Detailed Design Review
Multidisciplinary Senior Design 1
Friday, February 15th, 2013
P13051
P13051 – PIV Experiment for Flow
Mapping in Lungs
• Customers:
▫ Dr. Risa Robinson
▫ Dr. Steven Day
• Team Guide:
▫ Michael Antoniades – Chemical Engineering
• Team:
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Kristin Roberts – Project Manager, ME
Morgan DeLuca – ME
Brad Demarest – EE
Ryan Mark – ME
Jimmy Moore – CE
Jake Snider – ISE
Agenda
• Project Background
• Customer Needs & Engineering Specifications
• Component Design & Feasibility
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Pressure Measurement & Control System
Pump System
Lung Tank & Reservoir
Camera/Laser Positioning System
• Preliminary Test Plans
• Risk Assessment
Project Background
• The Army Medical Research Lab needs to
validate their CFD models for healthy and
diseased lungs
• RIT will perform particle image velocimetry
(PIV) on lung models to validate the CFD.
• The senior design team will design and develop
the lung models and testing apparatus.
What is PIV?
• Used for flow visualization and velocity
measurements
• Fluid is seeded with tiny tracer particles
• The particles are illuminated using a laser sheet,
and a camera takes pictures of the particles.
• Fluid velocity profiles can be obtained by
analyzing particle movement from frame to
frame.
Key Customer Needs
1.
2.
3.
4.
Accommodate various image locations
Simulate inhalation and exhalation
Monitor flow rate and pressure
Control flow at outlets to mimic boundary
conditions of CFD model
5. Accommodate imaging with no distortion
6. Create LabVIEW Program and procedure to
run experiment
7. Can easily switch between models
Pressure Control Subsystem
Comprised of:
• T-hose splitter
• Dual flow needle valve
• Amplified voltage pressure
transducer
• Powered breadboard
Needle Valve
• High resolution, therefore
minor adjustments to flow can
be made (5 turns)
• Dual flow capability (allows
inhale and exhale simulation)
• Low profile for organization
purposes
• Low cost (20$)
T-Hose Splitter
Reasons for using a T-hose splitter:
• Separate static pressure from
dynamic flow
• Allow pressure readings to be
taken parallel to flow increasing
accuracy
• Organize flow path from model to
valve system
Amplified Pressure Sensor
• Accuracy (can measure static
pressures +/- 1% with proper
calibration)
• Cost (65$ per sensor)
• Compact design (no extensive
cables or adaptation, plug into
breadboard)
• Easy to calibrate and characterize
to increase accuracy
Breadboard Implementation
• Keeps voltage sensors
organized and setup compact
• Allows user to adjust voltage
getting applied to sensors easily
• Flow from pressure control to
DAQ device will be smooth
Pressure Control Path
Fluid will leave outlet
With steady state
conditions fluid will
separate due to splitter and
apply static pressure on
sensor
Back to
pump
Flow will be adjusted with
needle valve based on
logger pro readout
compared to desired
conditions
Calibration Technique
Fluke 718 series
• Can use to apply very accurate
known pressure
• Output voltage can then be
read and adjusted to create
new curves accurately
matching sensor performance
• Device is on loan from ME
Department
Flow Characteristics
• Viscosity determined through index matching,
(550 SSU, 109 cP, 0.109 Pa-s)
▫ Much higher than water (1 cP)
• Flow tested by Army is from 2-10 L/min
▫ Using Reynolds number matching, 6-32 GPM
• Pressure loss through system ranges from 20 psi
to 50 psi
▫ Calculated using Poiseuille flow
Positive Displacement vs. Centrifugal
Conclusion: PD pumps provided better flow control, regardless of
pressure and handle high viscosities.
Graph Credit: pumpschool.com
PD Pump Selection
Pump
Flow Rates
Pressures
Comments
Cost (3 highest)
Gear pump
Acceptable,
Up to 30 gpm
Acceptable,
Up to 50 psi
Common, can be selfpriming
2
Rotary Vane
Acceptable
Acceptable
1
Diaphragm
Acceptable
Acceptable
Not really used in our
application, better for
thin fluids and high
pressure differentials
Create pulsing flow,
need air supply,
cheaper
Lobe Pump
Acceptable
Acceptable
Used in Sanitary
applications where
fragile solids are
used, bi-rotational,
may be overly
complex
3
Image Credit: Wikipedia; Info Credit: pumpscout.com
1
3 GPM
35 GPM
6 GPM
19 GPM
Siewert, 1.6-16 GPM, $2,079
Siewert, 2.3-23 GPM, $2,189
Siewert, 3.2-32 GPM, $2,319
Emerick, 3.3-33 GPM, $2,754
33 GPM
Emerick
•
•
•
•
•
•
•
Max flow rate: 33 GPM
Min flow rate: 3.3 GPM
Max Pressure: 200 psi
Speed Ratio: N/A
Price: $2,745
Shipping not included
Lead time: 3-4 weeks
Siewert
•
•
•
•
•
•
•
•
Max flow rate: 32 GPM
Min flow rate: 3.2 GPM
Max Pressure: 100 psi
Speed Ratio: 10:1
Price: $2,319
Shipping included
Installation Assistance
Lead time: 5-6 weeks
Inhalation Pipe Schematic
Lung Tank Design
• The project team has
decided to go with acrylic
siding for the tank, as it is
easy to machine and is
readily available in the
needed sizes.
