The objective of this project was to design a dynamic similarity test rig to replicate the operating conditions of the main crank bearing in the Dresser-Rand ESH-1 air compressor in the Mechanical Engineering machine shop including such characteristics as oil temperature and pressure, dimensional equivalences, dynamic load profiles, and shaft speed. This test rig will ultimately provide further research into journal bearing operation and serve as a means for journal bearing failure detection in the ESH-1 compressor.

The Dresser Rand ESH-1 air compressor utilizes a floating ring journal bearing as its main crank bearing. A floating ring journal bearing is unique in that it houses an intermediate ring between the shaft and sleeve housing, providing a means of reducing relative sliding speeds between the respective bearing surfaces and thus power loss. Group P13453 focused on health monitoring of the bearing within the compressor through vibration measurements and wireless technology. This rig takes the next step by completely isolating the journal bearing vibration characteristics from those of the compressor to provide more accurate bearing measurements which will be used for bearing health monitoring and failure detection research.

System Design: Detailed Design:

William Nowak Dr. Jason Kolodziej Scott Delmotte James Sorokes Dr. Stephen Boedo Dr. Mark Kempski Robert Kraynik Jan Maneti David Hathaway Mark Smith Klein Steel Rob Wilkie

COMPRESSOR BEARING SIMILARITY TEST RIG

P14453Shawn Avery

Team FacilitatorME

Steven KaiserProject Engineer

ME

Steven LucchesiTeam Lead

ME

Josh PlumeauLead Engineer

ME

Luke TrapaniLubrication Engineer

ME

Background: Mission Statement:

Moving Forward: Special Thanks:

Load Actuation System

DDR CAD Rig Design

System design consisted of understanding system architecture in order to identify critical subsystems. The critical subsystems for the test rig were determined to be the load application system, test bearing, structural support system, control system, lubrication system, drivetrain system, and power system, in that order of importance. This subsystem identification was key for determining system componentry. During this phase, two axis load actuation was still a primary concern. Desired considerations and outcomes of the system design phase were:

• Customer Needs & Specifications

• Risk Assessment

• High Level Engineering Analysis

• Critical Subsystem Identification

• Concept Development/Selection

Whereas system design was focused on what the test rig consists of, detailed design takes these components and determines what the final structure will look like. The most significant issue to be addressed from the subsystem design was redesign of the load application system. For cost and time constraints, and single axis, mechanical lever loading system was chosen to replicate to max load exhibited within the ESH-1 compressor. Desired considerations and outcomes of the detailed design phase were:

• MSD II Budget/Time Constraints

• Customer Needs & Specifications

• Detailed Engineering Analysis

• Complete Design

• CAD Part & Drawing Package

• Complete Load Actuation Redesign

• MSD II Readiness & Build Plan

The future of this test rig will consist primarily of the design and implementation of a two-axis dynamic loading system for future iteration MSD projects. The current test rig has been designed in a way that implementing such a system will be possible without any major modifications. Other additions will include additional sensor implementation for bearing vibrations, and journal to sleeve clearance, as well as updates and improvements to the current system.

Testing:Testing was done to prove system functionality. Testing consisted of:• Shaft drive motor & motor controller • Shaft Encoder Feedback & Accuracy• Test Bearing Assembly Load Cell Feedback and Accuracy• Shaft Run-out• Lubrication System

• Leaks• Temperature• Flow Rate• Pressure

Piezoelectric Actuators

Conclusions:The MSD II phase of this project involved comprehensive problem solving and sub-system redesign using the six step problem solving process shown above. Major design changes included modifying the orientation of the bearing lubrication supply/return hoses, as well as switching out direct drive for a belt and pulley drive system to better utilize the DC motor’s available torque. The end result was a complete test rig capable of replicating journal bearing operating conditions under static loading with the ability to adapt to a dynamic loading system in the future. Exiting this project, the P14453 team not only is knowledgeable on all aspects of the design and manufacturing process through both MSD I & II, but has also gained a comprehensive understanding of journal bearing design and operation.

Manufacturing:As this was a large-scale first iteration project, a considerable amount of manufacturing took place during the build phase. The work was distributed among team members with assistance from faculty technicians in the RIT machine shop.

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SYSTEM PHOTO HERE