System Design ReviewProject Team 13453

Brandon NiescierErin Sullivan

Mike GorevskiSean Deshaies

Agenda

• Team and Project Introduction (5 min)• Customer Needs and Specifications (5 min)• Concept Generation (5 min)• Concept Selection (10 min)• Risk Assessment (5 min)• Project Plan (5 min)• Q&A

Team and Project MembersTEAM:Project Manager: Sean Deshaies (ME)Project Engineers: Brandon Niescier (ME)

Erin Sullivan (EE)Mike Gorevski (EE)

CUSTOMER:Dr. Jason Kolodziej, ME Department, RIT

SUPPORT:Project Guide: Bill Nowak (Xerox)Faculty Champion: Dr. Jason Kolodziej (RIT)Sponsors: Scott Delmotte (D-R)

Project Description and Objective

The purpose of this project is to monitor the health of the main crank bearing on RIT’s

Dresser-Rand ESH-1 compressor. This will be done through recording vibration measurements

via wireless sensor technology.

Previous Work

• Team 12453 installed a range of sensors on the compressor and expanded the capabilities of the data acquisition (DAQ) system

Customer Needs

Customer Need # Importance Description

CN1 9 Single axis accelerometer mounted to crankshaft (Rotates)CN2 9 2 Single axis accelerometers mounted inside housing (Stationary)CN4 9 Continuous sensor operationCN7 9 Robust design of wireless technology for harsh environmentCN8 9 Reliability and accuracy of measurementsCN9 9 Interface with DAQ

CN12 9 Must fit inside of compressorCN13 9 Must fit on shaftCN3 3 Minimal user intervention CN6 3 Wireless transmission of signalCN11 3 User manual/Important informationCN5 1 Low cost

CN10 1 Scalable to higher temperature (Internal environment)

Customer Specifications

Engr. Spec. # Importance Source Specification (description) Unit of

MeasureMarginal

Value Ideal Value Comments/Status

ES1 9 CN1/CN2 Acceleration Range (g) g   50  

ES2 9 CN1/CN2 Acceleration Accuracy (ft/sec^2) ft/sec^2      

ES4 9 CN6 Range of Wireless Transmission Distance (ft) ft      

ES8 9 CN7 Operational Maximum Temperature (degrees F) F 200    

ES10 9 CN12 Size of Sensor and Wireless Technology (in) in      

ES3 3 CN6 Data Transfer Rates (Hz) Hz   10-15k  

ES5 3 CN6 Range of Wireless Transmission Frequency (Hz) Hz      

ES6 3 CN3 User Intervention Rate (Interventions/time) inv/t      

ES7 3 CN3 Maintenance Intervention Rate (Interventions/time) inv/t      

ES9 3 Implied Power Consumption of System (W) W      

ES11 3 CN3/CN4 Lifespan of Technology (hours) hours      

ES12 1 CN5 Total Cost ($) $ 5000 0 Sensor Cost $500-$1500

House of Quality

Importance Rating

Size of Sensor and Wireless Technology (in)

Acceleration Accuracy (ft/sec^2)

Operational Maximum Temperature (degrees F)

Total Cost ($)

Power Consumption of System (W)

Range of Wireless Transmission Frequency (Hz)

Acceleration Range (g)

Range of Wireless Transmission Distance (ft)

Lifespan of Technology (hours)

User Intervention Rate (Interventions/time)

Data Transfer Rates (Hz)

Maintenance Intervention Rate (Interventions/time)

2 Single axis accelerometers mounted inside housing (Stationary) 9 9 9 9 3 9 0 9 3 3 1 1 1Continuous sensor operation 9 0 0 1 1 3 9 0 1 3 3 0 3Interface with DAQ 9 0 0 0 3 0 3 0 3 0 0 3 0Must fit inside of compressor 9 9 0 0 0 0 0 0 0 0 0 0 0Must fit on shaft 9 9 3 1 1 0 0 0 0 0 1 0 1Reliability and accuracy of measurements 9 1 9 1 9 1 9 3 3 1 0 3 0Robust design of wireless technology for harsh environment 9 3 1 9 9 3 3 0 1 3 1 1 1Single axis accelerometer mounted to crank shaft (Rotates) 9 9 9 9 3 9 0 9 3 3 3 1 3Minimal user intervention 3 0 0 1 0 3 0 0 0 3 9 0 3User manual/Important information 3 0 0 1 0 0 0 0 0 3 3 0 3Wireless transmission of analog signal 3 1 1 1 3 3 9 1 9 1 1 9 1Low cost 1 3 3 3 9 3 3 3 3 3 0 3 0Scalable to higher temperature and pressure (Internal environment) 1 1 3 3 1 1 0 3 0 1 0 0 0

