Detailed Design Review Kyle Abbott P14474 Mitch Sedore Brian - - PowerPoint PPT Presentation

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Detailed Design Review Kyle Abbott P14474 Mitch Sedore Brian - - PowerPoint PPT Presentation

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Detailed Design Review Kyle Abbott P14474 Mitch Sedore Brian Brenner Anushka Kalicharan Jake Manley Agenda Valve Customer Requirements Coupler Engineering Pressure Transducers Requirements Piping and Fitting

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SLIDE 1

Detailed Design Review

P14474

Kyle Abbott Mitch Sedore Brian Brenner Anushka Kalicharan Jake Manley

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SLIDE 2

Agenda

  • Customer Requirements
  • Engineering

Requirements

  • System Overview
  • Controller
  • Motor

○ Driver ○ Encoder ○ Gearbox ○ Motor Mount

  • Valve

○ Coupler

  • Pressure Transducers
  • Piping and Fitting

○ Enclosure ○ Manifold

  • Bill of Materials
  • Engineering Drawings
  • Schedule
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SLIDE 3

System Customer Requirements

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SLIDE 4

System Engineering Requirements

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SLIDE 5

System Overview

  • Components:

○ Piping and Fittings ○ Valves ○ Pressure transducers and manifold ○ Motor and motor mount ○ System Controller

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SLIDE 6

Overall Assembly

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SLIDE 7

System Diagram

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SLIDE 8

Ruggedized Data Acquisition Unit with Real Time Operating System

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SLIDE 9

CompactRIO Integrated Systems with Real- Time Controller and Reconfigurable Chassis

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SLIDE 10

Chassis Specifications

  • 4 Module Slots
  • 400 MHz Processor
  • Spartan-6 LX25 FPGA
  • 128 MB DRAM
  • 256 MB Nonvolatile Storage
  • 10/100 BASE-TX Ethernet Port
  • RS232 Serial Port
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SLIDE 11

FPGA Specifications

  • 24051 Logic Cells
  • 38 Multipliers
  • 936 KB RAM
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SLIDE 12

Embedded Software Diagram

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SLIDE 13

Analog Input Module NI 9215

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SLIDE 14

Analog Input Module Specifications

  • 4 Voltage Inputs
  • 100 kS/s per Channel
  • Channel Independent Analog to Digital

Converters

  • 16-bit Resolution
  • Built-In Signal Conditioning
  • Channel-to-Earth Double Isolation Barrier
  • Screw Terminal Connections
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SLIDE 15

Digital Input Module NI 9401

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SLIDE 16

Digital Input Module Specifications

  • DSub Connector with Screw Terminal Adapter
  • 8 5V/TTL Sinking/Sourcing Bidirectional Digital

I/O Ports

  • 100 ns Propagation Delay
  • 9 MHz Switching Frequency using All 8 Ports as

Inputs

  • 500 ns Max Input Rise/Fall Time
  • ±30 V Max Overprotection on One Channel at a

Time

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SLIDE 17

Digital Output Module NI 9472

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SLIDE 18

Digital Output Module Specifications

  • 8 Digital Output Channels
  • 100 ns Propagation Delay
  • 6 to 30V, Current Sourcing Digital Outputs
  • Screw Terminal Connections
  • 750 mA/Channel
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SLIDE 19
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SLIDE 20
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SLIDE 21
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SLIDE 22

Controller Engineering Requirements

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SLIDE 23

Controller Risk Analysis

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SLIDE 24

Bill of Materials for Rugged DAQ Unit

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SLIDE 25

Motor

  • Stepper motor chosen to control valve

○ Requirements: ■ Sufficient torque ■ Water resistant ■ Precise control

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SLIDE 26

Motor: Anaheim Automation NEMA 23Y65

  • IP65 Rated

○ Splash Proof and designed for humid environments

  • 175 oz inches max output torque
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SLIDE 27

Torque Requirements

  • Based on

valve opening torque

○ 10000 PSI = 11 in-lb ■ 176 oz-in

  • Taken from

manufacturer handbook

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SLIDE 28

Motor: Anaheim Automation NEMA 23

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SLIDE 29

Motor Wiring Diagram

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SLIDE 30

Bipolar Microstep Driver Pack DPY50001

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SLIDE 31

Current Sourcing Driver Pack Wiring

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SLIDE 32

Electrical Specifications

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SLIDE 33

Motor and Control Pin Descriptions

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SLIDE 34

Steps per Revolution Selection Switch Panel Configurations

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SLIDE 35

Output Current Selection via Potentiometer

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SLIDE 36

Gearbox

  • 3:1 reducing gearbox added:

