P13623: Conductive Heat Transfer
Lab Equipment
System Design Review
April 5th, 2013
Project Participants
Project Sponsor : RIT KGCOE, Chemical Engineering Dept.
Dr. Karuna S. Koppula
Mr. Paul Gregorius
MSD 1 Team Guide: Michael Antoniades
Project Members:
 David Olney - (ChemE) Project Manager
 Todd Jackson - (ME) Project Engineer
 Alysha Helenic - (ChemE) Documentation Engineer
 Edward Turfitt - (ChemE) Design/Concept Engineer
 Charles Pueschel - (ChemE) Data Acquisition Specialist
 Ian Abramson - (ChemE) Customer Liaison
Agenda
 Overview of project
 Design specifications, needs and
constraints




Customer needs
Engineering specifications
Project deliverables
Functional decomposition
 Design process
 Concept generation
 Functional architecture
 Physical architecture
 Design generation and assessment
 Initial concepts
 Pros and cons
 Final proposed design
 Final design assessment
 Benefits and limitations
 Feasibility
 Risk
 Project planning
 Project schedule
 Deliverables
 Quarter goals
 Questions
Heat Transfer and Thermal Conductivity
 Heat transfer can take place from three methods
(Conduction, Convection , Radiation).
 The most valuable method to calculate a constants for one
specific mode of heat transfer is to reduce or eliminate the
other two modes.
Project Overview
Problem Statement:
 Build an apparatus that can demonstrate thermal conductivity
reliably to students for educational purposes.
Resources:
 The only limitation we have is the set budget for the project.
 (space, cart, current lab equipment, donations) excluded
from budget.
Expectations:
 The purpose of this review session is for constructive
criticism, recommendations, and validation by the customer
for some of our current designs that we have derived.
Design Process Flow
PRP
Functional Decomposition
Problem Definition
Define Requirements
Engineering Matrix
House of Quality
Constraint Criteria
Define Constraints
Power Source
Temperature Sensors
Heating Element
Cooling Element
Insulation Methods
Data Collection
Contact Resistance
Interchangeability
Define Systems
Research Systems
Develop Solutions
Concept Generation
External
Assess Solutions
Generate Designs
Assess Designs
Final Design
Design assessment
Pugh Matrix
Design 1
Design 2
Design 3
Pro/Con List
Final Design
Customer Specifications review
Risk Assessment
Cost Assessment
Design 4
Customer Needs
Engineering Specifications
Engineering Specifications
Functional Decomposition
Functional Architecture
Heating Element
Provide a constant heat
source to the specimen
Cooling Element
Provide a constant heat
sink to the specimen
Temperature
Sensors
Provide a means for
measuring temperature
Insulation
Minimize the amount of
heat loss
Data Acquisition
Provide a means for
collecting data
Power Source
Provide a means for
power heating element
Concept Generation
Criteria Generation
Pugh Matrix: Heating and Cooling
Pugh Matrix: Insulation
Pugh Matrix: Sample Container
Pugh Matrix: Data Measurement and
Display
Design 1
Heater
Cooler
Temp Sensor
Insulation
Orientation
Set-up
Jacketed
Jacketed
Thermo Cp
Air
Horizontal
Easy
Pros & Cons of Design 1
Pros
 Simplicity
 Cheap
 Visual
 Compatible with different
samples
 Easy to set up
Cons
 Inconsistent insulation
Design 2
Heater
Cooler
Temp Sensor
Insulation
Orientation
Set-up
Disk
Jacketed
Thermo Cp
Air
Vertical
Mild
Pros & Cons of Design 2




Pros
Pressure can be applied to
the heater
Cheap
Visual
Compatible with different
length samples
Cons
 Hard to swap different
diameter samples
 Potential air leaks because
of water supply
connections.
Design 3
Heater
Disk
Cooler
Plate
Temp Sensor
Thermo Cp
Insulation
Solid or packed
Orientation
Vertical
Set-up
med-hot
Pros & Cons of Design 3




Pros
No convection
Compatible with different
length
Pressure can be applied on
both the heater and cooler
Solid insulation adds
support
Cons
 Complex
 Longer set up times
 Not completely visible
Design 4
Heater
Cooler
Temp Sensor
Insulation
Orientation
Set-up
Disk
Plate
Thermo Cp
Muti
Vertical
med-hot
Pros & Cons of Design 4





