System Design Review Project Team 13453 Brandon Niescier Erin Sullivan Mike Gorevski Sean Deshaies Sean

Agenda Team and Project Introduction (5 min) Customer Needs and Specifications (5 min) Concept Generation (5 min) Concept Selection (10 min) Risk Assessment (5 min) Project Plan (5 min) Q&A Sean Add times

Team and Project Members Project Manager: Sean Deshaies (ME) Project Engineers: Brandon Niescier (ME) Erin Sullivan (EE) Mike Gorevski (EE) CUSTOMER: Dr. Jason Kolodziej, ME Department, RIT Sean 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. Brandon

Previous Work Team 12453 installed a range of sensors on the compressor and expanded the capabilities of the data acquisition (DAQ) system

Customer Needs Customer Need # Importance Description CN1 9 Single axis accelerometer mounted to crankshaft (Rotates) CN2 2 Single axis accelerometers mounted inside housing (Stationary) CN4 Continuous sensor operation CN7 Robust design of wireless technology for harsh environment CN8 Reliability and accuracy of measurements CN9 Interface with DAQ CN12 Must fit inside of compressor CN13 Must fit on shaft CN3 3 Minimal user intervention CN6 Wireless transmission of signal CN11 User manual/Important information CN5 1 Low cost CN10 Scalable to higher temperature (Internal environment) Erin

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   50 ES2 Acceleration Accuracy (ft/sec^2) ft/sec^2 ES4 CN6 Range of Wireless Transmission Distance (ft) ft ES8 CN7 Operational Maximum Temperature (degrees F) F 200 ES10 CN12 Size of Sensor and Wireless Technology (in) in ES3 3 Data Transfer Rates (Hz) Hz 10-15k ES5 Range of Wireless Transmission Frequency (Hz) ES6 CN3 User Intervention Rate (Interventions/time) inv/t ES7 Maintenance Intervention Rate (Interventions/time) ES9 Implied Power Consumption of System (W) W ES11 CN3/CN4 Lifespan of Technology (hours) hours ES12 1 CN5 Total Cost ($) $ 5000 Sensor Cost $500-$1500 Erin

House of Quality Mike Remember similar data is on the following slide   Importance Rating Size of Sensor and Wireless Technology (in) Acceleration Accuracy (ft/sec^2) Operational Maximum Temperature (degrees F) Total Cost ($) Power Consumption of System (W) Range of Wireless Transmission Frequency (Hz) Acceleration Range (g) Range of Wireless Transmission Distance (ft) Lifespan of Technology (hours) User Intervention Rate (Interventions/time) Data Transfer Rates (Hz) Maintenance Intervention Rate (Interventions/time) 2 Single axis accelerometers mounted inside housing (Stationary) 9 3 1 Continuous sensor operation Interface with DAQ Must fit inside of compressor Must fit on shaft Reliability and accuracy of measurements Robust design of wireless technology for harsh environment Single axis accelerometer mounted to crank shaft (Rotates) Minimal user intervention User manual/Important information Wireless transmission of analog signal Low cost Scalable to higher temperature and pressure (Internal environment) Raw score 367 288 285 280 247 246 198 156 142 120 111 102 Relative % 14% 11% 10% 8% 6% 5% 4% Importance Rank 5 4 2 Combined Percentages 26% 37% 48% 58% 67% 75% 81% 87% 92% 96% 100% 0 or Blank = No Relationship 9 = High Importance Mike Remember similar data is on the following slide

Pareto Chart Mike Mention once 50% with reqs, 70% done with project

Functional Decomposition Monitor Bearing Health Measure Vibration Sense Vibration Use Accelerometer Mount Device Mount on Shaft Mount on Housing Transmit Signal from Stationary Source Transmit Signal from Rotational Source Recieve Signal Condition Signal Log Data Use Lab View Output Spead Sheet Measure Temperature Observe Noise Observe Wear Functional Decomposition Brandon - nice

Concept Development Brandon – Proper terminology Mount the Sensor Inside Housing Drill and Tap Hole Glue It Affix with Wax Weld It Mount the Sensor on the Shaft Transmit Signal from Stationary Source Use Induction Use Bluetooth Use Wifi Use Proprietary RF Network Use Dissimilar Data Channel Use Zigbee Transmit Signal From Rotational Source Use Slip Ring Around Shaft Recieve Signal Condition Signal Attenuate Noise Design Filter Amplify Signal Design Amplifier Output Data Output to Notepad Output to Excel Brandon – Proper terminology

Pugh Chart for Mounting Sensor Inside Housing Criteria Concepts Drill and Tap Hole Glue It Affix With Wax Weld It D A T U M Secure Fit - + Resist Maximum Operating Temperature Oil Resistant S Vibration Resistant Ease of Removal Clarity of Vibration Measurement Ease of Installation Life Expectancy Ease of Maintenance 1 3 7 6 Total + Total - Total S Drill and Tap is chosen method Glue and Wax clearly eliminated Weld eliminated due to difficultly with maintenance Sean

