1. P11251: Side Entry Agitator Test Stand MSD I: Detailed Level Design Review https://edge.rit.edu/content/P11251/public/Home Wednesday, February 16, 2011 @ 4:00-6:00PM RIT KGCOE: 09-4435 A100 A312

2. Project Team/Attendees Project Sponsor : Richard O. Kehn - "ROK" Senior Technologist - Mixing SPX Flow Technology MSD I, 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 & Description4:00-4:05 Customer Requirements 4:05-4:10 Engineering Specifications – Revised4:10-4:15 Impeller Assumptions 4:15-4:25 Concept Selection Process4:25-4:30 System Assembly 4:30-4:35 Feasibility Chart 4:35-4:40 Detailed Sub-System & Feasibility Analysis 4:40-5:35 Physical Structure Sealing System Shaft, Motor, & Impeller Integration Measurement System w/ Hardware Integration Load Cells: Thrust & FF Measurement LabVIEW, Motor Torque & RPM System BOM Budget5:35-5:40 Updated Risk Assessment5:40-5:45 Preliminary Test Plan 5:45-5:55 GANTT MSD II Schedule5:55-6:00 Questions, Comments, & Concerns…6:00-?? 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: Revised Engineering metrics were re-evaluated after design review and further communication with sponsor and/or component vendors. Maximum RPM under load increased to 1200 RPM. Wall voltage increased to 208-230 Volts Motor HP Increased

7. Impeller Assumptions Assumptions 20% of Total Power is Lost During Power Transmission Provided Formula is accurate: SHP, Torque, Thrust, & Fluid Force Provided Power Factors are accurate Water as Working Fluid (SG) Max Speed of Selected Impellers does not exceed 1200RPM Will need to check max values of any other impellers to ensure comfortable FOS Design Criteria Max Torque: 283.5 in-lbs Max Thrust: 108.9 lbs Max FF: 51.5 lbs Max Impeller Weight: 3.5 lbs

8. Concept Selection Process Subsystem Selection Week 5 Pugh 1 System Selection Week 6 Pugh 2 System Interface Selection Week 7 CAD Modeling

9. System Inter-connectedness Flowchart Simple flowchart indicating the connectedness of the subsystems and components within the unit. Green: Motor/Shaft/Coupling Blue: Sealing System Red: Physical Stand Purple: Tang. And Axial Force Measurement Orange: Torque/RPM Measurement, DAQ

10. System Assembly

11. Feasibility Checklist Feasibility checklist items were taken from the risk analysis. These items are most likely to cause future complications. Simple checklist to validate whether proposed design will work. Allows comparing before part is in-hand and then re-validating after part in obtained or the component is built.

12. Physical Structure Sub-System

13. Physical Structure

16. Physical Structure Feasibility Key Points 1) Lead screws support weight 2) Full range of travel 3) System will not bind Max lead screw load = 3840 lbs Additional travel built into system Linear shaft assembly interchangeable with lead screw assembly

17. Physical Structure Feasibility FEA analysis on key components Assembly meets or exceed FOS of 4.0

18. Physical Structure Adt. Adjustment Tank will need to be raised an additional 8”

19. Physical Structure BOM

20. Sealing System Sub-System Tank Flange Gasket Support Rod Tank Wall Rubber Bellows Support Rod Mount Mechanical Seal Seal FlangeGasket

21. Sealing System Feasibility Allowable leakage rate is reached. Literature* shows a 1:800 leak ratio for mechanical seals compared to stuffing box. Power loss is the main reason for use of a mechanical seal over stuffing box with a loss ratio of 1:6. The rubber bellows have not been spec’d currently, theory shows full range of movement is possible, but true range of motion is not known until a sample in in hand. * http://www.chemseals.com/msvgp.pdf

22. Sealing System - BOM

23. Shaft, Motor, & Impeller Integration PRO/E System Model Stepped Shaft (2) Piece Coupling 5HP AC Motor Ø.75” for Impeller Integration Ø1.375 Shaft (Matched Output Shaft) RIGID Shaft Coupling Acceptable Motor Bearings & Construction G McCarthy & Manuf. CAD Models System Overview Motor Shaft Rigid Coupling VFD (Dan) Integration w/: Seal, Physical Stand, DAQ, & Force Measurement

24. Shaft, Motor, & Impeller Integration WEG: 00512ET3E215TC-W22 η AXIAL = 2.52* η RADIAL = 13.45* IP55: “Dust Protected” & “Water Jet” Resistant NEMA C-Face Mount Sealed Construction Industrial Applications *Based on Max Published Load Values from Motor Manuf. in combination w/ calculated forces on the shaft Manuf. CAD Model

25. Shaft, Motor, & Impeller Integration MATL: 316 SS Initial Dia: Ø1.375” X 7” LG Final Dia: Ø0.75” X 14” LG Total Length: 24” Allows simple integration w/ motor output shaft +/-.005” Total Runout Precision Machined Shaft FOS Calculation η Mod-Goodman = 1.8 (Bending & Torsion) η Axial Thrust = 17.1 (Impeller Thrust Load) η Natural Freq = Acceptable (1 st NF of Shaft) G. McCarthy 2.13.11 Machinist: TBD

