Transcript of P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test Rig Final Review May 13,...
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- P14453: Dresser-Rand Compressor Bearing Dynamic Similarity Test
Rig Final Review May 13, 2014Rochester Institute of
Technology1
- Slide 2
- Project Team May 13, 2014Rochester Institute of Technology2
Team MemberMajorRole Steve LucchesiMechanical EngineeringProject
Manager Shawn AveryMechanical EngineeringGood Vibrations Steve
KaiserMechanical EngineeringProject Engineer Josh PlumeauMechanical
EngineeringLead Engineer Luke TrapaniMechanical
EngineeringLubrication Engineer
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- Stakeholders May 13, 2014Rochester Institute of Technology3
RIT:Researchers: RIT: Industry Engineers: Dresser-Rand: Dr. Jason
Kolodziej Assistant Professor (Primary Customer) Dr. Stephen Boedo
Associate Professor (Subject Matter Expert) ? James Sorokes
Principal Engineer Financial Support Scott Delmotte Mgr. Project
Engineering Point of Contact MSDII Team 14453 Graduate/Masters
Students William Nowak (Xerox)
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- Final Design Review Agenda May 13, 2014Rochester Institute of
Technology4 MSD I Action Items Manufacturing Problem Tracking
Testing Results Conclusions
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- MSD I Action Items: Lubrication May 13, 2014Rochester Institute
of Technology5 Customer feedback indicated that more oil would be
required than could be supplied by the initial design A gear pump
was chosen for its ability to flow a large quantity of oil at high
pressure Pump is capable of 0-150 psi 1.5 gpm flow possible at 50
psi A pressure relief valve was included to protect the system for
overpressure Valve is capable of handling up to 170 psi Oil seals
were incorporated into the test block to contain outgoing oil All
components were strengthened in order to maintain a robust
design
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- MSD I Action Items: Load System May 13, 2014Rochester Institute
of Technology6 Due to budgetary constraints our customer requested
that we redesign the load system to be single axis-static load A
pivoting lever system was chosen due to its simplicity A 10:1 ratio
was utilized in order to fully load the bearing with only 200 lbs
of weights Loading was done from under the table to reduce the
impact on the table surface for later development The design
remains robust enough to adapt to full dynamic loading for
follow-on projects
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- MSD I Action Items: Test Bearing Housing May 13, 2014Rochester
Institute of Technology7 Conversations with our guide determined
that the three piece housing would be too complicated to
manufacture A one piece design was implemented Test bearing became
a press fit design Oil seals were pressed into the block to control
oil flow A single piece eliminated concerns about stack up issues
and provided for more accurate readings A one piece steel part is
more durable with no concern about structural failure
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- Manufacturing December 10, 2013Rochester Institute of
Technology8 Table Base Steel tube stock pre-ordered to length
Cleaning Welding prep Welded together in machine shop: THANK YOU
ROB! Painted black Table Test Surface Hole profiles water-jetted in
machine shop Water-jetted holes hand tapped Mated to table
base
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- Manufacturing October 5, 2013Rochester Institute of Technology9
Test Bearing Block Steel Block milled to size Surface ground to
drawing spec All bearing hole machining done in lathe: THANK YOU
JAN! Oil feed/return lines, load cell hole, drilled and tapped Test
bearing pressed in Test Shaft Machined to size in lathe (THANK YOU
ROB!) Ground to clearance spec
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- Manufacturing December 10, 2013Rochester Institute of
Technology10 Load System Pivot Pin Mounts Cut to size, ground to
spec Holes drilled and tapped Pivot & Load Pins Lever Arm Cut
to size, ground to spec Holes drilled and tapped Weight strap
Lubrication System Holes drilled and tapped in table base for
locating pump motor, gear pump, filter bracket Hoses cut to size
and crimped, various hose couplings Oil reservoir
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- Final Build Photos December 10, 2013Rochester Institute of
Technology11
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- Problem Tracking: May 13, 2014Rochester Institute of
Technology12 Test Surface machining/finishing: Table-top was too
large to machine without re-indexing Re-indexing could lead to
misalignment Table-top was machined on the Brinkman Lab water jet
Lubrication System Motor Mount: Multiple options were available
regarding pump motor mounting locations/methods After a PUGH
analysis it was decided to mount the pump to the lower table using
the four mounting holes on the motor
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- Problem Tracking: May 13, 2014Rochester Institute of
Technology13 Lubrication Reservoir Weld-up/Assembly: Welding thin
sheet metal with an arc welder is extremely difficult. Being bad at
arc welding only makes it worse The team worked with Rob in the
machine shop to properly weld the tank The tank was completed
enough to make it operational Bearing-Shaft Clearance: When pressed
into the test-block the internal bore diameter of the bearing
decreased, causing negative clearance between it and the shaft The
team worked with Rob to measure the bore and adjust the shaft
outside diameter to accommodate the change
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- Problem Tracking: December 10, 2013Rochester Institute of
Technology14 Hydraulic Hose Crimping: The machine shop did not have
the proper crimping tools for the hydraulic fittings and most
companies would only crimp the fittings of their specific
manufacturer After calling many local businesses Empire Radiator
Service on Dewey Ave. was the only company that would crimp our
generic fittings Motor/Motor-Controller Overloading: The total
amount of torque required to drive the shaft was greater than the
motor was rated for due to calculation discrepancies After a PUGH
analysis it was decided to use a belt drive to decrease the torque
load on the motor
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- Problem Tracking: December 10, 2013Rochester Institute of
Technology15 Motor-Controller Overloading: Constant overloading and
an aggressive settings setup lead to the first motor controller
being destroyed. John Wellin donated a larger motor controller for
the group to use A mount was fabricated to mount the controller to
the original motor mount holes in the table, eliminating the need
for further table modification 2005 2014 Rest In Peace
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- Lessons Learned December 10, 2013Rochester Institute of
Technology16 Project Management Work prioritization Milestones
Teamwork Effective Communication Balancing Schedules Work
delegation Accountability Complete Design Process System breakdown
Customer Needs Concept Generation/Selection System Subsystem
Detailed Manufacturability Ask questions Problem Tracking
On-the-fly problem solving, solution implementation Anticipate
Complications
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- Questions May 13, 2014Rochester Institute of Technology17
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- BACK-UP Slides May 13, 2014Rochester Institute of
Technology18