P11251: Side Entry Agitator Test Stand
https://edge.rit.edu/content/P11251/public/Home
MSD I: System Level Design Review
REVISION A: For Reading/Review ONLY
(No Formal Presentation Given)
Project Team/Attendees
Project Sponsor : Richard O. Kehn - "ROK"
Senior Technologist - Mixing
SPX Flow Technology
MSD I, Team Guide: William J. Nowak
Principal Engineer,
BGO/XIG/XRCW/OSL/Media & Mechatronic Systems
Xerox Corporation
Team P11251: Kurt Lutz: P.M./(Measurement System w/ Integration)
Dennis Beatty: (Fluid-Tight Sealing Structure)
Joseph Bunjevac: (Physical Structure w/ Adjustability)
Daniel Geiyer: (Measurement System w/ Integration)
Gregory McCarthy: Scribe/(Motor/Shaft/Coupling Integration)
Meeting Agenda
Estimated Time
• Mission Statement
12:35 - 12:40
• Project Description
12:40 - 12:45
• Review of Customer Needs/Specs
12:45 - 1:50
• Review of Pairwise, Engineering Metrics, HoQ, Pareto
12:50 - 12:55
• Concept Sub-System Breakdown
12:55 - 1:00
• Initial Concept Generation & Selection
1:00 - 1:40
•
Physical Structure
1:00 - 1:10
•
Shaft/Motor/Impeller Integration
1:10 - 1:20
•
Sealing System
1:20 - 1:30
•
Measurement System w/ Hardware Integration
1:30 - 1:40
• Preliminary Risk Assessment/FMEA
1:40 - 1:50
• Project Schedule Review (GANTT)
1:50 - 1:55
• Questions/Comments/Concerns
1:55 - 2:00
Mission Statement
Mission Statement: To create a side entry agitator test stand that allows the user to
measure and calculate axial and tangential components of fluid forces, torque, and
impeller speed on the motor, impeller, and shaft, incorporating a wide range of
adjustable parameters.
Project Description
• Shaft protrudes through the side wall of the tank
• very large, under floor tanks where little headroom is available
• less costly than top entry mixers
• requires less motor torque to agitate the fluid
• three to five times the amount of power as a top entry mixer
• Rely heavily on impeller selection
• different diameters, physical sizes and blade profiles
• Previously developed top entry test-rig
• they currently have no way to benchmark these same impellers for side entry agitation
• Create a test-rig that allows reliable measurement
• through a range of adjustability (Impellers/Speeds/etc.)
• similar concepts to the top entry test rig
• different array of: bending moments, torque and fluid forces
• Very beneficial to our customer
• benchmark existing and future impeller designs for side entry applications.
Customer Requirements
Four Most Important Customer Needs:
•
•
•
•
Fluid Tight Seal
Calibration Incorporation
Tangential Fluid Forces
Fluid Thrust Force
Pairwise Comparison
Pairwise Comparison
Graphical Representation of Pairwise Comparison
Engineering Metrics
House of Quality
Pareto Analysis of Eng. Metrics
Pareto Analysis of Eng. Metrics
Power Law Distribution
By designing for only 40% of the Engineering Metrics,
We’ll gain 65% of the advantages of designing
for all the Engineering Metrics
Top (5) Most Important Engineering Metrics
• Tangential Force Measurement
• Thrust Force Measurement
• Shaft Rotational Speed
• Torque Measurement
• Ease of Calibration
• Time of Calibration
Concept Sub-System Breakdown
Physical Structure Sub-System
Stand Adjustability
