MSD P13453 Final Project Review Sean Deshaies (ME) Erin Sullivan (EE) Michael Gorevski (EE) Brandon Niescier (ME)

Agenda Project Goals Customer Needs Design Summary – Wired System – Wireless System Testing Expense Report Project Status Future Work Lessons Learned

Project Goals Install accelerometers on the compressor – One on the flywheel hub – One on the bearing housing Find a solution to wirelessly transmit data from one of the accelerometers Data collected in LabVIEW or through standalone software

Customer Needs Customer Need # ImportanceDescription CN19Single axis accelerometer mounted to crankshaft (Rotates) CN29Single axis accelerometer mounted inside housing (Stationary) CN49Continuous sensor operation CN89Reliability and accuracy of measurements CN129Must fit inside of compressor CN139Must fit on shaft CN73Robust design of wireless technology for harsh environment CN93Interface wth DAQ CN33Minimal user intervention CN63Wireless transmission of signal CN113User manual/Important information CN51Low cost CN101Scalable to higher temperature (Internal environment)

Wireless Accelerometer Mounting Location CN13 references mounting on the shaft – Accelerometer was too tall for keyway Pugh analysis was done to evaluate potential solutions – New mounting location was found on flywheel hub

Design Summary Wired Accelerometer: – PCB Swiveler is able to withstand the oil and higher temperatures inside the compressor Wireless Accelerometer: – PCB 660 Series is able to operate on the same low voltage as the wireless module Wireless Module: – TelosB module allows for low power, wireless transmission capabilities

Wired System

Wireless System

Test Fixture

Testing Accelerometer verification – PCB Swiveler vs. B&K 4393 – PCB 660 Series vs. B&K 4393 Wireless transmission verification – TelosB module vs. function generator

Accelerometer Test Results

Wireless Test Results

Compressor Data Wireless DataWired Data

Accelerometer Data Comparison

Total Expenses Team P13453 Expenses Order NumberVendorOrder DescriptionTotal Cost Amazon SupplyAluminum Bar and Angle$ McMaster-CarrSteel Bar, Pillow Block Bearings$ PhotocraftEncoder, Stub Shafts$ McMaster-CarrReturned Bearings($252.16) 4389PowerGatePower Supply$ Bolt DepotTest Rig Hardware$ McMaster-CarrCable Gland$ Allied ElectronicsUSB Extension cord and Enclosure$12.41 PL MemsicWireless Modules$ GraingerEpoxy$17.60 N/AAnaheim AutomationMotor$ N/AMcMaster-CarrCoupling$ McMaster-CarrScrews$ Allied ElectronicsEnclosure and Switches$36.76 A233703FuturlecHeader Pins$6.50 N/APCBAccelerometers and Signal Conditioner$ N/ALowe'sSafety Guard Brackets$3.18 N/AHarbor FreightHex Key Set and Rubber Mallet$8.98 N/AJeff WilczewskiWireless Module Programming$ McMaster-CarrHelicoil Thread Repair Kit$77.31 Initial Budget:$5,000 Funds Remaining:$2,482

Project Status Accelerometers installed successfully – Wired accelerometer integrated into LabVIEW – Wireless accelerometer interfaces through a standalone program Data is reliably transmitted wirelessly

Future Work Sync the data between wired and wireless accelerometer Integrate the wireless accelerometer into LabVIEW Mount wireless accelerometer to bearing housing inside compressor Improvements to wireless enclosure

Lessons Learned There is no viable off-the-shelf wireless solution Expert opinions are sometimes wrong Be sure to include all necessary tolerances on manufacturing drawings Machinists have the ability to make or break the project Communication of customer needs could have been improved Need to anticipate the speed of bureaucracy

Acknowledgements Bill Nowak – Guide Jeff Wilczewski – Programming wireless modules Rob Kraynik – Machining and installation assistance Dresser-Rand – Project sponsor Markus Holzenkamp – Project assistance Dr. Kolodziej – Faculty champion/customer

Thank You P.S. – Bill you owe us all a beer