1. Sustainable Technology For The Global Market Family of Projects James Brown Rishitha Dias Casey Dill Neranjan Dharmadasa Kevin Klucher Eric MacCormack Colin Roy

2. Underwater use Advanced tool use Advanced controls system Use with robotic platform Hydraulic 5 fingered hand with wrist motion Pneumatic 3 and 5 fingered hand Develop high speed camera system Integrate modules on D-R compressor Design new platform for open source Interchangeable propulsion/ lighting modules Scale and install on compressor Simulate sea bed conditions Meet load requirements Develop modules to fit D-R compressor Scale up & develop lab test stand Begin testing Diagnostics Wireless monitoring of DAQ Make improvements on current test stand Energy recovery from D-R VECTRA gas turbine Preparation for new compressor arrival Reciprocation compressor revamp and interface Scale up to D-R expectations Integrate robotic arm and optimize design Improve existing platform and interface Process Improvement Project Value engineering in manufacturing facility AY 2009-10AY 2010-11AY 2011-12AY 2008-09AY 2007-08 Turbomachinery flow visualization [table top] Robotic Arm Robotic Platform Turbo machinery Flow Visualization Thermoelectric Waste Heat Recovery Remote Health Monitoring System Process Improvement Preliminary Schedule

3. 2008-2 through 2008-3 Neranjan Dharmadasa James Brown P09451: Thermo-Electric Module for Large Scale Systems

4. Introduction Thermoelectrics are very simple solid state devices with two basic modes of operation. The Peltier Effect, involves the application of current through the module, absorbing heat from one side of the device and emitting from the other side. Conversely, the Seebeck Effect can be used for power generation purposes. When a temperature gradient is applied across a TE module an electric current is produced.

5. Previous Projects P07442 P08451

6. Mission Statement The focus of this project will be to make improvements to last year's power module unit design, perform more extensive testing and address some issues that surfaces from the preliminary testing done last year. This year‘s team will develop a second generation prototype power module that would more closely simulate a power unit that might be deployed on the exhaust stream of a Dresser-Rand Vectra or other turbine. This unit may include the use of air cooling to simulate a power unit serving both as a power generator as well as a recuperator. The team will make improvements in temperature sensor locations to better monitor heat spreading and understand multidimensional conduction which is currently not accounted for in the modeling. The team will also design and implement strategies for max power tracking and the handling of module array mismatch due to differing temperature gradients.

7. Customer Needs Test Stand Issues GUI and data processing Temperature measurements Swapping T.E. modules Max point tracking (power) Pressure losses Lack of sensors for multidimensional heat transfer Test Stand Improvements More fin options Design for power requirements Design for specific operating conditions Design for recuperative heating system Additional “zones”

8. Staffing Requirements Team MemberResponsibilities Team Leader Neranjan Dharmadasa Coordinate efforts to complete project, logistics, running meetings, purchasing, resource management and assistance to other team members as required. Chief Engineer James Brown Lead the engineering effort and ensure the final project goals are met by facilitating communication among team as well as carry out mechanical design. ME-Heat Transfer This student will focus on thermal resistance modeling and heat spreader design for the TE module. ME-Thermal Modeler This student is responsible for understanding theory behind TE modules and the thermal modeling of their resistances. EE-Electrical System Designer This student will assist in characterization of voltage current relationships for TE modules and test systems.

9. Work Breakdown Structure Team MemberWeek 1Week 2Week 3 Neranjan Dharmadasa Team Leader Set up meeting times, assign tasks, establish team values and norms Ensure access to necessary resources, create specifications, conduct idea generation exercises Continue project management exercises for concept selection, arrive at final project plan James Brown Chief Engineer Familiarize team with current test stand and issues, lay out engineering objectives Prioritize objectives, introduce team to stakeholders, concept generation Assist Team Leader with final project plan and team with concept selection ME- Heat Transfer Thoroughly examine EDGE and become familiarized with the past project Study existing test stand and work closely with Graduate Assistant, concept generation Update team with concept discussion and make selection ME- Thermal Modeler Thoroughly examine EDGE and become familiarized with the past project Study existing test stand and work closely with Graduate Assistant, concept generation Update team with concept discussion and make selection EE- Electrical Systems Designer Thoroughly examine EDGE and become familiarized with the past project Gain understanding of project issues and begin concept generation Update team with concept discussion and make selection

