1. Kris Kidder | John Dolan | Shay Stanistreet | Anthony Miuccio
P16453 System Design
Kris Kidder | John Dolan | Shay Stanistreet | Anthony Miuccio
Kris can probably read the first 2 slides as well, considering project manager or whatever

2. Agenda Objectives Problem Statement Customer Requirements
Engineering Requirements
House of Quality
Team Vision
Functional Decomposition
Current State and Architecture
Benchmarking
Morphological Chart
Pugh Analysis
Risk Assessment
Feasibility Analysis
3 Week Action Items

3. Problem Statement
Currently, RIT houses an ESH-1 compressor, which contains a particular type of fluid bearing, known as a journal bearing. These bearings are able to be tested on a rig which is a culmination of 2 years' work from other MSD teams. The first was tasked with the actual test rig design and structure, as well as a 1-D static load, and the second was tasked with creating a 2-D dynamic loading profile. Now, we've been tasked with providing additional measurement capability and final touches to some of the smaller issues on the existing rig. To name a few measurements we must collect:
Bearing Load
2-D Vibration Analysis
2-D Displacement Analysis
Oil Flow Rate
Film Thickness
In addition to these, we've also been asked to determine the eccentricity of the shaft, as well as the clearance between the shaft and bearing. We've also been tasked with creating three bearings in order to test the rig with pre-determined results.
At the end of the project, we will be required to give our design documents, a working prototype, a technical paper, a poster, and we'll be presenting our project at ImagineRIT during the spring semester. We've been asked to complete this within a certain budget, using only LabVIEW, and to create a system that's local, convenient, and easy to use for somebody who isn't necessarily involved in its conception.

4. Customer Requirements

5. Engineering Requirements

6. House of Quality

7. Team Vision - System Design Phase
Developed concepts to eliminate backlash
Benchmarking, Pugh analysis
Risk Assessment
Investigated oil flow
Additional testing needed
Rig Disassembly
Incomplete, pending updated motor controller

8. Functional Decomposition
A fully functional test rig, capable of simulating the load profile from the ESH-1 Dresser-Rand Compressor. Rig will be capable of measuring load, oil flow rate, vibrations, eccentricity, and bearing clearance. Three additional journal bearings will be fabricated in order to test validity of the rig. Rig will be presented at a relevant conference, as well as Imagine RIT. A theoretical paper will also be developed to demonstrate our reasoning and findings.

9. Current State & Architecture

10. Vibration Sensor Benchmarking
Industrial 2-Pin Accelerometer is best fit for our system
Inexpensive, effective range, sensitive, and high enough sampling rate
PCB High Sensitivity would also be effective
More costly, but 50% higher sampling rate
PCB Triaxial is too much for our application
Triaxial would be nice to have, but highly unnecessary considering our parameters. Cost is not justified. However, more sensitive and higher overload level if necessary in a future project or expansion of current project.
All available from National Instruments: guaranteed compatibility

11. Displacement Sensor Backlash Benchmarking
Lasers more expensive, and range is excessive for our needs
NC-DVRT uses non-contact solution, meaning possible from outside of bearing housing (required for our application)
Confocal Sensors effective with minimal intrusion

12. Anti-Backlash Benchmarking
SKF PGF Precision Ground Ball Screw
Uses one piece nut with internal preload
Haydon Kerk Anti-backlash Nut
Wear compensating, Custom configurations
Thompson Leadscrew Assembly
Wear compensating, engineering design assistance, max 1185 lbs

13. Software Benchmarking
MatLab Comparison:
Similar complexity, less efficient course of action than LabView, more difficult to debug
C++ Comparison:
More complex, less efficient than LabView, more difficult to manage/debug
LabView program (already implemented) is most suited for a job of this type.

14. Morphological Chart

15. Pugh Chart

16. Pugh Chart (Iteration 2)

17. Risk Assessment

18. Risk Assessment Cont.

19. Feasibility Analysis
Quick calculations to determine realistic parameters
Determined values to be well within reasonable limits
Not expecting unstable behavior from additional spring

20. Feasibility Analysis Cont.
Graph of position vs. time
Makes sense considering sinusoidal nature of loading scenario in the Compressor

21. Action Items Select final design for backlash elimination
Investigate oil flow
Machine and test additional bearings
Include Moog motors into system
Full disassembly of test rig

22. Questions?