1. Detailed Design Review Multidisciplinary Senior Design 1 Friday, February 15 th, 2013 P13051

2. P13051 – PIV Experiment for Flow Mapping in Lungs Customers: ▫Dr. Risa Robinson ▫Dr. Steven Day Team Guide: ▫Michael Antoniades – Chemical Engineering Team: ▫Kristin Roberts – Project Manager, ME ▫Morgan DeLuca – ME ▫Brad Demarest – EE ▫Ryan Mark – ME ▫Jimmy Moore – CE ▫Jake Snider – ISE

3. Agenda Project Background Customer Needs & Engineering Specifications Component Design & Feasibility ▫Pressure Measurement & Control System ▫Pump System ▫Lung Tank & Reservoir ▫Camera/Laser Positioning System Preliminary Test Plans Risk Assessment

4. Project Background The Army Medical Research Lab needs to validate their CFD models for healthy and diseased lungs RIT will perform particle image velocimetry (PIV) on lung models to validate the CFD. The senior design team will design and develop the lung models and testing apparatus.

5. What is PIV? Used for flow visualization and velocity measurements Fluid is seeded with tiny tracer particles The particles are illuminated using a laser sheet, and a camera takes pictures of the particles. Fluid velocity profiles can be obtained by analyzing particle movement from frame to frame.

6. Key Customer Needs 1.Accommodate various image locations 2.Simulate inhalation and exhalation 3.Monitor flow rate and pressure 4.Control flow at outlets to mimic boundary conditions of CFD model 5.Accommodate imaging with no distortion 6.Create LabVIEW Program and procedure to run experiment 7.Can easily switch between models

8. Pressure Control Subsystem Comprised of: T-hose splitter Dual flow needle valve Amplified voltage pressure transducer Powered breadboard

9. Needle Valve High resolution, therefore minor adjustments to flow can be made (5 turns) Dual flow capability (allows inhale and exhale simulation) Low profile for organization purposes Low cost (20$)

10. T-Hose Splitter Reasons for using a T-hose splitter: Separate static pressure from dynamic flow Allow pressure readings to be taken parallel to flow increasing accuracy Organize flow path from model to valve system

11. Amplified Pressure Sensor Accuracy (can measure static pressures +/- 1% with proper calibration) Cost (65$ per sensor) Compact design (no extensive cables or adaptation, plug into breadboard) Easy to calibrate and characterize to increase accuracy

12. Breadboard Implementation Keeps voltage sensors organized and setup compact Allows user to adjust voltage getting applied to sensors easily Flow from pressure control to DAQ device will be smooth

13. Pressure Control Path Fluid will leave outlet With steady state conditions fluid will separate due to splitter and apply static pressure on sensor Flow will be adjusted with needle valve based on logger pro readout compared to desired conditions Back to pump

14. Calibration Technique Fluke 718 series Can use to apply very accurate known pressure Output voltage can then be read and adjusted to create new curves accurately matching sensor performance Device is on loan from ME Department

15. Flow Characteristics Viscosity determined through index matching, (550 SSU, 109 cP, 0.109 Pa-s) ▫Much higher than water (1 cP) Flow tested by Army is from 2-10 L/min ▫Using Reynolds number matching, 6-32 GPM Pressure loss through system ranges from 20 psi to 50 psi ▫Calculated using Poiseuille flow

16. Positive Displacement vs. Centrifugal Conclusion: PD pumps provided better flow control, regardless of pressure and handle high viscosities. Graph Credit: pumpschool.com

17. PD Pump Selection PumpFlow RatesPressuresCommentsCost (3 highest) Gear pump Acceptable, Up to 30 gpm Acceptable, Up to 50 psi Common, can be self- priming 2 Rotary VaneAcceptable Not really used in our application, better for thin fluids and high pressure differentials 1 DiaphragmAcceptable Create pulsing flow, need air supply, cheaper 1 Lobe PumpAcceptable Used in Sanitary applications where fragile solids are used, bi-rotational, may be overly complex 3 Image Credit: Wikipedia; Info Credit: pumpscout.com

18. 3 GPM35 GPM 6 GPM33 GPM19 GPM Siewert, 1.6-16 GPM, $2,079 Siewert, 3.2-32 GPM, $2,319 Siewert, 2.3-23 GPM, $2,189 Emerick, 3.3-33 GPM, $2,754

