ryan_palmer mechanical design competition
TRANSCRIPT
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Company Sponsor Pacific States Cast Iron Pipe Company
Candidate:Ryan Palmer
CAPSTONE PROJECT
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Overview Background Information Customer Needs Concept Generation Concept Selection Testing Results Design
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Pacific States Cast Iron Pipe Company
Provo, Utah
• Everyday PSCIPCO produces on average 1500 pipes
• The pipes are about 18’ long and are between 6” and 36” in diameter
• The pipes are cast using the centrifugal method
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Problem Statistically, 1 out of 1500 pipes produced a day experiences cracking.
Cracking occurs between casting and annealing stages.
The cracks are of various sizes and are all through cracks.
Yearly, Pacific States loses on average $130,000 in claims due to damages.
Hairline crack in pipe
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Project Objective StatementResearch a suitable technology to detect cracks in cast iron pipe and design a crack-detection system for a cast iron pipe production line that will cost less than $20,000 by March 30th, 2012.
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Challenges Surface temperature of the pipe (700° F)
Testing speed (4 pipes per minute)
Pipe length and varying diameter (18’ length, 6”-30” diameter)
Environment (noise, humidity, heat)
Surface roughness of the pipe
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Concept Selection and ScreeningCrack Detection
Photo Diodes X-rays Pressurized Gas
with Thermal Imaging
Underwater
Submersion
Spraying with water
Pressurized Fluid
Increase Pressure
Thermal Imaging
Improving the seal
Electrical/Magnetism
Magnetic Leak
Detection
Eddie Currents
Electrical Resistanc
e
Resonance/Vibrations
Pinging the Pipe
Ultrasonic
Vibration After Shear Wave
Optical Methods
High-resolution Camera
Thermal Imaging
Visual Inspectio
n
Shining a Bright Light
Unrealistic Ideas
Probes Measurin
g Deflectio
n and Strain
Waterfall
Reduce Pipe
Length to 3"
More Ideas on Separate
Paper
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Scoring Based on Testing
Thermal Imaging w/ Pres. Gas Vibration Eddy Current
RatingWeighted
Score RatingWeighted
Score RatingWeighted
Score RatingWeighted
Score RatingWeighted
ScoreSensitivity to surface roughness 20% 5 1 4 0.8 3 0.6 1 0.2 3 0.6Compatibility to op. Environment 20% 3 0.6 2 0.4 3 0.6 2 0.4 1 0.2Adapts to varying diameters 20% 4 0.8 1 0.2 3 0.6 3 0.6 4 0.8Speed of detecting 20% 4 0.8 3 0.6 3 0.6 2 0.4 4 0.8
Reliability/Accuracy - TOTAL 80% 4 3.2 2.5 2 3 2.4 2 1.6 3 2.4Cost (initial) 10% 2 0.2 3 0.3 3 0.3 2 0.2 4 0.4Cost (operating) 10% 3 0.3 3 0.3 3 0.3 3 0.3 4 0.4
Total ScoreRank
Continue?
Vision System Photo Diode
2.10 3.205 2
3.003
2.601 4
Selection Criteria Weight
3.70
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Thermal Imaging w/ pressurized air
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Testing ResultsGood Pipe
Before Pressurization After 10 Seconds
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Testing Results
Before Pressurization After 10 Seconds
Cracked Pipe
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Eddy Current
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Testing Results
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Photo Diode Detection System
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Test Results
Oscilloscope detecting light 500 W work lamp on pipe
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Failed Tests Automated Visual Detection System (Keyence)
Rough surface finish
Vibrations Detection SystemInconsistency of resonance frequencies between pipes
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Failed Tests Electro Magnetic Acoustic Transducer
Too expensive and too slow
X-Ray DetectionToo expensive and too slow
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Implementation of Eddy Current
Strategy• Rotate pipe• Translate probes across the surface 1/4”
distance• Adjust to pipe diameter• Use equipment familiar to PSCIPCO• Use as many ready to order parts as possible
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Lifting SystemRack and Pinions
End Rollers
Suspension System
Rectangle Tube Beam
Design
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Lifting System
Adjustable Mounting Bracket
Pneumatic Cylinder
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End Rollers
Steel Roller
End Rollers
Igus Rail and Carriage
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Suspension System
Eddy Current SensorSuspension System
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Suspension SystemCopper Tubing for
cooling system
Suspension Spring
Phenolic Plate
Steel Roller
Eddy Current Sensor
Hinge
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Drawings
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Questions