Raw score 367 288 285 280 247 246 198 156 142 120 111 102

Relative % 14% 11% 11% 11% 10% 10% 8% 6% 6% 5% 4% 4%

Importance Rank 5 4 4 4 3 3 2 2 2 1 1 1

Combined Percentages 14% 26% 37% 48% 58% 67% 75% 81% 87% 92% 96% 100%

Relationships:9 = Strong3 = Moderate1 = Weak0 or Blank = No Relationship

Importance Rating:1 = Low Importance3 = Moderate Importance9 = High Importance

Pareto Chart

Functional Decomposition

Monitor Bearing Health

Measure Vibration

Sense Vibration Use Accelerometer Mount Device

Mount on Shaft

Mount on HousingTransmit Signal

from Stationary Source

Transmit Signal from Rotational

Source

Recieve Signal

Condition Signal

Log Data Use Lab View Output Spead Sheet

Measure Temperature

Observe Noise

Observe Wear

Concept Development

Mount the Sensor Inside

Housing

Drill and Tap Hole

Glue It

Affix with Wax

Weld It

Mount the Sensor on the

Shaft

Drill and Tap Hole

Glue It

Affix with Wax

Weld It

Transmit Signal from Stationary

Source

Use Induction

Use Bluetooth

Use Wifi

Use Proprietary RF

Network

Use Dissimilar Data Channel

Use Zigbee

Transmit Signal From Rotational

Source

Use Slip Ring Around Shaft

Use Bluetooth

Use Wifi

Use Proprietary RF

Network

Use Zigbee

Recieve Signal

Use Induction

Use Bluetooth

Use Wifi

Use Proprietary RF

Network

Use Zigbee

Condition Signal

Attenuate Noise• Design Filter

Amplify Signal• Design Amplifier

Output Data

Output to Notepad

Output to Excel

Pugh Chart for Mounting Sensor Inside Housing

CriteriaConcepts

Drill an

d Tap Hole

Glue It Affix With

Wax

Weld It

DATUM

Secure Fit - - +

Resist Maximum Operating Temperature - - +

Oil Resistant S - S

Vibration Resistant - - +

Ease of Removal - + -

Clarity of Vibration Measurement - + S

Ease of Installation + + -

Life Expectancy - - S

Ease of Maintenance - - -

1 3 3

7 6 3

1 0 3

Total +

Total -

Total S

• Drill and Tap is chosen method

• Glue and Wax clearly eliminated

• Weld eliminated due to difficultly with maintenance

Placement of Sensor Inside Housing

Pugh Chart for Mounting Sensor on Shaft

•Drill and Tap is the chosen method

•Glue and Wax are clearly inferior options

•Welding is roughly on par • However, welding is

not practical

Criteria Concepts

Drill an

d Tap Hole

Glue It

Affix With

Wax

Weld It

Secure Fit (Relative to Rotational Force) - - +Oil Resistant S - SVibration Resistant - - +Clarity of Vibration Measurment - + SEase of Removal - + -Ease of Installation + + -Life Expectancy - - SEase of Maintenance - - -

1 3 26 5 31 0 3

Total +Total -Total S

Rotational Mounting Location

Pugh Chart for Transmitting Signal From a Stationary Source

Criteria

Conc

epts

Use Pr

opriet

ary R

F Netw

ork

Use In

ducti

onUse

Bluetooth

Use W

iFi

Use D

issim

ilar D

ata Cha

nnel

Use Zi

gbee

Loss of Signal Through Housing S S S S S

- - - - S

- - - - S

S S S S S

- - - - S

S S S + S

S - - S S

+ - - + S

1 0 0 2 0

3 5 5 3 0

4 3 3 3 8

Loss of Signal Through Housing

Power Consumption

Complexity of Implementation

Total +

Potential for Interferance in Environment

Cost of Implementation

Continuity of Signal

Ease of Maintance

Life Expectancy

Total -

Total S

•Proprietary RF Network was chosen method

•The customer has requested a wired sensor to be implemented as well to verify data