Placement of Sensor Inside Housing Sean

Pugh Chart for Mounting Sensor on Shaft Criteria Concepts Drill and Tap Hole Glue It Affix With Wax Weld It Secure Fit (Relative to Rotational Force) - + Oil Resistant S Vibration Resistant Clarity of Vibration Measurment Ease of Removal Ease of Installation Life Expectancy Ease of Maintenance 1 3 2 6 5 Total + Total - Total S Drill and Tap is the chosen method Glue and Wax are clearly inferior options Welding is roughly on par However, welding is not practical Brandon *cut temperature criteria

Rotational Mounting Location Brandon

Pugh Chart for Transmitting Signal From a Stationary Source Criteria Concepts Use Proprietary RF Network Use Induction Use Bluetooth Use WiFi Use Dissimilar Data Channel Use Zigbee Loss of Signal Through Housing S - + 1 2 3 5 4 8 Power Consumption Complexity of Implementation Total + Potential for Interferance in Environment Cost of Implementation Continuity of Signal Ease of Maintance Life Expectancy Total - Total S Proprietary RF Network was chosen method The customer has requested a wired sensor to be implemented as well to verify data Based on the simplicity of our sensor network Mike Make sure you can explain why prop RF over zigbee. Expert advice is ace-in-hole.

Pugh Chart for Transmitting a Signal From a Rotational Source Criteria Concepts Use Proprietary RF Network Use Induction Use Bluetooth Use WiFi Use Slip Ring Method Use Zigbee Power Required - S + 2 5 4 1 7 Simplicity of Technology Potential for Interferance in Environment Cost of Implementation Total S Continuity of Signal Ease of Maintance Life Expectancy Total + Total - Proprietary RF Network was chosen method Based on the simplicity of our sensor network Erin

System Block Diagram Option 1: Commercial Off The Shelf Option 2: Develop In-House with PCB Mounted Accelerometer Option 3: Develop In-House with Commercial Accelerometer Option 3 was chosen due to expert reccommedation Integrated Accelerometer Transmitter Accelerometer Microcontroller/ Transmitter Mike Integrated Accelerometer Microcontroller/ Transmitter

Risk Assessment Erin Risk # Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner R1 Damage of Sensor Sensor transmits Inaccurate or No Data and Requires Increased User Interference Environment - Oil and Temperature 7 9 63 Properly Spec Components Sean R2 Noise in the Wireless Signal Poor Data Quality Surrounding Environment 5 45 Use Filters Mike R3 Trip Hazard for Wires Fall Injuries and Damage to the System Cables and wires in walk ways 35 Route wires away from walkways Brandon R4 Wireless Signal Cannot Penetrate Housing Data Not Received 1 in Cast Iron Housing with Wireless Technology 3 27 Research and Test Wireless Ability Erin R5 Insufficient Battery Life Increased User Intervention Power Consumption Too High 25 Calculate and Minimize Power Composition and Consider Battery Choice R6 Compressor is Not Operational Cannot Validate Solutions Other Parties Use the Compressor 15 Create Test Rig Erin

Risk Assessment (cont.) Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner R7 Accelerometer Falls Off- Inside Housing Damage to Accelerometer and to the Compressor Improperly Mounted 1 9 Ensure Proper Installation Method Brandon R8 Damage to Compressor During Install Broken Compressor and Project Failure Improper Installation Thoroughly Plan Installation with Input From D-R R9 Sensors Break On Installation Need to Buy New Sensors 7 Read the Product Manual Sean R10 Injury While Machining Parts Team Member Hurt Disregard to Safety Precautions Proper Training in Use of Machine Operation Mech Es R11 Accelerometer Fails to Satisfy Needs Data is Not Measured Correctly Uncertainty in Operating Conditions 5 Communicate with Manufacturers Erin R12 Accelerometer Falls Off- Outside Housing Damage to Accelerometer R13 Shaft is Unbalanced Induced Vibrations in System Weight of Technology Mounted on Shaft Do Calculations and if Necessary Apply Counter Weights to Balance Shaft R14 Wireless Signal Affected By Shaft Rotation Data is Not Transmitted Correctly Doppler Effect Consult Experts in Wireless Transmission Erin

Test Rig In order to validate the wireless signal transmission on the rotating shaft, 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 Brandon

Test Rig Model Power Supply Coupling Brandon Encoder Motor

Gantt Chart Through MSD I Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Task Name S M T W F Define Project   Develop Code of Ethics Define Customer Needs Define Specifications House of Quality Functional Decomposition Concept Development Select Team Roles Gather Info From Experts Pugh Charts Risk Assessment Create 1 Page Summary Develop System Layout Model Test Rig Create Presentation for System Design Review Revise Concepts Based on Feedback Design Test Rig Complete Vibration Analysis Calculate Force Required to Keep Sensor Mounted on Shaft Develop Concepts for Detailed Design Select Detailed Design Concepts Create a Bill of Materials Choose Mounting Locations Create Schematic Drawings Create Presentation for Detailed Design Review Change Design Based on Feedback Order Parts Prepare for MSD II Create Schedule for MSD II Sean Feel free to add talking points for me

Questions Sean, everyone