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P11251: Side Entry Agitator Test Stand
REVISION A: For Reading/Review ONLY
(No Formal Presentation Given)
MSD I: System Level Design Review
https://edge.rit.edu/content/P11251/public/Home
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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)
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Meeting Agenda
• Mission Statement
• Project Description
• Review of Customer Needs/Specs
• Review of Pairwise, Engineering Metrics, HoQ, Pareto
• Concept Sub-System Breakdown
• Initial Concept Generation & Selection
• Physical Structure
• Shaft/Motor/Impeller Integration
• Sealing System
• Measurement System w/ Hardware Integration
• Preliminary Risk Assessment/FMEA
• Project Schedule Review (GANTT)
• Questions/Comments/Concerns
Estimated Time
12:35 - 12:40
12:40 - 12:45
12:45 - 1:50
12:50 - 12:55
12:55 - 1:00
1:00 - 1:40
1:00 - 1:10
1:10 - 1:20
1:20 - 1:30
1:30 - 1:40
1:40 - 1:50
1:50 - 1:55
1:55 - 2:00
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Mission Statement
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.
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Project Description
• Shaft protrudes through the side wall of the tank• very large, under floor tanks where little headroom is available• less costly than top entry mixers• requires less motor torque to agitate the fluid• three to five times the amount of power as a top entry mixer
• Rely heavily on impeller selection• different diameters, physical sizes and blade profiles
• Previously developed top entry test-rig• they currently have no way to benchmark these same impellers for side entry agitation
• Create a test-rig that allows reliable measurement• through a range of adjustability (Impellers/Speeds/etc.)• similar concepts to the top entry test rig• different array of: bending moments, torque and fluid forces
• Very beneficial to our customer• benchmark existing and future impeller designs for side entry applications.
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Customer Requirements
Four Most Important Customer Needs:• Fluid Tight Seal• Calibration Incorporation• Tangential Fluid Forces• Fluid Thrust Force
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Pairwise Comparison
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Pairwise Comparison
Graphical Representation of Pairwise Comparison
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Engineering Metrics
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House of Quality
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Pareto Analysis of Eng. Metrics
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Pareto Analysis of Eng. Metrics
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Concept Sub-System Breakdown
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Physical Structure Sub-System
Stand Adjustability
• Vertical and horizontal adjustment
• Depth into tank
• Angle left and right
• Angle up and down
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Physical Structure: Concept Drawings
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Physical Structure: PUGH Matrix
Height Adjustment
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Physical Structure: PUGH Matrix
Horizontal Adjustment
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Physical Structure: PUGH Matrix
Depth Adjustment
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Physical Structure: PUGH Matrix
Vertical Angle Adjustment
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Physical Structure: PUGH Matrix
Horizontal Angle Adjustment
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Physical Structure: PUGH Matrix
System Design
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Physical Structure: Concept Selection
Key Advantages
• Removes need for tilt plate
• Reduces potential issue with structure height
• No limit to step increments on any axis
• Possibility for fully automated positioning via stepper motors
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Shaft, Motor, & Impeller Integration Sub-System
Explanation of this sub-system & components:Shaft: Transmits torque & angular velocity via the motor & impellerCoupler: Transmits power between the motor output shaft & shaftMotor: Provides Mechanical Energy to the systemImpeller: “Work” horse of the system: agitates the fluid to be mixed
ShaftImpeller Coupling Motor
Tank Wall
Fluid Agitation
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SMI: System Diagram w/ Impellers
•Given Impeller Dia.: 4.5 – 10”
•Off Wall Distance: TYP. 0.5D
<0.4D, Flow Drops Off
>0.5D, Minimal Additional Flow, Adds Cost for Minimal flow benefit
•MATL: 316 S.S.
6”Ø: 2”
10Ø: 3”
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SMI: Shaft Design Selection
Shaft Length, (From Tank Wall) = APROX. 2.25 – 5”
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SMI: Shaft Design Selection PUGH
•Best Choice: Solid, Continuously Long Shaft
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SMI: Shaft Design Prelim. Equations
• Static Cantilever Beam Analysis
• Mod-Goodman Shaft Analysis
• Natural Frequency Ck
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SMI: Shaft to Shaft Coupling
Set Screw DiscGear
• All must have high torsional strength, for accurate fluid force & thrust measurement
• Minimize parallel mis-alignment (RIGID) for accurate fluid force & thrust measurement
• Provide a secure connection between the (2) elements
• Long lasting and minimal maintenance/overhaul required
Manuf: LoveJoy Req’s:
1) Required Max Torque
2) Motor Speed/HP Req.
3) Shaft/Motor Shaft Dia.