10. Team Values and Norms Punctuality Organized Devoted/Committed Professional and Ethical Thorough Accurate Meet Guidelines Meet Deliverables on Time

11. Required Resources Current lab test stand Machine shop Time with Graduate Assistance Time with Faculty Guide, Dr. Stevens Time with Dresser-Rand contacts

12. Staffing requirements will be met throughout course of project Estimated budget will be provided Existing test stand can be used and improved for this year’s project Assumptions

13. Budget: $ 7500 Technical Expertise: Familiarizing students with TE modules and the current system Time: All deliverables must be performed within the allotted 22 week timeframe Resources: Time required on machine shop towards building phase of project. Obtaining TE modules that operate under higher temperatures Platform: The project must build upon the existing module and test stand Safety Constraints

14. Intellectual Property Project will be open source, open architecture. Any information on Dresser-Rand products will be kept confidential Currently established patents will be researched and taken into consideration with progress of project.

15. Issues and Risks Availability of off the shelf TE modules Delivery of parts on time Parts exceeding budget Data inaccessibility or loss

16. Outstanding Items Deliverables over the course of the project are to be determined Target specifications are yet to be established

17. 2008-2 through 2008-3 P09454: Design and Testing of Centrifugal Pump Components

18. Project Status Update Project Name Design and Testing of Centrifugal Pump Components Project Number P09454 Project Family Sustainable Technology for the Global Market Track Turbomachinery Flow Visualization Start Term 2008-2 End Term 2008-3 Faculty Guide Dr. Stephen Day Primary Customer Dresser-Rand

19. Introduction Particle Imaging Velocimetry (PIV) uses a sheet laser beam to illuminate particles that cross the sheet. The particles will diffract the light of the laser and thereby allow for imaging. Based on the data gathered from imaging these particles, the flow through the system can be visualized.

20. Starting Point The existing test system was developed for MSD in 2007 -2 & 2007-3 quarters under P08453 The system consisted of a centrifugal pump that sits within an automated and instrumented flow loop. The apparatus and pump housing will be fabricated from optically clear materials to allow flow visualization within the pump using Particle Imaging Velocimetry The system was designed and built with a modular construction so that design variations of impellers, diffusers, and housings may be easily exchanged.

21. Planning

22. Customer Needs Perform PIV experiments to characterize different flows through the pump system Use as an teaching tool for undergraduate coursework, projects & labs Use for Graduate research & projects

23. Deliverables Design & manufacture interchangeable Impellers & Diffusers (3 items each) Set up & perform PIV measurement on pump system using new Impellers & Diffusers

24. Mission Statement The purpose of this project is to design & develop interchangeable impellers and diffusers which will work on the existing PIV system in order to characterize different flows through the pump system. Team will deliver 3 impellers & 3 diffusers for the existing system. Furthermore, team will also be responsible for setting up experiments and performing PIV reading using the new impellers & diffusers

25. Constraints Budget: $7,500 Technical Expertise: Not all KGCOE ME students possess the requisite knowledge in Turbomachinery Time: All deliverables must be performed within the allotted 22 week timeframe Resources: Impeller and diffuser manufacturing requires precision machining operation Platform: The project must build upon the existing PIV system (P08453)

26. Assumptions All roles planned this quarter will be filled during both quarters Existing test stand can be used and improved for this year’s project Existing test stand is in acceptable condition Outsourcing the manufacture of Impellers and Diffusers will not adversely effect the timeliness of the deliverables

27. Work Breakdown Structure Team MemberResponsibilities Team Leader Rishitha Dias Coordinate efforts to complete project, logistics, running meetings, purchasing, and resource acquisition Chief Engineer Kevin Klucher Lead the engineering effort and ensure the final project goals are met, interchangeability, flow testing, reduced setup time, and complete test stand ME-Design Engineer All modeling of structures in relevant programs, and fluid mechanics computation and simulations ME-Turbomachinery Expert Improvement of the fluid mechanics and flow through the turbomachinery portion of the test stand for better testing ME- Systems Integration LabVIEW integration with sensors installed within the PIV system, integration of the flow loop with the PIV unit

