Group 14671

Group 14671Expansion Joint Active MonitoringTeam MembersJoe SavinoMechanical Engineer

Adam RemickElectrical Engineer

Andrew Hintermeier Mechanical Engineer

Expansion Joints

Bolted between pipesMade of Rubber, Fabric and MetalsDiameters of 2 to 130Factors that contribute to failure:Axial DisplacementWearPressure/Temperature

BenchmarkingNo system in the marketDifficult to measure composite/rubber degradationMultiple reasons for degradationCurrent method is regular preventative maintenanceVisual InspectionQualitative data no quantitative data

Our GoalDeliverablesSensor package for EJs 4in and largerCollect and Store dataMeasure axial displacement, pressure and temperatureStretch Goals:Mountable on any type of EJMeasure difference in vibration across EJIntegrate with previous software groups packageCustomer RequirementsCustomer Rqmt. #ImportanceDescriptionCR11Monitor Temperature, Pressure, DisplacementCR21Withstand working environment CR31Easy data accessCR42Compatible with existing hardwareCR51Alterations must not significantly affect the strength of the EJCR61Fit on the EJCR71Capture data for 3-6 monthsEngineering Requirementsrqmt. #ImportanceSource Engr. Requirement (metric)Unit of MeasureMarginal ValueIdeal ValueS15CR1Measure PressurePSI11S25CR1Measure TemperatureF400450S35CR1Measure Axial Displacementin24S45CR2/CR5Temperature cycles to Failcycles500750S55CR2/CR5Pressure cycles to failcycles10001500S65CR2/CR5Mechanical cycles to failcycles30004500S72CR6Small Size in24S84CR4Sensors connect to old systemBinary11S93CR6Easily Mountablenumber of steps81S103CR3Analog Votage outputBinary11S115CR7Battery Life Days90180S125CR7Data Storage Days90180Functional DecompositionActively Monitoring of Sensor DataActive monitoring on EJ mount:Real time measurements of pressure, temperature, etc, for warning about exceeding limitations of EJCould be based off time (ex: temperature over limits for 1 sec may be ok, but 10 sec is not)LED or other signal visible to passersby to show errorDifficult to resetIn addition to data captureEvent Triggered MonitoringIf the EJ is subjected to a harmful environment, start collecting dataFaster sample rateCollect for a smaller period of timeShow warning LEDWould be used to gather a smaller amount of data then send to Garlock for analysis

Block Diagram of Electrical SystemData Storage RequirementsAssuming:Rate of 1 sample/second16 bits/sampleRequired 3 to 6 months of data6 months would take 240MBEasily obtainable

MicroProcessorTemperature SensorPressure SensorDisplacement SensorReset ButtonPre-processingPre-processingPre-processingMicroProcessorI/O 1I/O 2I/O 3I/O 4LED CircuitLED CircuitLED CircuitI/O 5I/O 6I/O 7Concept DevelopmentMeasure PressureMeasure TemperatureMeasure Axial DisplacementMount sensors to EJDiaphragm (strain) sensorThermocouple(Grounded)UltrasoundBuilt into EJDiaphragm (capacitance) sensorThermocouple(ungrounded)Laser sensorGlued on outsideDiaphragm (piezoelectric) sensorThermocouple(Exposed)Linear Potentiometer

Zip TiesLVDTBracketInfraredMetal insertString PotentiometerAxial DisplacementLinear Potentiometer/LVDTWater/Environment

Accelerometer eliminated due to effects from vibrationUltrasound was picked for measuring wear, worried about interference

15Axial DisplacementUltrasonicLaser

Axial DisplacementInfraredString Potentiometer

DisplacementLVDTLinear Potentiometer

Accuracy : High

Water proof, shock and impact ressistant

Price : $495

Accuracy: +/-0.0001 in

Vibration/impact

Price: $395

DisplacementLaserUtrasonicAccuracy: Diffracts too easily

Durability: IP54 not dust resistant, water resistant

Price: $377

Accuracy: Heat/wind

Durability: Splash/shock/impact

Price: $250

DisplacementInfaredString PotentiometerAccuracy:+/- 0.04 in

Durability: IP67 Dust protected, Water proof

Price: $305

Accuracy: +/- 0.025 in

Durability: Water ProofImpact/shock resistant

Price: $247

Pugh Chart for Axial Displacement

Temperature Measurement

Thermocouple ExposedBenefitsPreviously tested successfullyFits between layers within EJDifficultiesCalculating temperature difference between inner layer of EJ and fluidTemperatureGrounded Faster Response time, Vulnerable to noise

Ungrounded Slower Response, Reduced Noise

Pugh Chart for Temperature

PressureRegular sensor with heat dissipation stem$350-$500

Simple non insulated straight pipeHigh Temperature sensorHigh Price

Custom madeMounting OptionsSpacer additionPotentially one per sideAllows access to fluid without altering EJUse with Pressure Sensor and potentially vibration sensorOutside MountUsed with displacement and thickness sensorInside MountUsed with ThermocoupleAlready been tested by previous iteration

Mounting Black RTVWith nut

Mounting Plate

Threaded inserts

Engineering AnalysisSimulated an EJ under compression and tension in ANSYS WorkbenchDisplacement of 1 inchUsed to determine where stress concentrations will beHelps to determine sensor placementCompression

Tension

Engineering AnalysisAvoid areas in the middle of EJ and areas right below or above flangesEmbed sensors in between these areasMinimize risk of EJ leaking after sensors are embedded

Engineering Analysis-Insert

Temperature Isolation of Pressure sensorMay not be able to find a pressure sensor that can withstand the temperature EJ doesCan use a tube protruding from EJ to dissipate heatA stainless steel tube would need to extend at least 6 in out for our applications

ScheduleWeek 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9Week 10Week 11Week 12Week 13Week 14Week 15TRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSCreate Problem DefinitionCreate Customer NeedsCreate Engineering SpecsCreate Interview QuestionsInterview Customer/Garlock VisitCreate Functional Decomposition Concept DevelopmentCreate Pugh ChartsRisk AssesmentBenchmarkingSensor Research Basic ANSYS ModelEngineering Analysis (1st Order)Engineering Analysis (2nd Order)Sensor SelectionTest Plans CreatedCustom Parts DesignedOrder SensorsPresentationsProblem Definition PresentationSystem Design ReviewSubsystem Design ReviewFourth PresentationDDR PresentationQuestions?Back Up Slide

Risk AnalysisIDRisk ItemEffectCauseLikelihoodSeverityImportanceAction to Minimize Risk1Weaken EJDoesnt past test cyclesPoor design implementation339Consult Garlock design Engineers2Sensors fail earlyDoes not measure failure criteriaSensors not rated for EJ requirements133Pick sensors with high safety factor3Scope too largeNot able to accomplish all requirementsMore goals than team is capable of224Discussed with customer4Parts ordered too lateNot enough time to build and testLate deign choices133Identify and order long lead time parts early in design process5Poor team work ethicDo not complete work on timePoor communication/motivation122Bonding activities/high communication6Not sensing local failureFailure to measure failure criteriaInsufficient research339Research rubber failure degradation thoroughly7Mounting failureEase of mounting/cycle failure/ doesnt measure failurePoor construction236Consult Garlock Engineers