○ Finer valve control ■ Standard motor step is 1.8 degrees

  • .6 degrees per step with gearbox
  • Approximately 4.1 psi/step

○ Increased side loading capability ■ Potential side loading from motor-valve misalignment wears motor bearings ■ Gearbox bearings carry much higher load ○ Increased margin of safety on valve opening torque

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SLIDE 37

Gearbox

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SLIDE 38

Motor Mounting Assembly

  • Requirements

○ Support motor weight and torque loads ○ Adjustable installation to accommodate variation in plumbing/valve installation location ○ Ability to transverse along valve stem during opening and closing

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SLIDE 39

Motor Mounting Assembly

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SLIDE 40

Motor Mounting Assembly

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SLIDE 41

Motor Mounting Assembly

  • Minimum of ¾ inch freedom

in all 3 directions

  • Shaft coupler allows for 3

degrees shaft angle misalignment

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SLIDE 42

Motor Mount: Stress Analysis

  • Analysis done in Ansys Workbench (V 14.5.7)
  • Moment applied to motor flange
  • Motor and gearbox weight applied to motor flange
  • Fixed supports at linear slide mounts
  • Bolt pretensions at support plate
  • Material: 6061-T6 aluminum plate

○ 42 KSI Ultimate, 35 KSI Yield

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SLIDE 43

Motor Mount: Stress Analysis

Overview

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SLIDE 44

Motor Mount: Stress Analysis

Overview

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SLIDE 45

Motor Mount: Stress Analysis

Mesh: .050” Element Size

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SLIDE 46

Motor Mount: Stress Analysis

Von Mises Stress Results

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SLIDE 47

Motor Mount: Stress Analysis

Von Mises Stress Results

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SLIDE 48

Motor Mount: Stress Analysis

Von Mises Stress Results

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SLIDE 49

Motor Mount: Stress Analysis

Von Mises Stress Results

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SLIDE 50

Motor Mount Stress Analysis

  • Results:

○ Majority of part well over F.O.S. of 2 (17.5 KSI) ○ Max stress exceeds F.O.S. of 2 allowable but is in compression ■ Mostly caused by bolt pretension and not component loading

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SLIDE 51

Encoder: ENC-A3I Single-Ended High Resolution w/ Index Channel

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SLIDE 52

Encoder: Engineering Requirements

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SLIDE 53

Encoder: FMEA

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SLIDE 54

Encoder- BOM

Company Part Part Number Quantity Unit Price Subtotal Tax & Shipping Total Anaheim Automation ENC-A3I Single- Ended High Resolution w/ Index Channel ENC-A3I- 0400-984- H-T 1 $96 $96 $96

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SLIDE 55

Valve

  • Swagelok IPT series high

pressure needle valve

○ 4-5 turns to open ○ 10000 PSIG operating pressure ○ CV value of 5.1 ■ High flow, low pressure drop

  • Lowers minimum test enclosure

pressure

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SLIDE 56

Valve

  • Pressure drop across valve:

○ a ■ Q (gpm), ΔP (psi)

  • 11.1 psi pressure drop

○ At 17 gpm max flow

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SLIDE 57

Valve & Motor Requirements

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SLIDE 58

Valve and Motor FMEA

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SLIDE 59

Coupler Selection

  • Flex Coupling - 3 degrees
  • Clamp on type - provides freedom in

mounting and adequate torque

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SLIDE 60

Pressure Transducer Specs

  • NIST Certified
  • 0-5Vdc
  • Stainless Steel
  • Life of 10 million cycles
  • Accuracy

○ 10,000psi= +/- 0.25% ○ 5,000psi and 1,000psi= +/-0.8%

  • Response time of less than 1 millisecond
  • 5ft 3 conductor cable
  • 5 Point NIST traceable included
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SLIDE 61

