1. System Design Review Project Team 13453
Brandon Niescier
Erin Sullivan
Mike Gorevski
Sean Deshaies
Sean

2. Agenda Team and Project Introduction (5 min)
Customer Needs and Specifications (5 min)
Concept Generation (5 min)
Concept Selection (10 min)
Risk Assessment (5 min)
Project Plan (5 min)
Q&A
Sean
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3. Team and Project Members
Project Manager: Sean Deshaies (ME)
Project Engineers: Brandon Niescier (ME)
Erin Sullivan (EE)
Mike Gorevski (EE)
CUSTOMER:
Dr. Jason Kolodziej, ME Department, RIT
Sean
SUPPORT:
Project Guide: Bill Nowak (Xerox)
Faculty Champion: Dr. Jason Kolodziej (RIT)
Sponsors: Scott Delmotte (D-R)

4. Project Description and Objective
The purpose of this project is to monitor the health of the main crank bearing on RIT’s Dresser-Rand ESH-1 compressor. This will be done through recording vibration measurements via wireless sensor technology.
Brandon

5. Previous Work
Team installed a range of sensors on the compressor and expanded the capabilities of the data acquisition (DAQ) system

6. Customer Needs Customer Need # Importance Description CN1 9
Single axis accelerometer mounted to crankshaft (Rotates)
CN2
2 Single axis accelerometers mounted inside housing (Stationary)
CN4
Continuous sensor operation
CN7
Robust design of wireless technology for harsh environment
CN8
Reliability and accuracy of measurements
CN9
Interface with DAQ
CN12
Must fit inside of compressor
CN13
Must fit on shaft
CN3 3
Minimal user intervention
CN6
Wireless transmission of signal
CN11
User manual/Important information
CN5 1
Low cost
CN10
Scalable to higher temperature (Internal environment)
Erin

7. Customer Specifications
Engr. Spec. #
Importance
Source
Specification (description)
Unit of Measure
Marginal Value
Ideal Value
Comments/Status
ES1 9
CN1/CN2
Acceleration Range (g) g 50
ES2
Acceleration Accuracy (ft/sec^2)
ft/sec^2
ES4
CN6
Range of Wireless Transmission Distance (ft) ft
ES8
CN7
Operational Maximum Temperature (degrees F) F
200
ES10
CN12
Size of Sensor and Wireless Technology (in) in
ES3 3
Data Transfer Rates (Hz) Hz
10-15k
ES5
Range of Wireless Transmission Frequency (Hz)
ES6
CN3
User Intervention Rate (Interventions/time)
inv/t
ES7
Maintenance Intervention Rate (Interventions/time)
ES9
Implied
Power Consumption of System (W) W
ES11
CN3/CN4
Lifespan of Technology (hours)
hours
ES12 1
CN5
Total Cost ($) $
5000
Sensor Cost $500-$1500
Erin

8. House of Quality Mike Remember similar data is on the following slide
Importance Rating
Size of Sensor and Wireless Technology (in)
Acceleration Accuracy (ft/sec^2)
Operational Maximum Temperature (degrees F)
Total Cost ($)
Power Consumption of System (W)
Range of Wireless Transmission Frequency (Hz)
Acceleration Range (g)
Range of Wireless Transmission Distance (ft)
Lifespan of Technology (hours)
User Intervention Rate (Interventions/time)
Data Transfer Rates (Hz)
Maintenance Intervention Rate (Interventions/time)
2 Single axis accelerometers mounted inside housing (Stationary) 9 3 1
Continuous sensor operation
Interface with DAQ
Must fit inside of compressor
Must fit on shaft
Reliability and accuracy of measurements
Robust design of wireless technology for harsh environment
Single axis accelerometer mounted to crank shaft (Rotates)
Minimal user intervention
User manual/Important information
Wireless transmission of analog signal
Low cost
Scalable to higher temperature and pressure (Internal environment)
Raw score
367
288
285
280
247
246
198
156
142
120
111
102
Relative %
14%
11%
10% 8% 6% 5% 4%
Importance Rank 5 4 2
Combined Percentages
26%
37%
48%
58%
67%
75%
81%
87%
92%
96%
100%
0 or Blank = No Relationship
9 = High Importance
Mike
Remember similar data is on the following slide