28. Team MemberWeek 1Week 2Week 3 Rishitha Dias Team Leader Set up meeting times, inform everyone of their tasks Establish team values and norms Ensure team members have access to necessary resources to begin allocated tasks Oversee the information exchange between all relevant members Kevin Klucher Chief Engineer Begin examination of lab test stand and lay out engineering objectives Develop study plan for engineers to learn the necessary skills set required for the project Work with Design Engineer in finalizing the impeller to outsource ME- Design Engineer Thoroughly examine EDGE and become familiarized with the project & predecessors Reverse engineer existing and familiarize with the system Examine the existing system and identify components that are critical to the project ME- Turbomachinery Expert Thoroughly examine EDGE and become familiarized with the project & predecessors Review/study turbomachinery technical material related to project ME- Systems Integration Thoroughly examine EDGE and become familiarized with the project & predecessors Develop study plan for engineers to learn the necessary skills set required for the project Examine previous LabVIEW setup & Code

29. Intellectual Property Considerations Project will be open source, open architecture Thorough patent research must be carried out prior to starting design phase

30. Team Values & Norms Punctual Thorough Accurate Professional & Ethical Committed Good Communication – Team members should make a conscious effort to keep all members in the team informed with new information, knowledge and project developments, especially the two leaders

31. Required Resources Technical learning materials such as Turbomachinery text books, research papers Access to existing (P08453) PIV pump system Time with Faculty Guide, Dr. Day Access to manufacturing resources: CNC machining, Rapid prototyping or outsourcing CAD & Engineering software packages EDGE

32. Concept Development

33. Customer Needs Customers require a upgraded PIV system to perform reading on more sophisticated flow patterns provided by new impellers & diffusers. The new impellers and diffusers must be interchangeable and must fit with the existing pump system.

34. Brainstorming Questions How can the team best familiarize themselves with turbomachinery concepts? What material can be used to make the impellers & diffusers? Which manufacturing method will be used to make the products?

35. Target Specifications Impellers & Diffusers must be interchangeable New parts should work interface with existing PIV system

36. Risk Assessment Technical expertise of ME student might be inadequate for the design task at hand Time needed for impeller manufacturing will affect the timeliness of deliverables Existing PIV module may not function as desired

37. Risk Assessment Flow parameters are not met by the design Design stage leaks over allocated time due to complications Manufacturing resources at RIT might be inadequate to produce the required parts Budget might be insufficient to cover outsourcing of manufacturing

38. Risk Management Team Lead, Lead Engineer will work with faculty advisor to develop a plan to learn the technical skills required to design turbomachinery Team lead will look for alternative manufacturing methods to save time, cost ex: rapid prototyping, outsourcing

39. Risk Management Lead engineer designs a study plan with the assistance of faculty advisor & consultants to learn the required skills Project lead allocates excess time for manufacturing parts & reallocate labor & resources to expedite other processes.

40. Risk Management Team Lead & Lead Engineer assigns a plan and adequate labor to ensure that the existing PIV system will meet required levels of operation Team Lead & Lead Engineer will reevaluate and prioritize design goals to ensure timeliness of deliverables

41. Risk Management Lead engineer will reevaluate design to ensure that products can be manufactured using resources at RIT (while meeting specifications) OR Project Lead and Lead Engineer will work towards outsourcing the manufacturing to outside vendors

42. Risk Management Project Lead will work with Faculty Advisor to reevaluate the budget OR Reevaluate the scope of the deliverable to meet the existing budget

