Water Flow Uniformity Test System Final Design Presentation Team - - PowerPoint PPT Presentation

Water Flow Uniformity Test System

Final Design Presentation

Jonathan Cook MECH Andrew Benson MECH Perla Garcia MECH Jason Haldane MECH Mike Rasmussen MECA

Team Members

Project Support

FAFCO

(Sponsor) Mike Rubio

(Technical Contact)

Greg Kallio (Advisor)

Problem/ Need

Problem

Joining header and tube array leads to obstructed tubes. Leads to a non uniform water flow in panel Reduces efficiency of panel Quality control is destructive and inefficient testing process

Need

Nondestructive, fast quality check procedure

Function of device

Accurately measure the flow rate inside each

individual tube.

To determine the number and severity of

• bstructed tubes.

Specifications

Requirement Engineering Specification Units Target Should do/ Must du/ Would be nice Quantitative Accurate measurement Flow rate GPM ±.0008 GPM/tube Must do Quantitative Resolution Area Sq Meters 9 sq mm Must do Quantitative Complete testing quickly Time Minutes < 10 minutes Should do Quantitative Repeatability Precision Unit less ±5% Must do Quantitative Requirement Qualitative Must do/ Should do/ Would be nice Test opaque tubes non-intrusively Qualitative Must do Accommodate two standard panel sizes Qualitative Must do Automated measurement Qualitative Would be nice

Design Solution

Engineering Analysis

( Tsn − T∞ Tsn+1 − T∞ ) = e

−α(xn −xn+1 )

[ ]

Tm n = Tmi − T∞

( )e

−α(xn )

[ ] + T∞

V

• =

1 ′ R

totalCpαρ

Tsn = Surface temperature T∞ = Ambient temperature Xn= Distance between IR sensors Tmn = inside temperature Rtotal = Total resistance Cp= Specific Heat ρ = Density of water α = Cooling decay coefficient V= Volumetric flow rate

Tmi Ts1 Ts2 Ts3 X2 X3 Tm1 Tm2 Tm3

Fabrication

Design Changes

Frame material change from extruded aluminum to steel Switch to steel linear bearings

Purchased parts:

• Temperature sensors
• Linear bearings
• Automation components

Fabricated parts

• Frame structure
• All mounting brackets
• Carriage

Testing

Calibrate the Heat Transfer Cooling

Coefficient of the system

• Correlation between inside temperature

and outside temperature (Rab)

Accuracy of the System

• Comparison between the manually

measured flow rate and the output flow rate

• f the machine

Repeatability

• Data was collected from several timed

runs and statistical analysis was performed

Calibration

Run Tmi (°C) T1 (°C) T2 (°C) T3 (°C) WEIGHT (oz) m*

1 55.9 40.3 39.7 37.7 3.4 0.053125 2 55.3 40.6 40.2 38 2.9 0.045313 3 49.7 38.9 37.9 36.2 4 0.0625 4 49.9 39.1 37.8 36.4 2.8 0.04375 5 51 39.2 39.8 36.6 2.8 0.04375 6 51.3 39.4 38.5 37 2.2 0.034375 7 51.4 39.9 38.2 36.9 2.2 0.034375

Alpha Tmn Rtotal Rab/Rtotal Rab

0.081746 54.77179 3.23242 0.455492 1.451269 0.175722 52.50114 0.43392 0.257699 50.09709 0.457506

Accuracy

Run Tube # Time (min) Mass (oz) V* (Measured) V* (Calculated)

1 1 1 6.7 0.052 0.017 2 1 2 9.3 0.036 0.014 3 2 2 8.2 0.032 0.019 4 2 2 6.7 0.026 0.005

Repeatability

6.56% Repeatability

0.005 0.01 0.015 0.02 0.025 0.03 20 40 60 80 100 120 140 160 Flow Rate (GPM) Tube Number Test 1 Test 2 Test 3

Did it meet the specs?

Requirement Target Should do/ Must du/ Would be nice Spec Met? Value Tested Accurate measurement ±.0008 GPM/tube Must do No Inconclusive Resolution 9 sq mm Must do Yes 5 sq mm Complete testing quickly < 10 minutes Should do Yes 4 Minutes Repeatability ±5% Must do No ±6.56% Requirement Must do/ Should do/ Would be nice Spec met? Test opaque tubes non-intrusively Must do Yes Accommodate two standard panel sizes Must do Yes Automated measurement Would be nice Yes

Final Budget

Sources of funding-

Industrial Sponsor Donated labor

Part Estimated cost

Hall effect sensor $21.70 Stepper drive $199.00 Power supply $136.00 I/O device $182.04 Automation direct $86.56 Tubing position sensors $87.28 IR sensors $1,451.35 Frame (Steel) $120.00 Fans $80.00 Bearings $175.00 electronic housing $62.00 hardware $15.00 Sensor opics $150.00 thermocouples $43.28 Carrage $155.11 Total Material cost $2,964 Total Estimated budget for the project Total MECH hours= 2251 Total MECA hours= 481 Estimated total hours for labor 2732 Estimated budget for labor $105,478 Estimated budget for material $2,964 Total Project cost=$108,210

Reflection

Problems encountered:

Frame took a little longer than expected Positioning of sensing tubes Water heater Change of frame material

Suggestions for the future

Further Calibration Required Recommended Design Changes

Add an additional lead screw Add a position home sensor

Revised specification

Relax tolerance for accuracy of flow rate

Acknowledgements

FAFCO

• Dr. Kallio (advisor)

Tech shop Members of the team

Questions?