MSD P13453 Final Project Review Sean Deshaies (ME) Erin Sullivan (EE) Michael Gorevski (EE) Brandon...
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Transcript of MSD P13453 Final Project Review Sean Deshaies (ME) Erin Sullivan (EE) Michael Gorevski (EE) Brandon...
MSD P13453Final Project Review
Sean Deshaies (ME)Erin Sullivan (EE)
Michael Gorevski (EE)Brandon Niescier (ME)
Agenda
• Project Goals• Customer Needs• Design Summary– Wired System– Wireless System
• Testing• Expense Report• Project Status• Future Work• Lessons Learned
Project Goals
• Install accelerometers on the compressor– One on the flywheel hub– One on the bearing housing
• Find a solution to wirelessly transmit data from one of the accelerometers
• Data collected in LabVIEW or through standalone software
Customer Needs
Customer Need # Importance Description
CN1 9 Single axis accelerometer mounted to crankshaft (Rotates)CN2 9 Single axis accelerometer mounted inside housing (Stationary)CN4 9 Continuous sensor operationCN8 9 Reliability and accuracy of measurements
CN12 9 Must fit inside of compressorCN13 9 Must fit on shaftCN7 3 Robust design of wireless technology for harsh environmentCN9 3 Interface wth DAQCN3 3 Minimal user intervention CN6 3 Wireless transmission of signal
CN11 3 User manual/Important informationCN5 1 Low cost
CN10 1 Scalable to higher temperature (Internal environment)
Wireless Accelerometer Mounting Location
• CN13 references mounting on the shaft– Accelerometer was too tall for keyway
• Pugh analysis was done to evaluate potential solutions– New mounting location was found on flywheel
hub
Design Summary
• Wired Accelerometer:– PCB Swiveler is able to withstand the oil and
higher temperatures inside the compressor• Wireless Accelerometer:– PCB 660 Series is able to operate on the same low
voltage as the wireless module• Wireless Module:– TelosB module allows for low power, wireless
transmission capabilities
Wired System
Wireless System
Test Fixture
Testing
• Accelerometer verification– PCB Swiveler vs. B&K 4393– PCB 660 Series vs. B&K 4393
• Wireless transmission verification– TelosB module vs. function generator
Accelerometer Test Results
0 500 1000 1500 2000 2500 30000
0.2
0.4
0.6
0.8
1
1.2
1.4
-35
-30
-25
-20
-15
-10
-5
0
5
Transfer Function Magnitude and Phase (PCB 660/ B&K 4393)
Magnitude Phase
Frequency (Hz)
Mag
nitu
de (m
/s^2
/m/s
^2)
Phas
e (d
egre
es)
0 500 1000 1500 2000 2500 30000
0.2
0.4
0.6
0.8
1
1.2
1.4
-35
-30
-25
-20
-15
-10
-5
0
5
Transfer Function Magnitude and Phase (PCB Swiveler/ B&K
4393)
Magnitude Phase
Frequency (Hz)
Mag
nitu
de (m
/s^2
/m/s
^2)
Phas
e (d
egre
es)
Wireless Test Results
0 50 100 150 200 2500
0.5
1
1.5
2
2.5
Wireless vs. Function Generator (50Hz)
Wireless Signal Express Wireless with Scale Factor
Number of Samples
Volta
ge (V
olts
)
Wireless Test Results
Compressor Data
Wireless Data Wired Data
Accelerometer Data Comparison
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5-1.5
-1
-0.5
0
0.5
1
1.5
Wireless vs. Wired Acceleration Measurement
Wireless Wired
Time (sec)
Acce
lera
tion
(g)
Total Expenses
Team P13453 ExpensesOrder Number Vendor Order Description Total Cost
105-7615249-5268227 Amazon Supply Aluminum Bar and Angle $121.13 3017475-01 McMaster-Carr Steel Bar, Pillow Block Bearings $323.35
55953 Photocraft Encoder, Stub Shafts $208.16 3017475-01 McMaster-Carr Returned Bearings ($252.16)
4389 PowerGate Power Supply $60.93 374572 Bolt Depot Test Rig Hardware $7.24
4002194-01 McMaster-Carr Cable Gland $12.71 2500375331 Allied Electronics USB Extension cord and Enclosure $12.41
PL-121120002 Memsic Wireless Modules $362.00 48997576 Grainger Epoxy $17.60
N/A Anaheim Automation Motor $163.00 N/A McMaster-Carr Coupling $35.77
4547023-01 McMaster-Carr Screws $15.04 2500389198 Allied Electronics Enclosure and Switches $36.76
A233703 Futurlec Header Pins $6.50 N/A PCB Accelerometers and Signal Conditioner $798.30 N/A Lowe's Safety Guard Brackets $3.18 N/A Harbor Freight Hex Key Set and Rubber Mallet $8.98 N/A Jeff Wilczewski Wireless Module Programming $500.00
45448853 McMaster-Carr Helicoil Thread Repair Kit $77.31
Initial Budget: $5,000 Funds Remaining: $2,482
Project Status
• Accelerometers installed successfully– Wired accelerometer integrated into LabVIEW– Wireless accelerometer interfaces through a
standalone program• Data is reliably transmitted wirelessly
Future Work
• Sync the data between wired and wireless accelerometer
• Integrate the wireless accelerometer into LabVIEW
• Mount wireless accelerometer to bearing housing inside compressor
• Improvements to wireless enclosure
Lessons Learned
• There is no viable off-the-shelf wireless solution• Expert opinions are sometimes wrong• Be sure to include all necessary tolerances on
manufacturing drawings• Machinists have the ability to make or break the
project• Communication of customer needs could have
been improved• Need to anticipate the speed of bureaucracy
Acknowledgements
• Bill Nowak – Guide• Jeff Wilczewski – Programming wireless
modules• Rob Kraynik – Machining and installation
assistance• Dresser-Rand – Project sponsor• Markus Holzenkamp – Project assistance• Dr. Kolodziej – Faculty champion/customer
Thank YouP.S. – Bill you owe us all a beer