43. Eric MacCormack (IE) Colin Roy (IE) Project Status Update P09457 – Process Improvement Project

44. Project Status Update Project Name Process Improvement Project Project Number P09457 Project Family Sustainable Technology for the Global Market Track Process Improvement Innovations Start Term 2008-2 planned academic quarter for MSD1 End Term 2008-3 planned academic quarter for MSD2 Faculty Guide Professor John Kaemmerlen Faculty Consultant Dr. Kuhl, choice for simulation Faculty Consultant Dr. Carrano, choice for manufacturing processes Primary Customer Dresser-Rand with the point of contact being Dennis Rice at the Olean facility

45. Mission Statement The mission of the Process Improvement Project is to implement lean principles into the piping and packaging line at Dresser-Rand Corporation’s Olean facility. Goal: reduce cycle time by 30%. Approach: improve the flow of products, warehousing of parts, visual controls, and reduce the waste within the line.

46. Current Layout Piping Assembly & Packaging Assembly Test Parts

47. Customer Needs Reduce Cycle Time Improve Flow of Product Visual Controls System Standardize Work Processes Accurate Drawings Free Up Floor Space Maintain High Level of Safety

48. Staffing Requirements NameDisciplineRoles/Skills Professor John KaemmerlenFaculty Guide Will work closely with the team on an on-going basis to facilitate success. Colin RoyI.E.Project Manager, Point of contact for Dresser-Rand. Construct and submit deliverables. Lead in Simulation and Factory CAD software. Eric MacCormackI.E.Chief Engineer, Focus direction of work. Assist in any necessary tasks. Lead in lean. I.E. Student (TBD)I.E.Engineer, Strong background in the fields simulation, lean and ergonomics. I.E. Student (TBD)I.E.Engineer, Strong background in the fields simulation, lean and ergonomics. M.E. Student (TBD)M.E.Engineer, Skills for work with parts family assessment and part number consolidation. Custom tooling. Set-up reduction opportunities.

49. Work Breakdown Structure Improve Flow/Cycle Time Establish Baseline Identify Current Metrics Create Current State Value Stream Map Find Solutions Evaluate Alternative Line Design Accurate Drawings Lean Techniques Create KANBAN System Create Future State Value Stream Map Reduce Set- up Time Eliminate Bottlenecks 6SKAIZEN Evaluate New Equipment Visual Controls Analyze/Verif y Solution Cost-Benefit Analysis Modeling or Simulation P – D – C – A

50. Work Breakdown Structure MemberWeek 1Week 2Week 3 Colin Tour the Facility. Bring all group members up to speed with Customer Needs Direct each team member/obtain data on current state Monitor and facilitate each team member in their active roles Eric Tour the Facility. Bring all group members up to speed with Customer Needs Acquire all current data D-R has on the current process. Reiterate current state value stream map IE Tour the Facility. Bring all group members up to speed with Customer Needs Begin Factory CAD analysis on current D-R CAD layout. Continue on Factory CAD analysis on current D-R CAD layout IE Tour the Facility. Bring all group members up to speed with Customer Needs Begin preliminary current state simulation model. Continue on current state simulation model. ME Tour the Facility. Bring all group members up to speed with Customer Needs Become familiar with the various parts that are used in the assembly process Evaluate ways part drawings can become more accurate to the products

51. Risks and Constraints Risks Quality – Tradeoff of quality vs. speed Worker resistance to change Disruption to other processes Increased cost to production Constraints Factory distance (Olean plant 2 hour drive) 22 week improvement period Cameras not allowed in facility D-R staff availability

52. Resources Required Personnel Professor Kaemmerlen Dr Kuhl Dennis Rice Dan Krenn Environment Senior Design Lab ISE/ME Computer Labs Olean Facility Equipment Arena Software Factory CAD Software

53. Deliverables Current State Value Stream Map Future State Value Stream Map Detailed Current State Layout Future State Layout Factory CAD Drawings and Analysis Simulation Models and Analysis Cost-Benefit Analysis Visual Control System

54. Team Values Punctual Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one teammate prior to the expected absence. An absent team-member should confirm that a teammate has received their message. Thorough Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow. Timely Each team member will fully complete their tasks at or before the due date for the deliverable. Professional and Ethical Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers. Committed Each team member will contribute an equal share to the success of the project Teamwork Each team member will be supportive of one another. All must realize we are working to achieve a common goal. If any conflicts are to arise during problem solving or execution they shall be resolved professionally and timely. If necessary, mediation will be provided by group leads.

