SPX Data Acquisition PRELIMINARY DETAILED DESIGN REVIEW John Dong David Haller Adam Johnson Thomas Klaben Luke Kranz

Presentation Agenda Phase Objective Statement(2 Minutes) Lab Setup(3 Minutes) Schematics(10 Minutes) Telemetry Wiring Diagram Strain Gauge Wiring Diagram Overall System Transmitter Case Flow Charts(5 Minutes) Data Energy Procedures(5 Minutes) Operations Manual Expectations Assembly of Telemetry Case Wiring Installation – Strain Gauges Proof of Concepts/Feasibility(10 Minutes) Gauge Mounting Gauge Removal Wire Waterproofing Transmission Through Case Test Plans(5 Minutes) Gauge Accuracy Case Waterproofing Project Management(10 Minutes) Engineering Requirements Bill Of Materials New Purchases Risk Assessment Detailed Design Project Plan Questions(10 Minutes)

Phase Objective Statement Overall Objective: ◦To provide SPX with a system capable of measuring strain on an operating impeller and then wirelessly transmitting the data to a third party user interface. The system is to be validated on a small-scale setup and then transferred to a full-scale setup. Goals for this Phase: ◦Set up lab space for small-scale testing ◦Compile and update all project and design documents ◦Trace designs back to customer and engineering requirements ◦Continue to purchase components and write test plans to validate specs ◦Continue feasibility studies on subsystem designs ◦Revise designs based on new findings

Lab Setup Location ◦Institute Hall Room 2180 Supplies ◦34” diameter stainless steel tank (134 gallon capacity) ◦1.25 hp motor ◦1000W variable frequency power supply ◦R&D impeller for small- scale mixing ◦Gauges ◦Wires ◦Soldering iron and solder

Schematic Telemetry Wiring Diagram

Schematic Strain Gauge Wiring Diagram

Wire tables

Schematic Overall System Changes to transmitter case Removed wire tube Spiral wires up shaft to case

Schematic Transmitter Case

Flow Chart Data

Flow Chart Energy Details the path of energy flow throughout the Wireless Strain Measurement system.

Procedure Operation Manual Expectations Pending Documentation: Node Commander Software Setup & Installation Base Station Configuration Data Logging Procedure

Procedure Installation – Strain Gauge Surface Preparation ◦Solvent degreasing ◦Surface abrading ◦Application of layout lines ◦Surface conditioning Gauge Bonding and Waterproofing ◦Handling and gauge preparation ◦Gauge placement using cellophane tape ◦Bonding with quick dry adhesive (super glue) ◦Waterproofing with epoxy Images courtesy of

Proof of Concept/Feasibility Gauge Mounting Question: Will we be able to mount gauges onto impellers? Will they stay mounted once underwater? Method of Test: Consult subject matter expert on best adhesive and waterproofing agent. Use suggestions and practice mounting on scrap metal. Subject Matter Expert: Rob Kraynick. Suggestions: Thin layer of super glue for adhesive, layer of epoxy for waterproofing. Gauges will only be usable once, and should have ribbon connections to avoid soldering damage. Proof of Concept: Conclusions/Learnings: ◦We must practice cleanly attaching gauges and using the least amount of epoxy/adhesive as possible. ◦Gauge lines will be needed to guarantee accurate placement. ◦Underwater adhesion testing will begin once we fill stainless steel tank in lab space.

Procedure Assembly of Telemetry Case Wiring

Procedure Strain Gauge Wiring

Proof of Concept/Feasibility Gauge Removal Preliminary Test: 1.Affix gauge to test sample. Place known load on sample, creating a known strain. 2.Remove gauge. 3.Affix gauge to test sample in same location. Re-test with the same known load. 4.If second strain reading is within 2% of initial reading, gauge can be reused. 5.Repeat until gauge measures a strain that is greater than 2% of the initial strain. 6.Record number of times the gauge was removed and the process used to remove the gauge.

Proof of Concept/Feasibility Gauge Removal Revised Test: 1.Affix gauge to test sample. Place known load on sample. 2.Use calculations to determine if the gauge is placed accurately on the test sample (see: Gauge Accuracy Feasibility). 3.Remove gauge. Record method of removal and any visual defects created by the removal of the strain gauge. 4.If any visible gouges are created while removing the gauge, the tested process fails and will be revised.

Proof of Concept/Feasibility Wire Waterproofing Feasibility Results: ◦Liquid Electrical Tape Insulates Underwater Wires ◦Heat Shrink Wrap Insulates Wires underwater Deltas: ◦Care must be taken with the wires once coated in electrical tape to not bend to extremes ◦When using heat shrink wrap make sure no stray wires are sticking through ◦Use a Real heat gun ◦Use multiple Waterproofing methods where possible

Proof of Concept/Feasibility Transmission Through Case Concept: Based off of cell phone Research we should be able to transmit through plastic Phones only need antenna lines to transmit through metal. Make a test plan to test for range reduction

Test Plans Gauge Accuracy/Calibration Clamp test piece to perform tests. Affix strain gauges a measured distance from the free end of the test piece. Apply a load on the end of the clamped test piece (cantilevered beam model) Calculate stress and strain as follows: Determine moment using singularity functions: q(x) = P -1 M(x) = P 1 = P(x) Where x is the distance from the free end of the test sample Stress Calculations: σ = -MC/I Where C is one half of the beam thickness and I = (1/12)bh 3 Strain Calculations: ε = σ/E = -MC/EI Where E is Young’s Modulus If the calculations and the actual experiment yield results within 5%, this shows our gauge placement and calibrations to be accurate.

Test Plans Case Waterproofing Spec S12: Submerged in water at depth of 1 meter for 1 hour with less than 0.1 grams of leakage Test plan: 1.Take enough sponges to fill case 2.Weigh sponges 3.Place sponges in case 4.Submerge case in water at depth of 1 meter for 1 hour 5.Take sponges out of case 6.Weigh sponges 7.See if difference in mass is less than 0.1 grams

Project Management Engineering Requirements

Project Management Bill of Materials

Project Management New Purchases Item: Telemetry System Brand: Lord Microstrain Price: $ Delivery: November 27, 2015 Item: Semi-Conductor Gauges Brand: Micron Instruments Price: $22.11 each Delivery: November 16, 2015 Item: Ribbon Gauges Brand: Omega Price: $13.60 each Delivery: November 10, 2015 Budget Update: $ /$5000 = 49.07% budget spent

Project Management Risk Assessment

Project Management Detailed Design Project Plan

Efficiency Schematics- 25% 1.Finished Schematics, realized no room for ground wire in plug 2.Changed to add new plugs 3.Found wiring error while doing wire tables, so recompleted tables and second Schematic Cad Efficiency 33% 1.Improvements- Fellow member found latch CAD file which saved time 2.Needing two plugs in case, needed to redo case design 3.Changed case design to include antenna inside for less water intrusion points

Questions