19. Max flow rate: 33 GPM Min flow rate: 3.3 GPM Max Pressure: 200 psi Speed Ratio: N/A Price: $2,745 Shipping not included Lead time: 3-4 weeks Max flow rate: 32 GPM Min flow rate: 3.2 GPM Max Pressure: 100 psi Speed Ratio: 10:1 Price: $2,319 Shipping included Installation Assistance Lead time: 5-6 weeks Emerick Siewert

20. Inhalation Pipe Schematic

21. Lung Tank Design The project team has decided to go with acrylic siding for the tank, as it is easy to machine and is readily available in the needed sizes. The tank will be 24” x 16’’ x 16’’, which will hold slightly less than 27 gallons worth of liquid.

22. Lung Tank Design The case will be made watertight using silicone gel, and then made more structurally sound using L-brackets along the side. 8 holes will be drilled along the bottom of the side panels for the multi- tube connectors A single hole on the top of the case will allow liquid to be pumped in to the model.

23. Tank Wall Deformation Analysis ANSYS Workbench was used to analyze wall deflection due to hydrostatic pressure (P=ρgh). Original choice of 1/8” thick acrylic resulted in 1.868” outward deflection. Needed to find appropriate wall thickness that would not affect PIV results 1/8” 5/16”

24. Tank Wall Deformation Analysis Treated tank wall as a simply supported beam Able to calculate deflection and slope of deflection Calculate angle between laser and perpendicular

25. Tank Wall Deformation Analysis Used Snell’s Law to calculate the angle of the laser after it enters the tank (θ 2 ). We can then calculate the error associated with refraction using the distance the lung is from the wall. θ2θ2 Error Distance to model

26. Tank Wall Deformation Analysis Panel Thickness (in) I (in 4 ) Max P (psi) (q) Max Deflection (approx) Max Slope (Magnitude) θ 1 (deg)θ 2 (deg) Distance to Model (in) Error due to refraction (in) Error due to refraction (mm) 0.250.02081.05950.24410.03471.98851.334480.18634.7333 0.31250.04071.05950.12500.01781.01840.683580.09542.4240 0.43750.11171.05950.04550.00650.37120.249180.03480.8835 0.50.16671.05950.03050.00430.24870.166980.02330.5919 0.68750.43331.05950.01170.00170.09570.064280.00900.2277 0.93751.09861.05950.00460.00070.03770.025380.00350.0898 11.33331.05950.00380.00050.03110.020980.00290.0740

27. Tank Wall Deformation Analysis For a 16”x24” acrylic panel, 7/16” thick

28. Reservoir Design Similar design to Lung Tank 1/8” thick acrylic will be fine since tank is not used for PIV – only 0.17” deflection. 12”x12”x12” box Holes cut for connection to pump system

29. Omega Multi-tube Connectors Can handle 10 tubes per connector. Will allow easy connection/disconnect when we switch out models. Allows for thru-wall connection to simplify the tank and tube interface.

30. Lung Holder Used to hold lung in tank Put rubber between holder and lung model to ensure a tight and secure fit Can rapid prototype in clear Watershed XC 11122 for ~$300

31. Lung Holder Drawing

32. Labview – Data Acquisition NI-USB-6225, Screw Terminated ▫80 Analog Input Ports ▫Compatible with Labview ▫$1749 This will output to the Labview program which will collect the pressure data and display it to the user.

33. Labview Code Not fully completed ▫Need all components before testing and construction can occur.

34. Positioning System Need: Ability to take PIV pictures of all branches and bifurcations XYZ Stages alone are not the answer ▫Used for low travel, high resolution ▫Very expensive for more than one Optics rods and clamps also too expensive & precise Make it ourselves – 80/20

35. Design Essentially a square arch that translates L-Handle brakes to keep it in position Strong frame – no vibration Drop-in T-studs allow for camera movement When combined with a rotation allows for all angles

36. Result Contacted Bob Proscher at Ralph W. Earl Co. Developed a kit including all requested machining ▫Quote: $243.75 Mount an optical stage (5 – 10 mm) ▫$600 - $1,000

38. Refractive index (RI) of fluid must match that of the model. ▫Model will be made using RedEye Veroclear  n = 1.47 Fluid used will be made from glycerin. ▫85% Glycerin, 15% Water  n = 1.45  While RI may not be matched exactly, the difference is negligible. Index Matching Fluid