55. Artificial Limb Project By Casey Dill

56. Mission Statement This project will improve upon existing plans for an artificial arm with the same capabilities of a human arm. Extensive work will be done to study the motions of the human hand, the forces acting on the parts and the effects of scaling up and down; all on various designs that reproduce human motion acurately.

57. Staffing Requirements ME Lead – To lead the team and make sure all the goal of the project are met and on time. ME1 – To work on computer models and to do mechanics analyses. ME2 – To work on computer models and to do mechanics analyses. EE1/CE1 – To program a controls systems. EE2/CE2 – To work on a software interface package or to create a human interface.

58. Intellectual Property Considerations  There are many patents for robotic designs that are still in effect. There are 5 for robotic arms that perform maintenance and 12 that have to do with medical procedures. None of these arms mimic the movement of the human anatomically, probably due to the fact that no one can patent human motion. Source: http://patft.uspto.gov/

59. Preliminary Work Breakdown Structure PersonWeek 1Week 2Week 3Week 4 ME Lead Familiarize with past projects’ accomplishments and challenges. Meet with faculty guide to talk about goals and concepts. Brainstorm concepts for development. Become a team. Initial design concepts for the wrist and forearm. Continue designs for accurate motion. Work on CAD models. Feasibility of budget analysis for prototype ME 1 Scaling up analysis ME 2 Scaling down analysis EE/CE 1 Design for position controls Design for human interface. Scaling up analysis EE/CE 2 Scaling down analysis

60. Team Values and Resources Team Values and Norms Professional and Ethical, Committed, Demonstrates the core RIT spirit, Thorough, Accurate and Punctual Required Resources Access to The RIT Library’s resources for research Access to CAD programs, control programs, etc. Meeting space

61. Customer Needs Customers: Dr. Lamkin-Kennard – Faculty guide Past Senior Design Team Medical Industry Dresser Rand in the future, if enough is proven possible Needs: The project needs to add to the value of the roadmap Proof of concept CAD model with the mechanics worked out, of the whole arm  Should demonstrate tool usage and natural range of motion  Structural analysis for scaling up and down An interface system with a computer model and a real robotic arm  Simple and well documented (if funding is found) a prototype arm demonstrating wrist motions The project should be interesting for senior design students

62. Target Specifications By the end of the first quarter CAD models of several different designs for a robotic human arm are to be developed. They should be accurate with respect to human motion, and include designs from past groups and include wrist, forearm and elbow motion. Designs to improve motion sensing should also be completed. By the end of the second quarter, if no funding for a prototype is found, a complete analysis for scaling, up and down should be completed. If funding is found, then a prototype demonstrating the wrist design concepts will be developed. Overall improvement to the controls system should be made.

63. Issues & Risks Risk Management Table Description of RiskPossible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L)Contingency Plan Money is not found for prototyping Not able to build prototype HLL Alternate path a for more rigorous engineering analysis is followed. Because most of this work will be done on the computer, there is always the potential of data loss Lost time and workMMM Daily back up on EDGE server EDGE server has down time Not able to retrieve work off of EDGE LHM Keep work in progress backed up on local machine The school computer could crash with too detailed CAD work with too many parts Model not renderableHLL Work with parts of a model at a time. Not enough programming knowledge to support efforts Too much work would be placed on those who do know programming MHM See help from another faculty guide able to help with the programming & teach it.

64. Concept Development Option 1Option 2Option 3Option 4 Knuckle 1 DOF Pin jointFlexible material Ball and socket Floating Knuckle 2 DOF Ball and socket Two pin jointsGyroscopeFlexible connector WristTwo pin jointBall and socket Two ball and socket joints Flexible connector “Bone” material SteelAluminumHard plasticsTitanium Position Sensing 3D position sensing Joint angle monitoring Tendon length monitoring Control system calculations ForearmTwo “bones” that wrist Load-bearing bearing Rotate at elbow

65. Concept Development

66. Questions?