• Vertical and horizontal adjustment
• Depth into tank
• Angle left and right
• Angle up and down
Physical Structure: Concept Drawings
Physical Structure: PUGH Matrix
Height Adjustment
Linear Rail
Columns
5
0
0
0
Repeatability
4
1
0
1
Test Stand Independent
4
0
0
0
Height Adjustment
3
0
0
0
Time for Setup
1
0
0
0
Appearance
Cost
Ease of Fabrication
Complexity
Stand Size
Potential for Slop
Increments of adjustment
1
0
0
0
4
4
2
2
4
3
-1
1
1
0
1
0
-1
1
1
0
1
0
-1
1
1
1
1
0
6
12
TOTAL
Customer Needs
Ball Screw
Calibration
Weight
Additional Criteria
Scissors Jack
Concept
10
0
Physical Structure: PUGH Matrix
Horizontal Adjustment
Ground Rods
Floating Plate
with magnetic
locking
Ball Screw
Plate with Pins
Weight
Rails
Additional Criteria
Customer Needs
Concepts
Calibration
5
0
0
-1
-1
Repeatability
4
-1
-1
-1
-1
Test Stand Independent
4
0
0
0
0
Horizontal Adjustment
3
1
1
1
1
Time for Setup
1
1
1
1
-1
Appearance
1
0
0
0
-1
Cost
4
-1
-1
1
-1
Ease of Fabrication
4
0
0
1
1
Complexity
2
0
0
0
-1
Stand Size
2
0
0
0
0
Potential for Slop
4
-1
-1
-1
-1
Increments of adjustment
3
1
1
1
1
-5
-5
2
TOTAL
0
-11
Physical Structure: PUGH Matrix
Depth Adjustment
Rails
Ball Screw
5
-1
0
0
0
Repeatability
4
-1
0
0
-1
Test Stand Independent
4
0
0
0
0
Distance Into Tank
2
0
0
0
0
Time for Setup
1
0
1
1
-1
Appearance
Cost
Ease of Fabrication
Complexity
Stand Size
Potential for Slop
Increments of adjustment
1
0
0
0
0
4
4
2
2
4
3
1
1
1
1
-1
1
0
0
0
0
-1
1
0
0
0
0
0
1
-1
1
-1
0
-1
1
2
0
4
TOTAL
Customer Needs
Plate with Pins
Move Impeller on
shaft
Calibration
Weight
Additional Criteria
Floating Plate with
magnetic lock
Concepts
0
-8
Physical Structure: PUGH Matrix
Vertical Angle Adjustment
Rotary Disc
Curved Track
Tilt Table
Columns
Cable Suspension
5
0
1
-1
1
1
-1
Repeatability
4
-1
0
0
1
1
-1
Test Stand Independent
4
0
0
0
0
0
0
Vertical Angle
3
0
0
0
0
0
0
Time for Setup
1
0
0
0
0
0
-1
Appearance
1
0
0
0
0
0
0
Cost
4
1
1
0
0
1
0
Ease of Fabrication
4
1
1
0
1
1
-1
Complexity
2
1
-1
0
1
1
0
Stand Size
2
0
0
0
0
0
-1
Potential for Slop
4
0
0
0
0
0
-1
Increments of adjustment
3
0
0
0
0
0
0
6
11
-5
15
19
-20
Weight
TOTAL
Gear Adjustment
Wedge Screw
Customer Needs
Calibration
Additional Criteria
Concepts
0
Physical Structure: PUGH Matrix
Horizontal Angle Adjustment
Swivel Plate
Cable Suspension
Floating plate with
magnetic lock
0
0
0
1
0
0
-1
-1
0
0
0
0
-1
-1
0
-1
-1
0
-1
-1
0
0
-1
0
Cost
4
0
1
0
0
Ease of Fabrication
4
0
0
-1
0
Complexity
2
0
0
-1
-1
Stand Size
2
-1
0
-1
1
Potential for Slop
4
0
-1
-1
-1
Increments of adjustment
3
0
0
0
0
-9
-25
-14
TOTAL
1
Rotary Table
5
4
4
3
1
1
Weight
Curved Track
Customer Needs
Calibration
Repeatability
Test Stand Independent
Horizontal Angle
Time for Setup
Appearance
Additional Criteria
Concepts
0
Additional Criteria
Customer Needs
Calibration
Repeatability
Test Stand Independent
Height Adjustment
Horizontal Angle
Vertical Angle
Distance Into Tank
Time for Setup
Appearance
Cost
Ease of Fabrication
Complexity
Stand Size
Potential for Slop
Allows full range of motion
Increments of adjustment
0
0
0
0
0
0
0
1
0
-1
-1
-1
-1
1
1
1
0
-1
0
0
0
0
0
-1
0
0
0
-1
-1
-1
1
1
-1
-1
0
0
1
0
0
-1
0
0
0
0
1
-1
1
1
1
-5
-1
Four columns with ball
screws with curved track.