39. Complete Test Setup Positioning System Lung Tank Pump System Reservoir

40. SubsystemCost Tanks and Containment$1207.46 Camera Positioning$191.45 Pumping System $2,597.91 Common Header$266.62 Pressure Control and Measurement$11,703.00 Total:$15,966.44 Budgetary Overview

41. PartPrice/UnitQuantityCost Acrylic Sheet, 48"x24", 7/16" thick $132.392 $264.78 Multitube Quick Coupling Set $64.008 $512.00 Perforated framing, zinc-plated steel, 4ft each, pkg qty 12 $8.781 Plain Steel Square Head Low Strength Bolt 5/16"-18 Thread, 1" Length, pkg. 25 $5.592 $11.18 18-8 SS Type A USS Flat Washer 5/16" Screw Size, 7/8" OD,.06"-.11" Thick, pkg. 25 $5.602 $11.20 Plain Grade 8 Steel Hex Nut 5/16"-18 Thread Size, 1/2" Width, 17/64" Height, pkg. 100 $4.281 Steel Perforated Flat and Angle Framing Hardware: Zinc- Plated Steel Bolts W/Nuts & Washers $7.421 Zinc-Plated Steel Machine Screw Hex Nut 2-56 Thread Size, 3/16" Width, 1/16" Height, pkg. 100 $1.211 316 SS Pan Head Phillips Machine Screw 2-56 Thread, 1/2" Length, pkg. 50 $6.181 Acrylic Sheet, 12"x12", 1/8" thick $8.636 $51.78 All-Seal Sealant for Wet and Oily Surfaces, Clear, 10.2 oz $18.271 Standard Pipe Thread Sealant 1-1/4-Ounce Stick $3.463 $10.38 Lung holder – rapid prototype in Watershed XC 11122$3001 Total: $1207.46 Tanks and Containment

42. PartPrice/UnitQuantit y Cost 1515 Profile $13.995 $69.95 Drop-in T-studs $2.145 $10.70 Single Flange Linear Bearing $38.602 $77.20 Hidden Corner Connectors $7.252 $14.50 L-handle Brake $9.552 $19.10 Total: $191.45 Camera Positioning

43. Pump System PartPrice/UnitQuantityCost H75M Gear Pump $2,319.001 Variable Frequency Drive Motor Tubing, 1'' ID $2.455$12.25 Tubing, 1/4'' ID, 3/8'' OD $0.7125$17.75 Tubing, 1.5'' ID $4.2210$42.20 Tube clamps, 1.5'' 10$7.22 Tube clamps, 1'' 10$7.07 Tube clamps, 3/8'' 20$5.67 Tube to pipe, adapter, 1'', 1'' $8.321 Pipe to tube, adapter, 1.5, 1.5 5$8.73 Tube to pipe, adapter, 1/4'', 1/2'' 10$4.97 Pipe to tube, adapter, 1/2, 1'' 10$8.48 Valve, ball, 1.5'' $44.561 Valve, ball, 1/2'' $9.841 Valve, ball, 1'' $22.311 Pipe, 1-1/2'', 4'', Male-Male $3.182$6.36 Reducer, 1'', 1 /2'' $32.461 Coupling, 1 1/2'' $6.372$12.74 Bulkhead, 1'' $6.052$12.10 Cap, rigid plastic, tubing, 1/2'' $0.06100$5.50 Stopper, rubber, 1-1/2'' $0.8712$10.38 Total: $2,597.91

44. Common Header PartPrice/UnitQuantit y Cost Manifold, 10 outlets, 1 inlet23.18$184.80 Fitting, wye, t-t-t, 1/4,1/4,1/44.911$4.91 Plug, tube, 1/40.971$0.97 Tubing, polyurethane, 1/4'', 1/8'', 100'24.71$24.70 Total:$266.62

45. Pressure Control and Measurement PartPrice/UnitQuantit y Cost Minature Voltage Sensor $65.0081 $5,265.00 Needle Valve $15.0081 $1,215.00 Urethane Hose 50 ft $15.0010 $150.00 Hose Connectors $188.006 $1,128.00 Polycarbonate sheet $50.006 $300.00 Data Acquisition Device $3,000.001 Powered Breadboard $90.003 $270.00 T splitter $5.0075 $375.00 Total: $11,703.00

46. Risk Assessment