Thru-Bolt
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SMI: Shaft Coupling PUGH
•Best Choice: Thru Bolt or Set Screw
• Thru Bolt for Added Rigidity & Resistance to Torsion
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SMI: Impeller/Shaft Connection
Based on given ID of provided impellers, (3) conditions could exist:
1) Shaft Dia. < Impeller Dia.
- need for a spacing collar
2) Shaft Dia. > Impeller Dia.
- need for a reducer
3) Impeller has threaded spacer that screws onto end of shaft (Similar to 2)
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SMI: Impeller/Shaft Connection PUGH
•Best Choice: Spacing Collar
• Method currently being used by industry
• OR
• Direct connect to shaft, if Shaft OD=Impeller ID
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SMI: Motor Selection
• DC or AC Motor
• Variable Drive (per Measurement & Integration)
• Highly dependent on “Physical Stand”
• Package Size/Weight/Mounting Options
• Capable of reaching 1100 RPM under load, with greatest thrust/torque producing impeller
• Spec’d based upon required shaft size
• Consider Side-Loading Effect on Motor Bearings/Life
•NEMA Rating for environment/safety
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Sealing System: Initial Concepts
Concept 1
Concept 4,5,6,7
Concept 3Concept 2
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Sealing System: Initial Concepts
Concept 10
Concept 11
Concept 8 Concept 9
Concept 12
Concept 13
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Sealing System: PUGH
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Sealing System: Final Concept
Critical Benefits:•Allows Adjustability
•Less parasitic to measured forces
•Does not alter tank geometry
•Very low leak rate
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Axial and Tangential Fluid Force Measurement Concept Generation
Measurement Technology:Strain Gauge; Donut, Pancake, Canister, or Column Load Cell; or Accelerometer.
Location of Measurement Devices:On the motor mount, beneath the coupler, or on the end of the shaft.
Motor Mount Design:Parallel Plates, Lever Arms, Shear Support Pins, Load Cell Cocoon, or Parallel Plates with Pointed Pivot.
Pictures from www.lcmsystems.com.
T=(L1/L2)F Pins resist shear effects.
Picture from www.circuitstoday.com
Picture from www.einstein.standford.edu
Motor
Inner and outer support boxes.
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Axial and Tangential Fluid Force Measurement Concept Evaluation
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Axial and Tangential Fluid Force Measurement Concept Selection
Three Most Critical Criteria:• Resists Affects of Shear• Measuring Sensitivity• Appropriate Time for Setup
Low Profile, Tension & Compression Load Cell Mounted to Parallel Plates with Shear Pins optional depending on supporting calculations.
Side View Isometric ViewPicture From www.lcmsystems.com
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Slip Ring:• Electrical connection through a rotating assembly• Low speed limitations• Ring wear and dust brushes impede signal transfer• Requires routine maintenance for cleaning
Torque and RPM Measurement Subsystem
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Rotary Transformer:• Tolerates high speeds• Non-contact• More accurate• Requires sophisticated signal condition instrumentation• Less tolerant to extraneous loading conditions (bending moments and thrust forces)
Torque and RPM Measurement Subsystem
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Digital Telemetry:• Software driven allowing changes on the fly• High resolution, sensitivity, and accuracy• More immune to vibration problems• Smaller, lighter, and more compact
Torque and RPM Measurement Subsystem
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Torque Transducer:• Utilizes a system of strain gauges (Wheatstone Bridge)• Uses slip rings or rotary transformers to power and transfer strain gauge data
Torque and RPM Measurement Subsystem
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Torque from Motor Constants:• Ideal for direct drive systems• Only requires measurement of motor current
Torque and RPM Measurement Subsystem
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Torque and RPM Measurement Subsystem
Critical Criteria• Measurement accuracy and sensitivity
• Ease of implementation
• Small package size
• Allow for multiple shaft diameters
• Ease of maintenance
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Final Integrated Concept Generation
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Final Integrated Concept Selection
•Physical Stand
•Tangential & Axial Force Measurement
•Shaft, Motor & Impeller Integration
•Torque & RPM Measurement
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Final Integrated Concept Selection
•Physical Stand
•Sealing System
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Preliminary Risk Assessment/FMEA
https://edge.rit.edu/content/P11251/public/Design%20Documentation
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Preliminary Risk Assessment/FMEA
Key Risk Items
• Full range of adjustability
• Seal Effects measurement instrumentation & readings
• Sensitivity of Measurement Systems
• Successful Integration of Sub-Systems
• Orientation affects measurements
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Project Plan Review
https://edge.rit.edu/content/P11251/public/Team%20Project%20Plan
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Questions/Comments/Concerns