26. Shaft, Motor, & Impeller Integration McMaster-Carr: 60845K941 a.k.a.: Ruland Manufacturing: SPX-22-22-SS FOS Calculation η Max Torque = 13.1* η Axial Loading = 17.5* η RPM/Speed = 3.3* *Based on Manuf. Supplied Data Type: 2 Piece Split Collar BoreA Dia: Ø1.375” BoreB Dia: Ø1.375” Outside Dia: Ø2.50” Length: 3.875” (8) 5/16-24” SS SHCS for Clamping Tol: +/-.002” on Bore Excellent Corrosion Resistance One of few Rated on all (3) FOS levels Manuf. CAD Model

27. Shaft, Motor, & Impeller Integration References & Justification Preliminary: HP/Tq, Thrust, & FF Requirements Preliminary Stepped Shaft Calculation (Solid Ø.75” Shaft fails under bending) Not Shown: Hand Calculations, Supplier Data Sheets, Matl Prop, Additional FBD’s, etc. Shaft FBD Stepped Shaft P1 of 3 Review of all this Data was necessary to make safe selection

28. Shaft, Motor, & Impeller Integration Subsystem BOM

29. Axial and Tangential Fluid Force Feasibility Motor Mount Plate Load Cell Mount Plate Support Pin

30. Load Cell Feasibility Assumptions Neglect friction between bushings and support pins Neglect reaction forces at load cells in X and Y directions Neglect static loads Load Cell compression is positive

31. Load Cell Feasibility Assumptions Extreme conditions Maximum Compressive Load 325 lbs Load Cell Specifications Model: LCF400 Manufacturer: FUTEK Rated Capacity: 1000 lbs Resolution 1.0 lbs Features: highly resistive to shear

32. Motor Mount Plate Feasibility

33. Maximum Stress: 7474.0 psiForce Vectors Maximum Displacement: 0.0014in

34. Load Cell Mount Plate Feasibility

35. Support Pin Feasibility

36. Minimum Design Criteria Factor of SafetyStress Concentration 42.8 Minimum Diameter in Shear (in)0.1180.263 Minimum Diameter in Bending Stress (in)0.5770.513 Assumptions: All forces acting in the worst case scenario Loads applied 6.000 in from shaft step (3.000 in max) Fillet radius 0.010 in Pin Location R 5.500 in (True R 8.000 in)

37. Axial and Tangential Fluid Force BOM Advantages: All items chosen are in stock

38. Torque and RPM Measurement Subsystem

39. National Instruments 9237: 24-bit resolution, ±25 mV/V analog inputs with RJ50 connectors 4 simultaneously sampled analog inputs; 50 kS/s maximum sampling rate Programmable half- and full-bridge completion; up to 10 V internal excitation 1 – 18V excitation Smart-sensor (TEDS) compatible Provides required signal conditioning for un-amplified load cells Data Acquisition List Price: $1,149.00

40. National Instruments 9201: 8 analog inputs, ±10 V input range 500 kS/s aggregate sampling rate 12-bit resolution, single-ended inputs, screw terminal or D-Sub connectors Hot-swappable operation; overvoltage protection; isolation NIST-traceable calibration Data Acquisition List Price: $379.00

41. National Instruments cDAQ-9174: Choose from more than 50 hot- swappable I/O modules with integrated signal conditioning Four general-purpose 32-bit counter/timers built into chassis (access through digital module) Run up to seven hardware-timed analog I/O, digital I/O, or counter/timer operations simultaneously Stream continuous waveform measurements with patented NI Signal Streaming technology Data Acquisition List Price: $699.00

42. Determine real time torque output from motor from VFD data Collect data from load cells Program algorithm to separate force measurements into tangential and axial components Determine direction of tangential forces Provide text file with data for easy importation into Matlab and/or Excel Labview Data Processing

43. System BOM Budget System BOM: https://edge.rit.edu/content/P11251/public/Detailed%20Design%20Review?rev=0

44. Updated Risk Assessment (FMEA)

45. Risk Assessment/ FMEA Revised Risk Items With The Highest Importance (≥6) Motor cannot handle the loads experienced during testing (9) Translation system does not lock into position (6) Motor cannot attain maximum speed range (6) Axial and tangential measurement devices are not sensitive to change (6) Load cells cannot measure the entire range of loads experienced during testing (6) Cannot construct Side Entry Horizontal Agitator Test Stand within allocated time period (6)

46. Preliminary Test Plan Key Objectives: Test Strategy Test Schedule Control Features Responsibilities Deliverables

47. GANTT MSD II Preliminary Schedule Project Plan: https://edge.rit.edu/content/P11251/public/Team%20Project%20Plan

48. Questions/Comments/Concerns