sustainable technology for the global market family of projects james brown rishitha dias casey dill...
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Sustainable Technology For The Global Market Family of Projects
James BrownRishitha Dias
Casey DillNeranjan Dharmadasa
Kevin KlucherEric MacCormack
Colin Roy
• 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
•Valueengineering inmanufacturing facility
AY 2009-10
AY 2010-11
AY 2011-12
AY 2008-09
AY 2007-08
• Turbomachinery flow visualization[table top]
Robotic Arm
Robotic Platform
Turbo machinery
Flow Visualization
Thermoelectric Waste
Heat Recovery
Remote Health
Monitoring System
Process Improvemen
t
Preliminary Schedule
2008-2 through 2008-3
Neranjan DharmadasaJames Brown
P09451: Thermo-Electric Module for Large Scale
Systems
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.
Previous Projects
P07442
P08451
Mission StatementThe 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.
Customer NeedsTest Stand IssuesGUI and data processingTemperature
measurementsSwapping T.E. modulesMax point tracking
(power)Pressure lossesLack of sensors for
multidimensional heat transfer
Test Stand Improvements
More fin optionsDesign for power
requirementsDesign for specific
operating conditionsDesign for
recuperative heating system
Additional “zones”
Staffing RequirementsTeam Member Responsibilities
Team LeaderNeranjan Dharmadasa
Coordinate efforts to complete project, logistics, running meetings, purchasing, resource management and assistance to other team members as required.
Chief EngineerJames 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.
Work Breakdown StructureTeam Member Week 1 Week 2 Week 3
Neranjan DharmadasaTeam 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 BrownChief 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 ModelerThoroughly 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
Team Values and NormsPunctualityOrganizedDevoted/CommittedProfessional and EthicalThorough AccurateMeet GuidelinesMeet Deliverables on Time
Required ResourcesCurrent lab test standMachine shopTime with Graduate AssistanceTime with Faculty Guide, Dr. StevensTime with Dresser-Rand contacts
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
Budget: $ 7500Technical Expertise: Familiarizing students
with TE modules and the current systemTime: All deliverables must be performed within
the allotted 22 week timeframeResources: 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
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.
Issues and RisksAvailability of off the shelf TE modules
Delivery of parts on time
Parts exceeding budget
Data inaccessibility or loss
Outstanding ItemsDeliverables over the course of the project
are to be determinedTarget specifications are yet to be
established
2008-2 through 2008-3
P09454: Design and Testing of Centrifugal Pump Components
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
IntroductionParticle 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.
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.
Planning
Customer NeedsPerform PIV experiments to characterize
different flows through the pump systemUse as an teaching tool for undergraduate
coursework, projects & labsUse for Graduate research & projects
DeliverablesDesign & manufacture interchangeable
Impellers & Diffusers (3 items each)
Set up & perform PIV measurement on pump system using new Impellers & Diffusers
Mission StatementThe 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
ConstraintsBudget: $7,500Technical 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)
AssumptionsAll 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
Work Breakdown StructureTeam Member Responsibilities
Team LeaderRishitha Dias
Coordinate efforts to complete project, logistics, running meetings, purchasing, and resource acquisition
Chief EngineerKevin 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
Team Member Week 1 Week 2 Week 3
Rishitha DiasTeam Leader
Set up meeting times, inform everyone of their
tasksEstablish 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 KlucherChief 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
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
Intellectual Property Considerations
• Project will be open source, open architecture
• Thorough patent research must be carried out prior to starting design phase
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
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
Concept Development
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.
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?
Target Specifications
• Impellers & Diffusers must be interchangeable
• New parts should work interface with existing PIV system
Risk AssessmentTechnical 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
Risk AssessmentFlow 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
Risk ManagementTeam 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
Risk ManagementLead 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.
Risk ManagementTeam 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
Risk ManagementLead engineer will reevaluate design to
ensure that products can be manufactured using resources at RIT (while meeting specifications)
ORProject Lead and Lead Engineer will work
towards outsourcing the manufacturing to outside vendors
Risk ManagementProject Lead will work with Faculty Advisor
to reevaluate the budget ORReevaluate the scope of the deliverable to
meet the existing budget
Eric MacCormack (IE)Colin Roy (IE)
Project Status UpdateP09457 – Process
Improvement Project
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
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.
Current Layout
Piping Assembly & Packaging
Assembly
Test
Parts
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
Staffing RequirementsName Discipline Roles/Skills
Professor John Kaemmerlen Faculty Guide
Will work closely with the team on an on-going basis to facilitate success.
Colin Roy I.E. Project Manager, Point of contact for Dresser-Rand. Construct and submit deliverables. Lead in Simulation and Factory CAD software.
Eric MacCormack I.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.
Work Breakdown Structure
P – D – C – A
Work Breakdown StructureMember Week 1 Week 2 Week 3
ColinTour 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
EricTour 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
IETour 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
IETour the Facility. Bring all group members up to speed with Customer Needs
Begin preliminary current state simulation model.
Continue on current state simulation model.
METour 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
Risks and ConstraintsRisks
Quality – Tradeoff of quality vs. speedWorker resistance to changeDisruption to other processesIncreased cost to production
ConstraintsFactory distance (Olean plant 2 hour drive)22 week improvement periodCameras not allowed in facilityD-R staff availability
Resources Required
Personnel
Professor KaemmerlenDr KuhlDennis RiceDan Krenn
EnvironmentSenior Design LabISE/ME Computer LabsOlean Facility
EquipmentArena SoftwareFactory CAD Software
DeliverablesCurrent State Value Stream MapFuture State Value Stream MapDetailed Current State LayoutFuture State LayoutFactory CAD Drawings and AnalysisSimulation Models and AnalysisCost-Benefit AnalysisVisual Control System
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.
Artificial Limb Project
By Casey Dill
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.
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.
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/
Preliminary Work Breakdown Structure
Person Week 1 Week 2 Week 3 Week 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
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
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
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.
Issues & Risks Risk Management Table
Description of Risk Possible 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
H L LAlternate 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 work M M MDaily back up on EDGE server
EDGE server has down time
Not able to retrieve work off of EDGE
L H MKeep work in progress backed up on local machine
The school computer could crash with too detailed CAD work with too many parts
Model not renderable H L LWork 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
M H M
See help from another faculty guide able to help with the programming & teach it.
Concept DevelopmentOption 1 Option 2 Option 3 Option 4
Knuckle
1 DOF
Pin joint Flexible material
Ball and socket
Floating
Knuckle
2 DOF
Ball and socket
Two pin joints Gyroscope Flexible connector
Wrist Two pin joint Ball and socket
Two ball and socket joints
Flexible connector
“Bone” material
Steel Aluminum Hard plastics Titanium
Position Sensing
3D position sensing
Joint angle monitoring
Tendon length monitoring
Control system calculations
Forearm Two “bones” that wrist
Load-bearing bearing
Rotate at elbow
Concept Development
Questions?