SPX Data Acquisition
PRELIMINARY DETAILED
DESIGN REVIEW
John Dong
David Haller
Adam Johnson
Thomas Klaben
Luke Kranz
Presentation Agenda
• Phase Objective Statement
• Lab Setup
• Schematics
•
•
•
•
Telemetry Wiring Diagram
Strain Gauge Wiring Diagram
Overall System
Transmitter Case
• Flow Charts
•
•
Operations Manual Expectations
Assembly of Telemetry Case Wiring
Installation – Strain Gauges
• Proof of Concepts/Feasibility
•
•
•
•
(5 Minutes)
(5 Minutes)
•
•
(5 Minutes)
Gauge Accuracy
Case Waterproofing
• Project Management
•
•
•
•
•
(10 Minutes)
Gauge Mounting
Gauge Removal
Wire Waterproofing
Transmission Through Case
• Test Plans
Data
Energy
• Procedures
•
•
•
(2 Minutes)
(3 Minutes)
(10 Minutes)
(10 Minutes)
Engineering Requirements
Bill Of Materials
New Purchases
Risk Assessment
Detailed Design Project Plan
• Questions
(10 Minutes)
Phase Objective Statement
Overall Objective:
◦ To provide SPX with a system capable of measuring strain on an operating impeller and then
wirelessly transmitting the data to a third party user interface. The system is to be validated
on a small-scale setup and then transferred to a full-scale setup.
Goals for this Phase:
◦
◦
◦
◦
◦
◦
Set up lab space for small-scale testing
Compile and update all project and design documents
Trace designs back to customer and engineering requirements
Continue to purchase components and write test plans to validate specs
Continue feasibility studies on subsystem designs
Revise designs based on new findings
Lab Setup
Location
◦ Institute Hall Room 2180
Supplies
◦ 34” diameter stainless steel
tank (134 gallon capacity)
◦ 1.25 hp motor
◦ 1000W variable frequency
power supply
◦ R&D impeller for smallscale mixing
◦ Gauges
◦ Wires
◦ Soldering iron and solder
Schematic
Telemetry Wiring Diagram
Schematic
Strain Gauge Wiring Diagram
Wire tables
Schematic
Overall System
• Changes to transmitter case
• Removed wire tube
• Spiral wires up shaft to case
Schematic
Transmitter Case
Schematic
Transmitter Case
Flow Chart
Data
Flow Chart
Energy
• Details the path of energy
flow throughout the Wireless
Strain Measurement system.
Procedure
Operation Manual Expectations
Pending Documentation:
• Node Commander Software Setup & Installation
• Base Station Configuration
• Data Logging Procedure
Procedure
Installation – Strain Gauge
Surface Preparation
◦ Solvent degreasing
◦ Surface abrading
◦ Application of layout lines
◦ Surface conditioning
Gauge Bonding and Waterproofing
◦ Handling and gauge preparation
◦ Gauge placement using cellophane tape
◦ Bonding with quick dry adhesive (super glue)
◦ Waterproofing with epoxy
Images courtesy of http://www.egr.unlv.edu/
Proof of Concept/Feasibility
Gauge Mounting
Question: Will we be able to mount gauges onto impellers? Will they stay mounted once underwater?
Method of Test: Consult subject matter expert on best adhesive and waterproofing agent. Use
suggestions and practice mounting on scrap metal.
Subject Matter Expert: Rob Kraynick.
Suggestions: Thin layer of super glue for adhesive, layer of epoxy for waterproofing. Gauges will only be
usable once, and should have ribbon connections to avoid soldering damage.
Proof of Concept:
Conclusions/Learnings:
◦ We must practice cleanly attaching gauges and
using the least amount of epoxy/adhesive as
possible.
◦ Gauge lines will be needed to guarantee accurate
placement.
◦ Underwater adhesion testing will begin once we fill
stainless steel tank in lab space.
Procedure
Assembly of Telemetry Case Wiring
Procedure
Strain Gauge Wiring
Proof of Concept/Feasibility
Gauge Removal
Preliminary Test:
1.
2.
3.
4.
5.
6.
Affix gauge to test sample. Place known load on sample, creating a known strain.
Remove gauge.
Affix gauge to test sample in same location. Re-test with the same known load.
If second strain reading is within 2% of initial reading, gauge can be reused.
Repeat until gauge measures a strain that is greater than 2% of the initial strain.
Record number of times the gauge was removed and the process used to remove the gauge.
Proof of Concept/Feasibility
Gauge Removal
Revised Test:
1.
2.
3.
4.
Affix gauge to test sample. Place known load on sample.
Use calculations to determine if the gauge is placed accurately on the test sample (see:
Gauge Accuracy Feasibility).
Remove gauge. Record method of removal and any visual defects created by the removal of
the strain gauge.
If any visible gouges are created while removing the gauge, the tested process fails and will
be revised.
Proof of Concept/Feasibility
Wire Waterproofing
Feasibility Results:
◦ Liquid Electrical Tape Insulates Underwater Wires
◦ Heat Shrink Wrap Insulates Wires underwater
Deltas:
◦ Care must be taken with the wires once coated in electrical tape to not bend to extremes
◦ When using heat shrink wrap make sure no stray wires are sticking through
◦ Use a Real heat gun
◦ Use multiple Waterproofing methods where possible
Proof of Concept/Feasibility
Transmission Through Case
Concept:
Based off of cell phone Research we should be able to transmit through plastic
Phones only need antenna lines to transmit through metal.
Make a test plan to test for range reduction
Test Plans
Gauge Accuracy/Calibration
Clamp test piece to perform tests.
Affix strain gauges a measured distance from the free end of the test piece.
Apply a load on the end of the clamped test piece (cantilevered beam model)
Calculate stress and strain as follows:
Determine moment using singularity functions:
q(x) = P<x>-1
M(x) = P<x>1 = P(x)
Where x is the distance from the free end of the test sample
Stress Calculations:
σ = -MC/I
Where C is one half of the beam thickness and I = (1/12)bh3
Strain Calculations:
ε = σ/E = -MC/EI
Where E is Young’s Modulus
If the calculations and the actual experiment yield results within 5%, this shows our gauge placement
and calibrations to be accurate.
Test Plans
Case Waterproofing
• Spec S12: Submerged in water at depth of 1 meter for 1 hour with less than 0.1 grams of leakage
• Test plan:
1. Take enough sponges to fill case
2. Weigh sponges
3. Place sponges in case
4. Submerge case in water at depth of 1 meter for 1 hour
5. Take sponges out of case
6. Weigh sponges
7. See if difference in mass is less than 0.1 grams
Project Management
Engineering Requirements
Project Management
Bill of Materials
Project Management
New Purchases
Item: Telemetry System
Item: Semi-Conductor Gauges
Item: Ribbon Gauges
Brand: Lord Microstrain
Brand: Micron Instruments
Brand: Omega
Price: $2000.00
Price: $22.11 each
Price: $13.60 each
Delivery: November 27, 2015
Delivery: November 16, 2015
Delivery: November 10, 2015
Budget Update: $2453.50/$5000 = 49.07% budget spent
Project Management
Risk Assessment
Project Management
Detailed Design Project Plan
Efficiency
Schematics- 25%
1.
Finished Schematics, realized no room for ground wire in plug
2.
Changed to add new plugs
3.
Found wiring error while doing wire tables, so recompleted tables and second Schematic
Cad Efficiency 33%
1.
Improvements- Fellow member found latch CAD file which saved time
2.
Needing two plugs in case, needed to redo case design
3.
Changed case design to include antenna inside for less water intrusion points
Questions