No depth
Pre-drilled plate concept with
a mounting rail with 1"
adjustability
Custom plate per setup
Ball joint on plate.
Ground rod with ball screw
for all movement. Swivel
plate
Linear rail for vertical,
horizontal, depth with rotary
table
0
Suspend motor by inverting
Rail concept
Plate with pre-drilled holes for
positioning motor with tilt plate
Stand with Vertical Angle
ajustment 'floating' on base
plate
TOTAL
5
4
4
3
3
3
2
1
1
4
4
2
2
4
5
3
Ground rods instead of rails
with locks
Weight
Rails with servos and screw
with a tilt and rotary plate
Physical Structure: PUGH Matrix
System Design
Concepts
0
0
0
0
0
0
0
0
-1
-1
-1
-1
0
-1
1
1
0
0
0
1
0
1
0
0
0
0
-1
0
1
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
-1
1
1
1
1
0
-1
-1
-1
-1
1
0
-1
1
1
1
1
-1
-1
-1
-1
0
0
1
1
0
-1
-1
-1
-1
-1
0
-1
1
1
0
0
0
1
0
0
0
-1
0
0
-1
0
0
0
1
1
0
0
0
1
0
0
1
0
0
0
-1
0
0
0
1
1
-7
12
4
-1
-11
6
9
Physical Structure: Concept Selection
Key Advantages
• Removes need for tilt plate
• Reduces potential issue with structure height
• No limit to step increments on any axis
• Possibility for fully automated positioning via
stepper motors
Shaft, Motor, & Impeller Integration
Sub-System
Explanation of this sub-system & components:
Shaft: Transmits torque & angular velocity via the motor & impeller
Coupler: Transmits power between the motor output shaft & shaft
Motor: Provides Mechanical Energy to the system
Impeller: “Work” horse of the system: agitates the fluid to be mixed
Fluid Agitation
Impeller Shaft
Coupling
Tank Wall
Motor
SMI: System Diagram w/ Impellers
6”Ø: 2”
10Ø: 3”
•Given Impeller Dia.: 4.5 – 10”
•Off Wall Distance: TYP. 0.5D
<0.4D, Flow Drops Off
>0.5D, Minimal Additional Flow, Adds Cost for Minimal flow benefit
•MATL: 316 S.S.
SMI: Shaft Design Selection
Shaft Length, (From Tank Wall) = APROX. 2.25 – 5”
SMI: Shaft Design Selection PUGH
•Best Choice: Solid, Continuously Long Shaft
SMI: Shaft Design Prelim. Equations
• Static Cantilever Beam
Analysis
• Mod-Goodman Shaft
Analysis
• Natural Frequency Ck
SMI: Shaft to Shaft Coupling
Set Screw
Thru-Bolt
Gear
Disc
• All must have high torsional strength, for accurate fluid force & thrust measurement
• Minimize parallel mis-alignment (RIGID) for accurate fluid force & thrust
measurement
• Provide a secure connection between the (2) elements
• Long lasting and minimal maintenance/overhaul required
Manuf: LoveJoy Req’s:
1) Required Max Torque
2) Motor Speed/HP Req.
3) Shaft/Motor Shaft Dia.
SMI: Shaft Coupling PUGH
•Best Choice: Thru Bolt or Set Screw
• Thru Bolt for Added Rigidity & Resistance to Torsion
SMI: Impeller/Shaft Connection
Based on given ID of provided impellers, (3)
conditions could exist:
1) Shaft Dia. < Impeller Dia.
- need for a spacing collar
2) Shaft Dia. > Impeller Dia.