9. Pareto Chart
Mike
Mention once 50% with reqs, 70% done with project

10. Functional Decomposition
Monitor Bearing Health
Measure Vibration
Sense Vibration
Use Accelerometer
Mount Device
Mount on Shaft
Mount on Housing
Transmit Signal from Stationary Source
Transmit Signal from Rotational Source
Recieve Signal
Condition Signal
Log Data
Use Lab View
Output Spead Sheet
Measure Temperature
Observe Noise
Observe Wear
Functional Decomposition
Brandon - nice

11. Concept Development Brandon – Proper terminology
Mount the Sensor Inside Housing
Drill and Tap Hole
Glue It
Affix with Wax
Weld It
Mount the Sensor on the Shaft
Transmit Signal from Stationary Source
Use Induction
Use Bluetooth
Use Wifi
Use Proprietary RF
Network
Use Dissimilar Data Channel
Use Zigbee
Transmit Signal From Rotational Source
Use Slip Ring Around Shaft
Recieve Signal
Condition Signal
Attenuate Noise
Design Filter
Amplify Signal
Design Amplifier
Output Data
Output to Notepad
Output to Excel
Brandon – Proper terminology

12. Pugh Chart for Mounting Sensor Inside Housing
Criteria
Concepts
Drill and Tap Hole
Glue It
Affix With Wax
Weld It D A T U M
Secure Fit - +
Resist Maximum Operating Temperature
Oil Resistant S
Vibration Resistant
Ease of Removal
Clarity of Vibration Measurement
Ease of Installation
Life Expectancy
Ease of Maintenance 1 3 7 6
Total +
Total -
Total S
Drill and Tap is chosen method
Glue and Wax clearly eliminated
Weld eliminated due to difficultly with maintenance
Sean

13. Placement of Sensor Inside Housing
Sean

14. Pugh Chart for Mounting Sensor on Shaft
Criteria
Concepts
Drill and Tap Hole
Glue It
Affix With Wax
Weld It
Secure Fit (Relative to Rotational Force) - +
Oil Resistant S
Vibration Resistant
Clarity of Vibration Measurment
Ease of Removal
Ease of Installation
Life Expectancy
Ease of Maintenance 1 3 2 6 5
Total +
Total -
Total S
Drill and Tap is the chosen method
Glue and Wax are clearly inferior options
Welding is roughly on par
However, welding is not practical
Brandon *cut temperature criteria

15. Rotational Mounting Location
Brandon

16. Pugh Chart for Transmitting Signal From a Stationary Source
Criteria
Concepts
Use Proprietary RF Network
Use Induction
Use Bluetooth
Use WiFi
Use Dissimilar Data Channel
Use Zigbee
Loss of Signal Through Housing S - + 1 2 3 5 4 8
Power Consumption
Complexity of Implementation
Total +
Potential for Interferance in Environment
Cost of Implementation
Continuity of Signal
Ease of Maintance
Life Expectancy
Total -
Total S
Proprietary RF Network was chosen method
The customer has requested a wired sensor to be implemented as well to verify data
Based on the simplicity of our sensor network
Mike
Make sure you can explain why prop RF over zigbee. Expert advice is ace-in-hole.

