Set Screw Thru Bolt for Added Rigidity & Resistance to Torsion

SMI: Impeller/Shaft Connection Based on given ID of provided impellers, (3) conditions could exist: 1)Shaft Dia. < Impeller Dia. - need for a spacing collar 2)Shaft Dia. > Impeller Dia. - need for a reducer 3) Impeller has threaded spacer that screws onto end of shaft (Similar to 2)

SMI: Impeller/Shaft Connection PUGH Best Choice: Spacing Collar Method currently being used by industry OR Direct connect to shaft, if Shaft OD=Impeller ID

SMI: Motor Selection DC or AC Motor Variable Drive (per Measurement & Integration) Highly dependent on “Physical Stand” Package Size/Weight/Mounting Options Capable of reaching 1100 RPM under load, with greatest thrust/torque producing impeller Spec’d based upon required shaft size Consider Side-Loading Effect on Motor Bearings/Life NEMA Rating for environment/safety

Sealing System: Initial Concepts Concept 1 Concept 4,5,6,7 Concept 3 Concept 2

Sealing System: Initial Concepts Concept 10 Concept 11 Concept 8 Concept 9 Concept 12 Concept 13

Sealing System: PUGH

Sealing System: Final Concept Critical Benefits: Allows Adjustability Less parasitic to measured forces Does not alter tank geometry Very low leak rate

Axial and Tangential Fluid Force Measurement Concept Generation Measurement Technology: Strain Gauge; Donut, Pancake, Canister, or Column Load Cell; or Accelerometer. Location of Measurement Devices: On the motor mount, beneath the coupler, or on the end of the shaft. Motor Mount Design: Parallel Plates, Lever Arms, Shear Support Pins, Load Cell Cocoon, or Parallel Plates with Pointed Pivot. Pictures from ems.com. T=(L 1 /L 2 )FPins resist shear effects. Picture from today.com Picture from n.standford. edu Motor Inner and outer support boxes.

Axial and Tangential Fluid Force Measurement Concept Evaluation

Axial and Tangential Fluid Force Measurement Concept Selection Three Most Critical Criteria : Resists Affects of Shear Measuring Sensitivity Appropriate Time for Setup Low Profile, Tension & Compression Load Cell Mounted to Parallel Plates with Shear Pins optional depending on supporting calculations. Side ViewIsometric ViewPicture From

Slip Ring: Electrical connection through a rotating assembly Low speed limitations Ring wear and dust brushes impede signal transfer Requires routine maintenance for cleaning Torque and RPM Measurement Subsystem

Rotary Transformer: Tolerates high speeds Non-contact More accurate Requires sophisticated signal condition instrumentation Less tolerant to extraneous loading conditions (bending moments and thrust forces) Torque and RPM Measurement Subsystem

Digital Telemetry: Software driven allowing changes on the fly High resolution, sensitivity, and accuracy More immune to vibration problems Smaller, lighter, and more compact Torque and RPM Measurement Subsystem

Torque Transducer: Utilizes a system of strain gauges (Wheatstone Bridge) Uses slip rings or rotary transformers to power and transfer strain gauge data Torque and RPM Measurement Subsystem

Torque from Motor Constants: Ideal for direct drive systems Only requires measurement of motor current Torque and RPM Measurement Subsystem

Critical Criteria Measurement accuracy and sensitivity Ease of implementation Small package size Allow for multiple shaft diameters Ease of maintenance

Final Integrated Concept Generation

Final Integrated Concept Selection Physical Stand Tangential & Axial Force Measurement Shaft, Motor & Impeller Integration Torque & RPM Measurement

Final Integrated Concept Selection Physical Stand Sealing System

Preliminary Risk Assessment/FMEA

Preliminary Risk Assessment/FMEA Key Risk Items Full range of adjustability Seal Effects measurement instrumentation & readings Sensitivity of Measurement Systems Successful Integration of Sub-Systems Orientation affects measurements

Project Plan Review

Questions/Comments/Concerns