Group 14671Expansion Joint Active Monitoring

Team MembersJoe Savino

Mechanical Engineer

Adam RemickElectrical Engineer

Andrew Hintermeier Mechanical Engineer

Risk AnalysisID Risk Item Effect Cause Like

lihood

Severity

Importance

Action to Minimize Risk

1 Battery Life DAQ Dies before Expected

Too much Power Consumption/Not Enough Batteries

2 2 4 Add Extra Batteries to Ensure Lifespan

2 Memory Storage Loses Most Recent Readings

Too Large of a Sample Size/Not Enough Memory

1 2 2 Add Ability to Add Extra uSD Cards/Increase Size of SD Card

3 Programming Time Unfinished Project Complexity/Scope of the Project

2 1 2 Using the Arduino Micro-controller to ease programming difficulties

4 Decrease in Max PSI on EJ

Reduced EJ Specs Sensor Mounting 2 2 4 Early Testing/Insert Design/Flange Mounting

5 Sensor failure Failure to Read New Data

Misunderstood Spec Sheet

1 2 2 Re-read Data Sheet and Call Suppliers with Questions

6 Mounting Failure Interference with EJ/Failure to Read Data

Bending/Poor Dimension Selection

1 2 2 Early Testing of Design

7 Electronics Box Failure

Electronics Ruined Unexpected External Factors

1 2 2 Full Understanding of Environmental Conditions

Full Assembly

Mounting Mounting Plates

Threaded inserts

Infrared Sensor

String Potentiometer

Axial DisplacementInfrared String Potentiometer

Ultrasonic

SpecsInfared String PotentiometerAccuracy: +/- 0.04 inPrice: $305Vin:Vout:

Accuracy: +/- 0.025 inPrice: $247Vin:Vout:

TemperatureInsert mounted ProbePrice:Vin:Vout:

Flange ProbePrice:Vin:Vout:

PressureRegular sensor with heat dissipation stemPrice:Vin:Vout:

Microprocessor Arduino Due

Arm Processor 3.3V Logic 3.3V and 5V Regulator on Board 54 Digital I/O’s 12 Analog Inputs (Can have up

to 12 sensor inputs) 4 UARTS 84MHz Clock Speed $50

Goals: Input Sensor Data Store sensor Data on SD Card Control a LCD Display Control LED ‘Out of Range’

Lights

Adafruit Micro-SD Card ReaderUses 1 UART Port

and 2 Extra I/O PortsMade to Work with

Arduino Board$15

LCD Display4 Lines of 20

Characters Each+5 V input from

Arduino DueUses 11 Digital I/O

PinsWill display the max

temperature, max displacement and max pressure

$25

LED OutputPass fail system:

If the EJ has experienced out of range data, LED’s turn on and stay on until uC is reset

One for each sensorUses One I/O port

per LED

Block Diagram

Micro

Pressure Sensor

Temperature Sensor

Displacement

Sensor

Pressure LED

Temperature LED

Displacement

LED

LCD Display

Micro-SD Card

D0-D7

Enable

R/W

D-Out

D-In

DataVccDataVccDataVcc

Clk

Bill of MaterialsItem Quantity Price (Total)

Arduino Due Test Board 1 $50.00

LCD Display 1 $25.00

Micro-SD Card Reader 1 $15.00Transistors 3 $5.00LED's 3 $5.00

uSD Card (32GB) 1 $22.00

Breadboard 1 $5.00

Random Electronics X $10.00

String Potetiometer 1 $199.00

Ultrasound Ping 1 $30.00

Thermocouple 2 $76.00

Pressure transducer 1 $350.001" bar stock 1 Ft $5.00

1/8"x6" steel plate 2 Ft $75.00

1/16" - 1/8" adapter 2 $8.00

1/8" to 1/4" adapter 1 $4.00

1/8" SS Piping 18" $20.00

Misc Harware x $40.00Total = $944.00

ScheduleT R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S

Detailed Design/Gate Review Order sensors Create insert for testing Have insert tested at Garlock Redesigned Inserts Retest Inserts Create code for DAQ Finalize drawings Determine where/how to create parts Testing Create Code for Data Analysis Create Code or Display

Questions?

Schedule Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10Week 11Week 12Week 13Week 14Week 15

T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S T R S

Create Problem Definition

Create Customer Needs

Create Engineering Specs

Create Interview Questions

Interview Customer/Garlock Visit

Create Functional Decomposition

Concept Development

Create Pugh Charts

Risk Assesment

Benchmarking

Sensor Research

Basic ANSYS Model

Engineering Analysis (1st Order)

Engineering Analysis (2nd Order)

Sensor Selection

Test Plans Created

Custom Parts Designed

Order Sensors

Presentations

Problem Definition Presentation

System Design Review

Subsystem Design Review

Fourth Presentation

DDR Presentation

Back Up Slide

Engineering AnalysisSimulated an EJ under compression and

tension in ANSYS WorkbenchDisplacement of ±1 inchUsed to determine where stress

concentrations will beHelps to determine sensor placement

Compression

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-InsertPullout force in ABS plastic is 900lbfAssume fluid pressure of 2000psi (higher

than burst pressure of EJ)For .25 diameter thread, OD is .391

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

Instructions/Example CodeSD Card:

http://learn.adafruit.com/adafruit-micro-sd-breakout-board-card-tutorial/wiring

Analog Input to SD Cardhttp://arduino.cc/en/Tutorial/Datalogger

Displaying to a LCD Displayhttp://arduino.cc/en/Tutorial/LiquidCrystalSeria

l

Connection Diagram to LED Screen