- need for a reducer
3) Impeller has threaded spacer that screws
onto end of shaft (Similar to 2)
SMI: Impeller/Shaft Connection PUGH
•Best Choice: Spacing Collar
• Method currently being used by industry
• OR
• Direct connect to shaft, if Shaft OD=Impeller ID
SMI: Motor Selection
• DC or AC Motor
•
Variable Drive (per Measurement & Integration)
• Highly dependent on “Physical Stand”
• Package Size/Weight/Mounting Options
• Capable of reaching 1100 RPM under load, with greatest
thrust/torque producing impeller
• Spec’d based upon required shaft size
• Consider Side-Loading Effect on Motor Bearings/Life
•NEMA Rating for environment/safety
Sealing System: Initial Concepts
Concept 1
Concept 2
Concept 3
Concept 4,5,6,7
Sealing System: Initial Concepts
Concept 10
Concept 11
Concept 12
Concept 13
Concept 8
Concept 9
Sealing System: PUGH
Sealing System: Final Concept
Critical Benefits:
•Allows Adjustability
•Less parasitic to measured forces
•Does not alter tank geometry
•Very low leak rate
Axial and Tangential Fluid Force
Measurement Concept Generation
Pictures from
www.lcmsyst
ems.com.
Picture from
www.circuits
today.com
Measurement Technology:
Strain Gauge; Donut, Pancake,
Canister, or Column Load Cell; or
Accelerometer.
Picture from
www.einstei
n.standford.
edu
Location of Measurement
Devices:
On the motor mount, beneath the
coupler, or on the end of the shaft.
Motor
T=(L1/L2)F
Pins resist shear effects.
Inner and outer
support boxes.
Motor Mount Design:
Parallel Plates, Lever Arms, Shear
Support Pins, Load Cell Cocoon, or
Parallel Plates with Pointed Pivot.
Axial and Tangential Fluid Force
Measurement Concept Evaluation
Axial and Tangential Fluid Force
Measurement Concept Selection
Three Most Critical Criteria:
• Resists Affects of Shear
• Measuring Sensitivity
• Appropriate Time for Setup
Low Profile, Tension & Compression Load Cell Mounted to Parallel Plates with Shear
Pins optional depending on supporting calculations.
Picture From www.lcmsystems.com
Side View
Isometric View
Torque and RPM Measurement
Subsystem
Slip Ring:
• Electrical connection through a rotating
assembly
• Low speed limitations
• Ring wear and dust brushes impede signal
transfer
• Requires routine maintenance for cleaning
Torque and RPM Measurement
Subsystem
Rotary Transformer:
• Tolerates high speeds
• Non-contact
• More accurate
• Requires sophisticated signal condition instrumentation
• Less tolerant to extraneous loading conditions (bending moments
and thrust forces)
Torque and RPM Measurement
Subsystem
Digital Telemetry:
• Software driven allowing changes on the fly
• High resolution, sensitivity, and accuracy
• More immune to vibration problems
• Smaller, lighter, and more compact
Torque and RPM Measurement
Subsystem
Torque Transducer:
• Utilizes a system of strain gauges (Wheatstone Bridge)
• Uses slip rings or rotary transformers to power and transfer strain
gauge data
Torque and RPM Measurement
Subsystem
Torque from Motor Constants:
• Ideal for direct drive systems
• Only requires measurement of motor current
Torque and RPM Measurement
Subsystem
Critical Criteria
• Measurement accuracy and sensitivity
• Ease of implementation
• Small package size
• Allow for multiple shaft diameters
• Ease of maintenance
Final Integrated Concept Generation
Final Integrated Concept Selection
•Physical Stand
•Tangential & Axial Force Measurement
•Shaft, Motor & Impeller Integration
•Torque & RPM Measurement
Final Integrated Concept Selection
•Physical Stand
•Sealing System
Preliminary Risk Assessment/FMEA
https://edge.rit.edu/content/P11251/public/Design%20Documentation
Preliminary Risk Assessment/FMEA
Key Risk Items
• Full range of adjustability
• Seal Effects measurement instrumentation & readings
• Sensitivity of Measurement Systems
• Successful Integration of Sub-Systems
• Orientation affects measurements
Project Plan Review
https://edge.rit.edu/content/P11251/public/Team%20Project%20Plan
Questions/Comments/Concerns