P11251: Side Entry Agitator Test Stand

REVISION A: For Reading/Review ONLY

(No Formal Presentation Given)

MSD I: System Level Design Review

https://edge.rit.edu/content/P11251/public/Home

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

• Mission Statement

• Project Description

• Review of Customer Needs/Specs

• Review of Pairwise, Engineering Metrics, HoQ, Pareto

• Concept Sub-System Breakdown

• Initial Concept Generation & Selection

• Physical Structure

• Shaft/Motor/Impeller Integration

• Sealing System

• Measurement System w/ Hardware Integration

• Preliminary Risk Assessment/FMEA

• Project Schedule Review (GANTT)

• Questions/Comments/Concerns

Estimated Time

12:35 - 12:40

12:40 - 12:45

12:45 - 1:50

12:50 - 12:55

12:55 - 1:00

1:00 - 1:40

1:00 - 1:10

1:10 - 1:20

1:20 - 1:30

1:30 - 1:40

1:40 - 1:50

1:50 - 1:55

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

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

Physical Structure: PUGH Matrix

Horizontal Adjustment

Physical Structure: PUGH Matrix

Depth Adjustment

Physical Structure: PUGH Matrix

Vertical Angle Adjustment

Physical Structure: PUGH Matrix

Horizontal Angle Adjustment

Physical Structure: PUGH Matrix

System Design

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 & impellerCoupler: Transmits power between the motor output shaft & shaftMotor: Provides Mechanical Energy to the systemImpeller: “Work” horse of the system: agitates the fluid to be mixed

ShaftImpeller Coupling Motor

Tank Wall

Fluid Agitation

SMI: System Diagram w/ Impellers

•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.

6”Ø: 2”

10Ø: 3”

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 DiscGear

• 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.

Thru-Bolt

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 4,5,6,7

Concept 3Concept 2

Sealing System: Initial Concepts

Concept 10

Concept 11

Concept 8 Concept 9

Concept 12

Concept 13

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

Measurement Technology:Strain Gauge; Donut, Pancake, Canister, or Column Load Cell; or Accelerometer.

Location of Measurement Devices:On the motor mount, beneath the coupler, or on the end of the shaft.

Motor Mount Design:Parallel Plates, Lever Arms, Shear Support Pins, Load Cell Cocoon, or Parallel Plates with Pointed Pivot.

Pictures from www.lcmsystems.com.

T=(L1/L2)F Pins resist shear effects.

Picture from www.circuitstoday.com

Picture from www.einstein.standford.edu

Motor

Inner and outer support boxes.

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.

Side View Isometric ViewPicture From www.lcmsystems.com

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

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