• The tank will be 24” x 16’’
x 16’’, which will hold
slightly less than 27
gallons worth of liquid.
Lung Tank Design
• The case will be made
watertight using silicone
gel, and then made more
structurally sound using
L-brackets along the side.
• 8 holes will be drilled
along the bottom of the
side panels for the multitube connectors
• A single hole on the top of
the case will allow liquid
to be pumped in to the
model.
Tank Wall Deformation Analysis
• ANSYS Workbench was
used to analyze wall
deflection due to
hydrostatic pressure
(P=ρgh).
• Original choice of 1/8” thick
acrylic resulted in 1.868”
outward deflection.
• Needed to find appropriate
wall thickness that would
not affect PIV results
1/8”
5/16”
Tank Wall Deformation Analysis
• Treated tank wall as a
simply supported beam
• Able to calculate deflection
and slope of deflection
(𝑠𝑙𝑜𝑝𝑒)
• Calculate angle between
laser and perpendicular
𝜃1 = tan−1 (𝜃𝑠𝑙𝑜𝑝𝑒 )
Tank Wall Deformation Analysis
• Used Snell’s Law to
calculate the angle of
the laser after it enters
the tank (θ2).
• We can then calculate
the error associated
with refraction using
the distance the lung is
from the wall.
θ2
Distance to model
Error
𝐸𝑟𝑟𝑜𝑟 = tan(𝜃2 )(distance)
Tank Wall Deformation Analysis
Error due
Panel
Max
Distance
Error due to
Max P (psi)
Max Slope
to
4
Thickness I (in )
Deflection
θ (deg) θ2 (deg) to Model
refraction
(q)
(Magnitude) 1
refraction
(in)
(approx)
(in)
(mm)
(in)
0.25
0.0208
1.0595
0.2441
0.0347
1.9885 1.3344
8
0.1863
4.7333
0.3125
0.0407
1.0595
0.1250
0.0178
1.0184 0.6835
8
0.0954
2.4240
0.4375
0.1117
1.0595
0.0455
0.0065
0.3712 0.2491
8
0.0348
0.8835
0.5
0.1667
1.0595
0.0305
0.0043
0.2487 0.1669
8
0.0233
0.5919
0.6875
0.4333
1.0595
0.0117
0.0017
0.0957 0.0642
8
0.0090
0.2277
0.9375
1.0986
1.0595
0.0046
0.0007
0.0377 0.0253
8
0.0035
0.0898
1
1.3333
1.0595
0.0038
0.0005
0.0311 0.0209
8
0.0029
0.0740
Tank Wall Deformation Analysis
For a 16”x24” acrylic panel, 7/16” thick
Reservoir Design
• Similar design to Lung
Tank
• 1/8” thick acrylic will
be fine since tank is not
used for PIV – only
0.17” deflection.
• 12”x12”x12” box
• Holes cut for
connection to pump
system
Omega Multi-tube Connectors
• Can handle 10 tubes per connector. Will allow
easy connection/disconnect when we switch out
models.
• Allows for thru-wall connection to simplify the
tank and tube interface.
Lung Holder
• Used to hold lung in
tank
• Put rubber between
holder and lung model
to ensure a tight and
secure fit
• Can rapid prototype in
clear Watershed XC
11122 for ~$300
Lung Holder Drawing
Labview – Data Acquisition
• NI-USB-6225, Screw
Terminated
▫ 80 Analog Input Ports
▫ Compatible with
Labview
▫ $1749
• This will output to the
Labview program
which will collect the
pressure data and
display it to the user.
Labview Code
• Not fully completed
▫ Need all
components before
testing and
construction can
occur.
Positioning System
• Need: Ability to take PIV pictures of all branches
and bifurcations
• XYZ Stages alone are not the answer
▫ Used for low travel, high resolution
▫ Very expensive for more than one
• Optics rods and clamps also too expensive &
precise
• Make it ourselves – 80/20
Design
• Essentially a square arch that
translates
• L-Handle brakes to keep it in
position
• Strong frame – no vibration
• Drop-in T-studs allow for
camera movement
• When combined with a
rotation allows for all angles
Result
• Contacted Bob Proscher at Ralph W. Earl Co.
• Developed a kit including all requested
machining
▫ Quote: $243.75
• Mount an optical stage (5 – 10 mm)
▫ $600 - $1,000
Index Matching Fluid
• Refractive index (RI) of fluid must match that of
the model.
▫ Model will be made using RedEye Veroclear
 n = 1.47
• Fluid used will be made from glycerin.
