Detailed Design Review - EDGE
Transcript of Detailed Design Review - EDGE
Agenda● Customer Requirements● Engineering
Requirements● System Overview● Controller● Motor
○ Driver○ Encoder○ Gearbox○ Motor Mount
● Valve○ Coupler
● Pressure Transducers● Piping and Fitting
○ Enclosure○ Manifold
● Bill of Materials● Engineering Drawings● Schedule
System Overview
● Components:○ Piping and Fittings○ Valves○ Pressure transducers and manifold○ Motor and motor mount○ System Controller
Chassis Specifications
● 4 Module Slots● 400 MHz Processor● Spartan-6 LX25 FPGA● 128 MB DRAM● 256 MB Nonvolatile Storage● 10/100 BASE-TX Ethernet Port● RS232 Serial Port
Analog Input Module Specifications● 4 Voltage Inputs● 100 kS/s per Channel● Channel Independent Analog to Digital
Converters● 16-bit Resolution● Built-In Signal Conditioning● Channel-to-Earth Double Isolation Barrier● Screw Terminal Connections
Digital Input Module Specifications● DSub Connector with Screw Terminal Adapter● 8 5V/TTL Sinking/Sourcing Bidirectional Digital
I/O Ports● 100 ns Propagation Delay● 9 MHz Switching Frequency using All 8 Ports as
Inputs● 500 ns Max Input Rise/Fall Time● ±30 V Max Overprotection on One Channel at a
Time
Digital Output Module Specifications
● 8 Digital Output Channels● 100 ns Propagation Delay● 6 to 30V, Current Sourcing Digital Outputs● Screw Terminal Connections● 750 mA/Channel
Motor
● Stepper motor chosen to control valve○ Requirements:
■ Sufficient torque■ Water resistant■ Precise control
Motor: Anaheim Automation NEMA 23Y65
● IP65 Rated○ Splash Proof and designed for humid environments
● 175 oz inches max output torque
Torque Requirements
● Based on valve opening torque○ 10000 PSI =
11 in-lb■ 176 oz-in
● Taken from manufacturer handbook
Gearbox
● 3:1 reducing gearbox added:○ Finer valve control
■ Standard motor step is 1.8 degrees● .6 degrees per step with gearbox● Approximately 4.1 psi/step
○ Increased side loading capability■ Potential side loading from motor-valve
misalignment wears motor bearings■ Gearbox bearings carry much higher load
○ Increased margin of safety on valve opening torque
Motor Mounting Assembly
● Requirements○ Support motor weight and torque loads○ Adjustable installation to accommodate variation in
plumbing/valve installation location○ Ability to transverse along valve stem during opening
and closing
Motor Mounting Assembly
● Minimum of ¾ inch freedom in all 3 directions
● Shaft coupler allows for 3 degrees shaft angle misalignment
Motor Mount: Stress Analysis● Analysis done in Ansys Workbench (V 14.5.7)● Moment applied to motor flange● Motor and gearbox weight applied to motor flange ● Fixed supports at linear slide mounts● Bolt pretensions at support plate
● Material: 6061-T6 aluminum plate○ 42 KSI Ultimate, 35 KSI Yield
Motor Mount Stress Analysis● Results:
○ Majority of part well over F.O.S. of 2 (17.5 KSI)○ Max stress exceeds F.O.S. of 2 allowable but is in
compression■ Mostly caused by bolt pretension and not
component loading
Encoder- BOM
Company Part Part Number Quantity Unit
Price Subtotal Tax & Shipping Total
Anaheim Automation
ENC-A3I Single-Ended High Resolution w/ Index Channel
ENC-A3I-0400-984-H-T
1 $96 $96 $96
Valve● Swagelok IPT series high
pressure needle valve○ 4-5 turns to open○ 10000 PSIG operating pressure○ CV value of 5.1
■ High flow, low pressure drop● Lowers minimum test enclosure
pressure
Valve
● Pressure drop across valve:○ a
■ Q (gpm), ΔP (psi)● 11.1 psi pressure drop
○ At 17 gpm max flow
Coupler Selection
● Flex Coupling - 3 degrees● Clamp on type - provides freedom in
mounting and adequate torque
Pressure Transducer Specs● NIST Certified● 0-5Vdc● Stainless Steel● Life of 10 million cycles● Accuracy
○ 10,000psi= +/- 0.25%○ 5,000psi and 1,000psi= +/-0.8%
● Response time of less than 1 millisecond● 5ft 3 conductor cable● 5 Point NIST traceable included
Pressure Transducer Sensitivity Calculations
● 0 - 10,000 psi Transducer○ 1 volt = 2000 psi○ Accuracy = ± 25 psi○ Step Voltage = 12.5 mV per 25 psi
● 0 - 5,000 psi Transducer○ 1 volt = 1000 psi○ Accuracy = ± 4 psi○ Step Voltage = 4mV per 4 psi
● 0 - 1,000 psi Transducer○ 1 volt = 200 psi○ Accuracy = ± 0.8 psi○ Step Voltage = 4mV per 0.8 psi
Pressure Transducer BOM
Omega10,000psi pressure
transducer w/ 5' cable PX309-10KG5V 1 $225.00 $225.00 $225
Omega5,000psi pressure transducer
w/ 5' cable PX309-5KG5V 1 $225.00 $225.00 $225
Omega1,000psi pressure transducer
w/ 5' cable PX309-1KG5V 1 $225.00 $225.00 $225
Company Part Part Number QuantityUnit Price Subtotal
Tax & Shipping Total
Piping and Fittings
● 1” XXH Black Pipe○ Working Pressure ~ 24,000
psi● Class 6000 Fittings
○ Equivalent to XXH piping○ x3 Elbows○ x3 Tees
Working Pressure Calculation
The maximum working pressures were found for various materials. The safety factor used is 2.5, determined by ASME Power Piping code B31.3.
Using the following equation:
Manifold
● Mounts 3 Pressure Transducers and 1 Digital Pressure Gauge
● 2 Shut-off Valves to Protect Low Pressure Transducers○ No valve needed for 10,000
psi Transducer
Manifold: Stress Analysis
● Analysis done in Ansys Workbench (V 14.5.7)
● 10000 PSI on all wetted surfaces● Blow-out loads on all threaded joints● Supports at 1” pipe joints
● Material: 7075-T6 aluminum○ 70 KSI Ultimate, 59 KSI Yield
Manifold: Stress Analysis● Results:
○ Majority of part well over F.O.S. of 2 (29.5 KSI)○ Max stress represents 1.27 F.O.S.
● Recommend development part in 7075 aluminum○ Ease of machining○ Cost
● Recommend production part in 15-5 PH stainless steel or equivalent strength stainless alloy○ Heat treated to ~100 KSI tensile yield or better
Enclosure: Overview
● Protect components from water spray and test part failure○ Vulnerable components include:
■ Motor■ Encoder■ Pressure Transducers