Pressure Transducer Sensitivity Calculations

  • 0 - 10,000 psi Transducer

○ 1 volt = 2000 psi ○ Accuracy = ± 25 psi ○ Step Voltage = 12.5 mV per 25 psi

  • 0 - 5,000 psi Transducer

○ 1 volt = 1000 psi ○ Accuracy = ± 4 psi ○ Step Voltage = 4mV per 4 psi

  • 0 - 1,000 psi Transducer

○ 1 volt = 200 psi ○ Accuracy = ± 0.8 psi ○ Step Voltage = 4mV per 0.8 psi

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SLIDE 62

Pressure Transducers- Eng. Reqmts

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SLIDE 63

Pressure Transducer Risk Analysis

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SLIDE 64

Pressure Transducer BOM

Omega 10,000psi pressure transducer w/ 5' cable PX309-10KG5V 1 $225.00 $225.00 $225 Omega 5,000psi pressure transducer w/ 5' cable PX309-5KG5V 1 $225.00 $225.00 $225 Omega 1,000psi pressure transducer w/ 5' cable PX309-1KG5V 1 $225.00 $225.00 $225

Company Part Part Number Quantity Unit Price Subtotal Tax & Shipping Total

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SLIDE 65

Piping and Fittings

  • 1” XXH Black Pipe

○ Working Pressure ~ 24,000 psi

  • Class 6000 Fittings

○ Equivalent to XXH piping ○ x3 Elbows ○ x3 Tees

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SLIDE 66

Working Pressure Calculation

The maximum working pressures were found for various materials. The safety factor used is 2.5, determined by ASME Power Piping code B31.3. Using the following equation:

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SLIDE 67

Working Pressure Calculation

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SLIDE 68

Calculations

Pressure drop calculations through drain pipe

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SLIDE 69

Piping and Fittings- Eng. Reqmts

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SLIDE 70

Piping and Fittings Risk Analysis

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SLIDE 71

Manifold

  • Mounts 3 Pressure

Transducers and 1 Digital Pressure Gauge

  • 2 Shut-off Valves to

Protect Low Pressure Transducers

○ No valve needed for 10,000 psi Transducer

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SLIDE 72

Manifold FMEA and Risk Analysis

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SLIDE 73

Manifold: Stress Analysis

  • Analysis done in Ansys Workbench (V

14.5.7)

  • 10000 PSI on all wetted surfaces
  • Blow-out loads on all threaded joints
  • Supports at 1” pipe joints
  • Material: 7075-T6 aluminum

○ 70 KSI Ultimate, 59 KSI Yield

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SLIDE 74

Manifold: Stress Analysis

  • Setup
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SLIDE 75

Manifold Stress Analysis

  • Mesh
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SLIDE 76

Manifold: Stress Analysis

Von Mises Stress Results

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SLIDE 77

Manifold: Stress Analysis

Stress Peak

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SLIDE 78

Manifold: Stress Analysis

  • Results:

○ Majority of part well over F.O.S. of 2 (29.5 KSI) ○ Max stress represents 1.27 F.O.S.

  • Recommend development part in 7075 aluminum

○ Ease of machining ○ Cost

  • Recommend production part in 15-5 PH stainless steel or

equivalent strength stainless alloy ○ Heat treated to ~100 KSI tensile yield or better

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SLIDE 79

Enclosure: Overview

  • Protect components from water spray and

test part failure

○ Vulnerable components include: ■ Motor ■ Encoder ■ Pressure Transducers

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SLIDE 80

Enclosure FMEA and Risk Analysis

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SLIDE 81

Enclosure: Geometry

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SLIDE 82

Enclosure: Geometry

  • Hinged door to allow

quick access to transducer shut-off valves

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SLIDE 83

Bill of Materials

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SLIDE 84

Bill of Materials cont.

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SLIDE 85

Bill of Materials cont.

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SLIDE 86

P14474_101

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SLIDE 87

P14474_103

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SLIDE 88

P14474_105

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SLIDE 89

P14474_107

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SLIDE 90

P14474_109

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SLIDE 91

P14474_111

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SLIDE 92

P14474_113

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SLIDE 93

MSD II Schedule

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SLIDE 94

Questions?

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SLIDE 95

Alternative Coupler: P14474_115

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SLIDE 96

Alternative Coupler: P14474_117

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SLIDE 97

Components