1. P11251: Side Entry Agitator Test Stand MSD II: Project Review https://edge.rit.edu/content/P11251/public/Home Friday, May 13, 2011 @ 10:00-11:00AM SPX Corporation/LIGHTNIN MIXERS A100 A312

2. Project Team/Attendees Project Sponsor : Richard O. Kehn - "ROK" Senior Technologist - Mixing SPX Flow Technology MSD 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)

3. Meeting Agenda Project Background & Description10:05-10:10 Customer Requirements 10:10-10:12 Engineering Specifications 10:12-10:15 Concept Summary10:15-10:20 System Architecture10:20-10:30 Physical Structure Sealing System Shaft, Motor & Impeller Integration Measurement System with Hardware Integration Load Cells: Thrust & FF Measurement LabVIEW, Motor Torque & RPM Design Summary10:30-10:35 System Testing Schedule & Results10::35-10:40 Objective Project Evaluation: Success and Failure10:40-10:45 Opportunities/Suggestions for Future Work10:50-10:55 Lessons Learned10:55-11:00 Acknowledgements Time Frame

4. Project Background & Description 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. A100 A312 Side Entry Agitator Top Entry Application

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

6. Engineering Specifications § Most important specs were deemed first priority. Ability to measure desired forces effectively. Designed to meet travel and angle requirements. Able to be calibrated and give repeatable results. Must have low rate of leakage or all else is moot.

7. Concept Summary Subsystem SelectionExisting Technology Vs Innovative Technology System Interface Selection

8. System Architecture Slotted support for vertical angle adjustment Ratcheting Handles Ball transfers for horizontal travel Horizontal Angle indicator Handle for horizontal angle adjustment Sprocket for lead screw sync Vertical position indicator

9. System Architecture [Physical Structure] § Vertical height and vertical angle integrated § Horizontal pivot point at tank wall § Smooth adjustment of horizontal angle § Easy to read position indicators § Directional ratchets on lead screws for height adjustment § FOS > 4

10. System Architecture [Sealing System] Tank Flange Gasket Support Rod Tank Wall Rubber Bellows Support Rod Mount Mechanical Seal Seal Flange Gasket § Rubber Bellows to allow for all of the motion necessary. § Mechanical Seal for less drag. § Support Rods to keep the Mechanical Seal parallel to the measurement plates and to prevent rotational movement.

11. System Architecture [Shaft, Motor & Impeller Integration] 316 SS Stepped Shaft 316 SS (2) Piece Coupling 5HP AC Motor Ø.75” for Impeller Integration Ø1.375 Shaft (Matched Output Shaft) RIGID Shaft Coupling Acceptable Motor Bearings & Construction § 5HP, 1800RPM AC Motor, VFD Controlled § Stepped Shaft to handle loading § Rigid Shaft Coupling for consistent measurement § Minimum FOS = 1.7 using worst case analysis Thrust Weight & FF Torque Axial & Radial Loads Critical Speed Speed Rating IP 55 Rating G McCarthy & Manuf. CAD Models SMI SYSTEM MODEL

12. System Architecture [Tangential and Axial Force Measurement] Motor Mount Plate Load Cell Mount Plate Support Pin § Load Cell Mount Plate and Motor Mount Plates designed for minimum deflection (less than.001”) § Support pins for easy assembly and overload protection for the 1000 lb capacity load cells § Support Pins to eliminate non-axial forces seen by the Load Cells § Support Pin Bushings for limited friction

13. System Architecture [LabVIEW, Motor Torque & RPM] § RPM dialed in as constant § Torque measured from VFD, input to LabView § Load cell signal acquired and converted to axial and tangential forces § Data written to spreadsheet file for future manipulation in Matlab and Excel Signal Amplifier Load Cell DAQ System

14. Design Summary § Breaking this system into Sub-Systems allows the opportunities for future revisions and development of a single system without affecting the entire system. § The use of simple technology with current hardware eliminates the need for new equipment with an added learning curve. § Design above set engineering specifications to compensate for unforeseen demands. § Single control for independent adjustability. § A fully integrated system limits the the demands on human resources while exceeding the expectations of the customer § Provide a full product with all required materials focusing on the use of standard tools

15. System Testing Schedule Intended Tests: Completed Tests: Tests to Finish:

16. System Testing Results

17. Objective Project Evaluation [Success/Failure] § Successes § System fully designed to meet 85% of all specifications § Load cells/DAQ communication § Seal system met requirements § Horizontal travel operates smoothly § Failures § Ordering incorrect parts § Purchases not made early enough § Deliver fully assembled system on time [5/17/11]

18. Opportunities/Suggestions For Future Work § Perform in-tank testing to evaluate design considerations § Perform multiple tests to prove reliability & repeatability of system § Compare new system data to historical data, equations, & calculations § Optimize design for more efficient functionality § Improve VI capabilities for data acquisition and handling § Add filtering capabilities to make collected data more meaningful § Utilize full functionality & programmability of VFD motor control

19. Lessons Learned § Do not under estimate the simplicity of the design in manufacturing parts § Anticipate vendors and/or suppliers will not be on time § Build flexibility into project plan to accommodate these anticipations § Anticipate delays amongst team members and sub-system development § Utilize local vendors as much as possible, promote local business § Maximize utilization of RIT’s machining resources § Possible outsourcing of complex machining § Establish design “lock points” where everyone agrees upon system design & functionality § Increase “uniform communication”: online note board/to do list/checklist § Introduce RIT’s purchasing system prior to beginning MSD II § Track documentation of: ordered, shipped, & received parts more effectively

20. Acknowledgements Special Thanks to: Richard Kehn, Bernie Gigas & Tom Taylor, on behalf of SPX, for making this project possible Bill Nowak for providing guidance & field experience throughout the project Prof. John Wellin for LabView & DAQ input Dr. Kempski & Dr. Bodeo for technical advising & theoretical input Dave Hathaway, Steve Kosciol, & Rob Kraynik for their assistance with machining, welding, and constructing the system. John Bonzo & the Brinkman Lab for CNC machining select parts Ryan Crittenden & FMS for electrical advise and wiring to NYS Code