Pros
Limits convections
Visual
Compatible with different
length and diameter
samples
Pressure can be applied on
both the heater and cooler
Compatible with multiple
insulations
Cons
 Complex
 Longer set up times
 More expensive
Boat Design
 Removable caps allow liquid , gases, and
pastes to be inserted into the boat.
 Temperature sensors will be placed at set
lengths within the boat so that they do
not move.
 The ends will be made out of a
conductive medal to minimize leakage.
Physical Architecture
Heat conduction
apparatus
System
Power
source
Temperature
sensor
Heating
element
Cooling
element
Insulation
Data
Collection
Contact
resistance
Multimaterial
Cold
plate
Variable
insulation
method
DAQ
Screw cap
(pressure)
Boats
Subsystem
Electric
Plate
variable
heater
power Thermocouple
generator or silicon based
temperature
sensor
Components
LCD
Critique of Designs
Data Collection - Design #1
DAQs
Cost
Interface (to PC)
Arduino
~60
USB/Other
Ni Equipment
>600
USB/Other
Labjack
~110
USB/Other
Needs
Manual Data
Collection
Digital Data
Collection
Effective For Students of Various Learning Styles
3
3
Utilization is complex enough to involve 3-4
students in the allotted time
1
1
Utilization Requires Fundamental
Understanding of Conducive Heat Transfer
Principles
3
-
Allows for manual Data Collection
9
-
Allows for Digital Data Collection
-
9
Data Collection - Design #1 (Digital Only)
Needs
Manual Data
Collection
Digital Data
Collection
Effective For Students of Various Learning Styles
N(3)
3
Utilization is complex enough to involve 3-4 students in the
allotted time
N(1)
1
Utilization Requires Fundamental Understanding of
Conducive Heat Transfer Principles
N(3)
-
Allows for manual Data Collection
N(9)
-
Allows for Digital Data Collection
-
9
Data Collection - Design #2 (Analog Version)
Needs
Manual Data
Collection
Digital Data
Collection
Effective For Students of Various Learning Styles
3
N(3)
Utilization is complex enough to involve 3-4 students in the
allotted time
1
N(1)
Utilization Requires Fundamental Understanding of
Conducive Heat Transfer Principles
3
-
Allows for manual Data Collection
9
-
Allows for Digital Data Collection
-
N(9)
Data Collection Design #3
Needs
Manual Data
Collection
Digital Data
Collection
Effective For Students of Various Learning Styles
3
3
Utilization is complex enough to involve 3-4 students in
the allotted time
1
1
Utilization Requires Fundamental Understanding of
Conducive Heat Transfer Principles
3
-
Allows for manual Data Collection
9
-
Allows for Digital Data Collection
-
9
Temperature In Sample versus Length
4000
Aluminum
Copper
Iron
3500
Temperature (K)
3000
2500
2000
1500
1000
500
0
0
50
100
150
200
250
300
Q W/(m.K)
350
400
450
500
• Assumptions: Steady State, No conduction or convection from the air on
the sample.
q = Q/A =-k(dT/dx)
Given Targets: Q = 500 W, Target ΔT = 120 K
Chosen Parameters: T0 = 273 K, D = ¾”, L = ½’
Feasibility Analysis
h
T1
•
•
•
•
T2
T3
T4
One Dimensional Transient Analysis
One Dimensional Finite Difference Steady State Analysis
T1 and T5 will be known temperatures
The length of the rod and properties will be known
T5
One Dimensional Transient Analysis
h
T1
T2
T3
T4
T5
One Dimensional Transient Analysis
h
T1
T2
T3
T4
T5
One Dimensional Finite Difference
Steady State Analysis
h
T1
T2
T3
T4
T5
Simulation Parameters
Copper Rod Parameters
Density (kg/m3)
8940
Thermal Conductivity (W/m*K)
401
Specific Heat (J/kg*K)
394
Length (m)
0.254
Diameter (m)
0.00635
Stainless Steel Parameters
Density (kg/m3)
7820
Thermal Conductivity (W/m*K)
43
Specific Heat (J/kg*K)
490
Length (m)
0.254
Diameter (m)
0.00635
Copper Rod Results
After 1 minute
After 2 minutes
Copper Rod Results
After 3 minutes
After 4 minutes
Stainless Steel Rod Results
After 5 minutes
After 10 minutes
Stainless Steel Rod Results
After 20 minutes
After 40 minutes
Stainless Steel Rod Results
After 60 minutes
Feasibility Conclusion
 Copper rod reaches steady state much quicker than the
stainless steel rod.
 In order to reach thermal equilibrium quicker, the length of
the specimen can be diminished.
 The lab can be conducted within the allotted time.
Means for Calculating Thermal
Conductivity – Steady State
Where:
Rs = thermal resistance of sample
F = heat flow transducer calibration factor
Tu = upper plate surface temperature
Ti = lower plate surface temperature
Q = heat flow transducer output
Where:
K = thermal conductivity
d = thickness of sample
Means for Calculating Thermal
Conductivity –Transient
Risk Assessment
Project
Organization
MSD I and MSD II Goals
and Deliverables
Define Customer
Needs and Specs
Develop Concepts
Create System
Level Design
•Hold System
Design Review
•Revise design
based on Review
Create Detailed
Design
•Create test and
assembly plans
•Write BOM
•Order Materials
Update Project
Plan
Design Verification
•Create test plans
•Build system
•Verify design
through testing
•Hold Detailed
Design Review
Write Technical
Paper
Create Poster
Final Presentation
Project Schedule for Quarter
Goal
Week Completed
Revise System Design based on Review feedback
Week 6
Create assembly plans
Week 7/8
Create test plans
Week 7/8
Write BOM
Week 9
Order materials
Week 9/10
Hold Detailed Design Review
Week 10/11
Questions?