•Based on the simplicity of our sensor network

Pugh Chart for Transmitting a Signal From a Rotational Source

CriteriaConce

pts

Use Pr

opriet

ary R

F Netw

ork

Use In

ducti

onUse

Bluetooth

Use W

iFi

Use Sl

ip Ring Meth

od

Use Zi

gbee

Power Required - S S + S

- - - - S

S S S + S

- - - - S

S S S S S

- S S - S

- S S - S

0 0 0 2 0

5 2 2 4 0

2 5 5 1 7

Power Required

Simplicity of Technology

Potential for Interferance in Environment

Cost of Implementation

Total S

Continuity of Signal

Ease of Maintance

Life Expectancy

Total +

Total -

•Proprietary RF Network was chosen method

•Based on the simplicity of our sensor network

• Option 1: Commercial Off The Shelf

• Option 2: Develop In-House with PCB Mounted Accelerometer

• Option 3: Develop In-House with Commercial Accelerometer

Option 3 was chosen due to expert reccommedation

Integrated Acceleromet

erTransmitter

Accelerometer

Microcontroller/

Transmitter

System Block Diagram

Integrated Acceleromet

er

Microcontroller/

Transmitter

Risk Assessment

Risk # Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner

R1 Damage of Sensor Sensor transmits Inaccurate or No Data and Requires Increased User

InterferenceEnvironment - Oil and

Temperature 7 9 63 Properly Spec Components Sean

R2 Noise in the Wireless Signal Poor Data Quality Surrounding Environment 9 5 45 Use Filters Mike

R3 Trip Hazard for Wires Fall Injuries and Damage to the System Cables and wires in walk ways 5 7 35 Route wires away from

walkways Brandon

R4 Wireless Signal Cannot Penetrate Housing Data Not Received 1 in Cast Iron Housing with

Wireless Technology 3 9 27 Research and Test Wireless Ability Erin

R5 Insufficient Battery Life Increased User Intervention Power Consumption Too High 5 5 25Calculate and Minimize Power Composition and Consider Battery Choice

Mike

R6 Compressor is Not Operational Cannot Validate Solutions Other Parties Use the

Compressor 3 5 15 Create Test Rig Sean

Risk Assessment (cont.)

Risk # Risk Item Effect Cause Likelihood Severity Importance Action to Mitigate Owner

R7 Accelerometer Falls Off- Inside Housing

Damage to Accelerometer and to the Compressor Improperly Mounted 1 9 9 Ensure Proper Installation

Method Brandon

R8Damage to

Compressor During Install

Broken Compressor and Project Failure Improper Installation 1 9 9 Thoroughly Plan Installation

with Input From D-R Brandon

R9 Sensors Break On Installation Need to Buy New Sensors Improper Installation 1 7 7 Read the Product Manual Sean

R10 Injury While Machining Parts Team Member Hurt Disregard to Safety Precautions 1 7 7 Proper Training in Use of

Machine Operation Mech Es

R11 Accelerometer Fails to Satisfy Needs Data is Not Measured Correctly Uncertainty in Operating

Conditions 1 5 5 Communicate with Manufacturers Erin

R12 Accelerometer Falls Off- Outside Housing Damage to Accelerometer Improperly Mounted 1 5 5 Ensure Proper Installation

Method Brandon

R13 Shaft is Unbalanced Induced Vibrations in System Weight of Technology Mounted on Shaft 1 1 1

Do Calculations and if Necessary Apply Counter Weights to Balance Shaft

Sean

R14Wireless Signal

Affected By Shaft Rotation

Data is Not Transmitted Correctly Doppler Effect 1 1 1 Consult Experts in Wireless Transmission Erin

Test Rig

• In order to validate the wireless signal transmission on the rotating shaft, a model test facility will be constructed

• 1:1 scale for shaft diameter and rotational speed

• Bearing configuration will not be identical to actual compressor for the sake of simplicity

Test Rig Model

Power Supply

MotorEncoder

Coupling

Gantt Chart Through MSD IWeek 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10

Task Name S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S

Define Project

Develop Code of Ethics

Define Customer Needs

Define Specifications

House of Quality

Functional Decomposition

Concept Development

Select Team Roles

Gather Info From Experts

Pugh Charts

Risk Assessment

Create 1 Page Summary

Develop System Layout

Model Test Rig

Create Presentation for System Design Review

Revise Concepts Based on Feedback

Design Test Rig

Complete Vibration Analysis Calculate Force Required to Keep Sensor Mounted on Shaft

Develop Concepts for Detailed Design

Select Detailed Design Concepts

Create a Bill of Materials

Choose Mounting Locations

Create Schematic Drawings

Create Presentation for Detailed Design Review

Change Design Based on Feedback

Order Parts

Prepare for MSD II

Create Schedule for MSD II

Questions