17. Pugh Chart for Transmitting a Signal From a Rotational Source
Criteria
Concepts
Use Proprietary RF Network
Use Induction
Use Bluetooth
Use WiFi
Use Slip Ring Method
Use Zigbee
Power Required - S + 2 5 4 1 7
Simplicity of Technology
Potential for Interferance in Environment
Cost of Implementation
Total S
Continuity of Signal
Ease of Maintance
Life Expectancy
Total +
Total -
Proprietary RF Network was chosen method
Based on the simplicity of our sensor network
Erin

18. System Block Diagram Option 1: Commercial Off The Shelf
Option 2: Develop In-House with PCB Mounted Accelerometer
Option 3: Develop In-House with Commercial Accelerometer
Option 3 was chosen due to expert reccommedation
Integrated Accelerometer
Transmitter
Accelerometer
Microcontroller/ Transmitter
Mike
Integrated Accelerometer
Microcontroller/ Transmitter

19. Risk Assessment Erin Risk # Risk Item Effect Cause Likelihood Severity
Importance
Action to Mitigate
Owner R1
Damage of Sensor
Sensor transmits Inaccurate or No Data and Requires Increased User Interference
Environment - Oil and Temperature 7 9 63
Properly Spec Components
Sean R2
Noise in the Wireless Signal
Poor Data Quality
Surrounding Environment 5 45
Use Filters
Mike R3
Trip Hazard for Wires
Fall Injuries and Damage to the System
Cables and wires in walk ways 35
Route wires away from walkways
Brandon R4
Wireless Signal Cannot Penetrate Housing
Data Not Received
1 in Cast Iron Housing with Wireless Technology 3 27
Research and Test Wireless Ability
Erin R5
Insufficient Battery Life
Increased User Intervention
Power Consumption Too High 25
Calculate and Minimize Power Composition and Consider Battery Choice R6
Compressor is Not Operational
Cannot Validate Solutions
Other Parties Use the Compressor 15
Create Test Rig
Erin

20. Risk Assessment (cont.)
Risk Item
Effect
Cause
Likelihood
Severity
Importance
Action to Mitigate
Owner R7
Accelerometer Falls Off- Inside Housing
Damage to Accelerometer and to the Compressor
Improperly Mounted 1 9
Ensure Proper Installation Method
Brandon R8
Damage to Compressor During Install
Broken Compressor and Project Failure
Improper Installation
Thoroughly Plan Installation with Input From D-R R9
Sensors Break On Installation
Need to Buy New Sensors 7
Read the Product Manual
Sean
R10
Injury While Machining Parts
Team Member Hurt
Disregard to Safety Precautions
Proper Training in Use of Machine Operation
Mech Es
R11
Accelerometer Fails to Satisfy Needs
Data is Not Measured Correctly
Uncertainty in Operating Conditions 5
Communicate with Manufacturers
Erin
R12
Accelerometer Falls Off- Outside Housing
Damage to Accelerometer
R13
Shaft is Unbalanced
Induced Vibrations in System
Weight of Technology Mounted on Shaft
Do Calculations and if Necessary Apply Counter Weights to Balance Shaft
R14
Wireless Signal Affected By Shaft Rotation
Data is Not Transmitted Correctly
Doppler Effect
Consult Experts in Wireless Transmission
Erin

21. Test Rig
In order to validate the wireless signal transmission on the rotating shaft, a model test facility will be constructed
1:1 scale for shaft diameter and rotational speed
Bearing configuration will not be identical to actual compressor for the sake of simplicity
Brandon

22. Test Rig Model
Power Supply
Coupling
Brandon
Encoder
Motor

23. Gantt Chart Through MSD I
Week 1
Week 2
Week 3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10
Task Name S M T W F
Define Project
Develop Code of Ethics
Define Customer Needs
Define Specifications
House of Quality
Functional Decomposition
Concept Development
Select Team Roles
Gather Info From Experts
Pugh Charts
Risk Assessment
Create 1 Page Summary
Develop System Layout
Model Test Rig
Create Presentation for System Design Review
Revise Concepts Based on Feedback
Design Test Rig
Complete Vibration Analysis
Calculate Force Required to Keep Sensor Mounted on Shaft
Develop Concepts for Detailed Design
Select Detailed Design Concepts
Create a Bill of Materials
Choose Mounting Locations
Create Schematic Drawings
Create Presentation for Detailed Design Review
Change Design Based on Feedback
Order Parts
Prepare for MSD II
Create Schedule for MSD II
Sean
Feel free to add talking points for me

24. Questions
Sean, everyone