▫ 85% Glycerin, 15% Water
 n = 1.45
 While RI may not be matched exactly, the difference
is negligible.
Complete Test Setup
Reservoir
Positioning
System
Pump System
Lung Tank
Budgetary Overview
Subsystem
Cost
Tanks and Containment
$1207.46
Camera Positioning
$191.45
Pumping System
$2,597.91
Common Header
$266.62
Pressure Control and Measurement
$11,703.00
Total:
$15,966.44
Tanks and Containment
Part
Acrylic Sheet, 48"x24", 7/16" thick
Multitube Quick Coupling Set
Perforated framing, zinc-plated steel, 4ft each, pkg qty
12
Plain Steel Square Head Low Strength Bolt 5/16"-18
Thread, 1" Length, pkg. 25
18-8 SS Type A USS Flat Washer 5/16" Screw Size, 7/8"
OD, .06"-.11" Thick, pkg. 25
Plain Grade 8 Steel Hex Nut 5/16"-18 Thread Size, 1/2"
Width, 17/64" Height, pkg. 100
Steel Perforated Flat and Angle Framing Hardware: ZincPlated Steel Bolts W/Nuts & Washers
Zinc-Plated Steel Machine Screw Hex Nut 2-56 Thread
Size, 3/16" Width, 1/16" Height, pkg. 100
316 SS Pan Head Phillips Machine Screw 2-56 Thread,
1/2" Length, pkg. 50
Acrylic Sheet, 12"x12", 1/8" thick
All-Seal Sealant for Wet and Oily Surfaces, Clear, 10.2 oz
Standard Pipe Thread Sealant 1-1/4-Ounce Stick
Lung holder – rapid prototype in Watershed XC 11122
Price/Unit
Quantity
Cost
$132.39
$64.00
2
8
$264.78
$512.00
$8.78
1
$8.78
$5.59
2
$11.18
$5.60
2
$11.20
$4.28
1
$4.28
$7.42
1
$7.42
$1.21
1
$1.21
$6.18
$8.63
$18.27
$3.46
$300
1
6
1
3
1
Total:
$6.18
$51.78
$18.27
$10.38
$300
$1207.46
Camera Positioning
Part
1515 Profile
Drop-in T-studs
Single Flange Linear Bearing
Hidden Corner Connectors
L-handle Brake
Price/Unit Quantit Cost
y
$13.99
5
$69.95
$2.14
5
$10.70
$38.60
2
$77.20
$7.25
2
$14.50
$9.55
2
$19.10
Total:
$191.45
Pump System
Part
Price/Unit Quantity
H75M Gear Pump
Variable Frequency Drive
Motor
Tubing, 1'' ID
Tubing, 1/4'' ID, 3/8'' OD
Tubing, 1.5'' ID
Tube clamps, 1.5''
Tube clamps, 1''
Tube clamps, 3/8''
Tube to pipe, adapter, 1'', 1''
Pipe to tube, adapter, 1.5 , 1.5
Tube to pipe, adapter, 1/4'', 1/2''
Pipe to tube, adapter, 1/2, 1''
Valve, ball, 1.5''
Valve, ball, 1/2''
Valve, ball, 1''
Pipe, 1-1/2'', 4'', Male-Male
Reducer, 1'', 1 /2''
Coupling, 1 1/2''
Bulkhead, 1''
Cap, rigid plastic, tubing, 1/2''
Stopper, rubber, 1-1/2''
$2,319.00
1
$2,319.00
$2.45
$0.71
$4.22
5
25
10
10
10
20
1
5
10
10
1
1
1
2
1
2
2
100
12
$12.25
$17.75
$42.20
$7.22
$7.07
$5.67
$8.32
$8.73
$4.97
$8.48
$44.56
$9.84
$22.31
$6.36
$32.46
$12.74
$12.10
$5.50
$10.38
$2,597.91
$8.32
$44.56
$9.84
$22.31
$3.18
$32.46
$6.37
$6.05
$0.06
$0.87
Total:
Cost
Common Header
Part
Manifold, 10 outlets, 1 inlet
Fitting, wye, t-t-t, 1/4,1/4,1/4
Plug, tube, 1/4
Tubing, polyurethane, 1/4'', 1/8'', 100'
Price/Unit Quantit Cost
y
23.1
8
$184.80
4.91
1
$4.91
0.97
1
$0.97
24.7
1
$24.70
Total:
$266.62
Pressure Control and Measurement
Part
Minature Voltage Sensor
Needle Valve
Urethane Hose 50 ft
Hose Connectors
Polycarbonate sheet
Data Acquisition Device
Powered Breadboard
T splitter
Price/Unit Quantit Cost
y
$65.00
81 $5,265.00
$15.00
81 $1,215.00
$15.00
10
$150.00
$188.00
6 $1,128.00
$50.00
6
$300.00
$3,000.00
1 $3,000.00
$90.00
3
$270.00
$5.00
75
$375.00
Total: $11,703.00
Risk Assessment