MSD P13453 Final Project Review Sean Deshaies (ME) Erin Sullivan - PowerPoint PPT Presentation

MSD P13453 Final Project Review Sean Deshaies (ME) Erin Sullivan (EE) Michael Gorevski (EE) Brandon Niescier (ME)

Agenda • Project Goals • Customer Needs • Design Summary – Wired System – Wireless System • Testing • Expense Report • Project Status • Future Work • Lessons Learned

Project Goals • Install accelerometers on the compressor – One on the flywheel hub – One on the bearing housing • Find a solution to wirelessly transmit data from one of the accelerometers • Data collected in LabVIEW or through standalone software

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

Wireless Accelerometer Mounting Location • CN13 references mounting on the shaft – Accelerometer was too tall for keyway • Pugh analysis was done to evaluate potential solutions – New mounting location was found on flywheel hub

Design Summary • Wired Accelerometer: – PCB Swiveler is able to withstand the oil and higher temperatures inside the compressor • Wireless Accelerometer: – PCB 660 Series is able to operate on the same low voltage as the wireless module • Wireless Module: – TelosB module allows for low power, wireless transmission capabilities

Wired System

Wireless System

Test Fixture

Testing • Accelerometer verification – PCB Swiveler vs. B&K 4393 – PCB 660 Series vs. B&K 4393 • Wireless transmission verification – TelosB module vs. function generator

Accelerometer Test Results Transfer Function Magnitude and Transfer Function Magnitude and Phase (PCB Swiveler/ B&K 4393) Phase (PCB 660/ B&K 4393) 5 5 1.4 1.4 0 0 1.2 1.2 -5 -5 Magnitude (m/s^2/m/s^2) Magnitude (m/s^2/m/s^2) 1 1 Phase (degrees) Phase (degrees) -10 -10 0.8 0.8 -15 -15 0.6 0.6 -20 -20 0.4 0.4 -25 -25 0.2 0.2 -30 -30 0 -35 0 -35 0 500 1000 1500 2000 2500 3000 0 500 1000 1500 2000 2500 3000 Frequency (Hz) Frequency (Hz) Magnitude Phase Magnitude Phase

Wireless Test Results Wireless vs. Function Generator (50Hz) 2.5 2 Voltage (Volts) 1.5 1 0.5 0 0 50 100 150 200 250 Number of Samples Wireless Signal Express Wireless with Scale Factor

Wireless Test Results

Compressor Data Wireless Data Wired Data

Accelerometer Data Comparison Wireless vs. Wired Acceleration Measurement 1.5 1 0.5 0 Acceleration (g) -0.5 -1 -1.5 -2 -2.5 -3 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 Time (sec) Wireless Wired

Total Expenses Team P13453 Expenses Order Number Vendor Order Description Total Cost 105-7615249-5268227 Amazon Supply Aluminum Bar and Angle $121.13 3017475-01 McMaster-Carr Steel Bar, Pillow Block Bearings $323.35 55953 Photocraft Encoder, Stub Shafts $208.16 3017475-01 McMaster-Carr Returned Bearings ($252.16) 4389 PowerGate Power Supply $60.93 374572 Bolt Depot Test Rig Hardware $7.24 4002194-01 McMaster-Carr Cable Gland $12.71 2500375331 Allied Electronics USB Extension cord and Enclosure $12.41 PL-121120002 Memsic Wireless Modules $362.00 48997576 Grainger Epoxy $17.60 N/A Anaheim Automation Motor $163.00 N/A McMaster-Carr Coupling $35.77 4547023-01 McMaster-Carr Screws $15.04 2500389198 Allied Electronics Enclosure and Switches $36.76 A233703 Futurlec Header Pins $6.50 N/A PCB Accelerometers and Signal Conditioner $798.30 N/A Lowe's Safety Guard Brackets $3.18 N/A Harbor Freight Hex Key Set and Rubber Mallet $8.98 N/A Jeff Wilczewski Wireless Module Programming $500.00 45448853 McMaster-Carr Helicoil Thread Repair Kit $77.31 Initial Budget: $5,000 Funds Remaining: $2,482

Project Status • Accelerometers installed successfully – Wired accelerometer integrated into LabVIEW – Wireless accelerometer interfaces through a standalone program • Data is reliably transmitted wirelessly

Future Work • Sync the data between wired and wireless accelerometer • Integrate the wireless accelerometer into LabVIEW • Mount wireless accelerometer to bearing housing inside compressor • Improvements to wireless enclosure

Lessons Learned • There is no viable off-the-shelf wireless solution • Expert opinions are sometimes wrong • Be sure to include all necessary tolerances on manufacturing drawings • Machinists have the ability to make or break the project • Communication of customer needs could have been improved • Need to anticipate the speed of bureaucracy

Acknowledgements • Bill Nowak – Guide • Jeff Wilczewski – Programming wireless modules • Rob Kraynik – Machining and installation assistance • Dresser-Rand – Project sponsor • Markus Holzenkamp – Project assistance • Dr. Kolodziej – Faculty champion/customer

Thank You P.S. – Bill you owe us all a beer