Detailed Design Review P13465 Water Table. February 8 th, 2013

Transcription

1 Detailed Design Review P13465 Water Table February 8 th, 2013 H E A R I T A N D F O R G E T I T, S E E I T A N D R E M E M B E R I T, D O I T A N D U N D E R S T A N D I T

2 Primary Customers: Ed Hanzlik John Wellin Faculty Guide: Gerald Garavuso Water Table MSD Team Team Members: John Harrington, Project Manager Andrew Nauss, Lead Engineer Timothy Jordan, Project Engineer Dan Abdeen, Project Engineer 2

3 Today s Agenda Overview (5 minutes, 1 Slide) Brief Project Description Intended System Model Design (45 minutes, 13 Slides) Main Capabilities System Components CAD System Design Assembly Plan System Operation Bill of Materials Feasibility Analysis, Prototyping, & Experimentation (35 minutes, 11 Slides) Overview of Systems Analyzed Feasibility Analysis for Major Components System Testing (10 minutes, 2 Slides) Testing Plan Updated Risk Assessment and What s Next? (15 minutes, 3 Slides) Updated Risk Assessment MSD II Phase Initial Plans Concluding Comments (15 minutes, 1 Slide) Questions/Comments/Concerns 3

4 Project Description Water Table Force straight flow over an object of some geometry to study fluid dynamic effects Primarily used for displaying concepts of: Streamlines Flow Separation Vortex Shedding Top down view Variable flow speeds To be used for educational use Assist in fulfilling the ME department s mission statement 4

5 Main System Capabilities Modular Transportable Variable test specimen geometry Adjustable angle-of-attack Variable flow from 1 to 12 in/s Adjustable flow height Adjustable nozzle section Laminar flow regime only Two main flow visualizers: Electrolysis Beads Ability to measure velocity through high speed camera and/or pulsing circuit Future adaptability for fluids other than water and different setups Will show concepts of flow separation, vortex shedding, and streamlines Possible potential for many other educational fluid dynamic purposes that the team is not responsible for demonstrating (concepts of energy balance, conservation of mass flow, electrolysis, Bernoulli equation, baffle design, nozzle design, head calculations, and many more) 5

6 Systems Design (View 1 of 2) 6 Footprint: Cart: 31 x 52 Water Table: 28 x 58 Test Specimen Nozzle Section Honeycomb Flow Straighteners Water Table Enclosure Baffle Reservoir Tank Flex Piping Drains PVC Piping Table Cart Ball Valve Piping Support Flowmeter

7 Systems Design (View 2 of 2) 7 Baffle Drains Piping Support Pull Handle Inlet Butterfly Control Valve Pulsing Circuit Enclosure Flex Tubing Pump Power Box/ Emergency Stop Button

8 Tank Assembly Procedure (Part 1 of 3) 8 Footprint of tank will be 28 x 58 Tank will be made of HDPE with 3/8 walls to ensure robustness Solvent welded joints manufactured by Curbell Plastics Tank will rest on a supplied table during operation The customer will be responsible for developing method of storage. One suggestion is to create mounting holes to hang on wall. Holes could be drilled for mounting on a wall

9 Tank Assembly Procedure (Part 2 of 3) 9 Step #1- Drill Holes Step #2- Add Magnet Strip Step #3- Add Nozzle Section Step #4- Add Flow Straighteners Step #5- Add Baffle Final Product

10 Tank Assembly Procedure (Part 3 of 3) Possible Adjustments needed for Baffle Design Baffle will initially not be permanently fixed to allow for modifications Feasibility calculations yielded max force on top plate of 5 lbf Baffle may need to be redesigned due to high pressure buildup Possible modifications include altering hole patterns/size, creating a horizontal baffle design, or adding a plate in front of flow straighteners to distribute flow better 10 Alternate Possible Design 2 Alternate Possible Design 1

11 Cart Assembly Procedure (Part 1 of 2) 11 Cart footprint will 31 x 52 Cart will be made from 2x4 wood boards. Qty: 6 2X4 board, 52 long Qty: 3 2X4 board, 31 long Deck screws will be used to secure each board. Cart will be wheeled on 4 casters.

12 Cart Assembly Procedure (Part 2 of 2) 12 Step #1 Build cart Step #2- Mount water tank Step #3- Mount pump Step #4- Attach power post/box Step #5- Mount support board Step #6- Attach handle

13 Piping Assembly Procedure (1 of 2) 13 All piping/fittings will be commercially bought Flowmeter will give rough idea of flow rate Pool flow meter GPM (±10%, ±15GPM) Assembled using PVC pipe primer/cement FlexPVC used for inlet/outlet of table and for inlet to pump PVC Unions used to disconnect table from pump/reservoir cart

14 Piping Assembly Procedure (2 of 2) Union Wall Fitting 14 Ball Valve Flow Meter Butterfly Valve (located before inlet to water table)

15 Test Specimens 15 Uses magnets to hold 2 Cylinder Flat Plate Contraction Section Bent out of metal, similar to nozzle Airfoil Cast using resin, MET department mold 10 3

16 Budget / BOM (Part 1/2- Mechanical)

17 Budget / BOM (Part 2/2- Electrical) *Projected budgeted for $2000 *Estimated total cost of project is totaled at $ *Conservative estimate for shipping costs 17

18 Feasibility Analysis and Experimentation Feasibility was performed on a wide range of items. Due to time constraints all of them will not be addressed in this presentation. Some of the feasibility analysis and experiments performed include: Pump calculations* Magnet calculations* Drain calculations (controlling flow)* Water supply calculations Electrolysis experimentation* Water table construction experiment Operating range analysis* Cart FEA analysis for strength Inlet flow force calculations Baffle design *Will be discussed in presentation 18

19 Pump Calculations (1 of 2) 19 Approach to Sizing Power: Step 1: Find flow rate 3in x 10in x 12in/s = 93.5 gpm Step 2: Find power to overcome 2.5ft of head at the flow (Power=Q*ΔP) Nominally ΔP=1.1psi Step 3: Calculate Major Head Losses Nominally ΔP=5.8psi Step 4: Compare pump head needed to pump power/efficiency and pump curves

20 Pump Calculations (2 of 2) Pump Performance Curve: 20 Throttled Desired Operating Point Unthrottled Operating Point

21 Drain/Flow Calculations Analyzed water table drain system as a circuit with no resistance (i.e. no pump or valves) No resistance yields an outlet flow rate of 500+ gpm Therefore, modeling the system with pump and valves creates resistance needed to meet flow specifications Drain resistance is negligible 21

22 Magnet Calculations Sidewalls and test specimen held in using At 1 ft/s, estimated force on walls ~1lbf side and 1/4lbf due to nozzle Assume μ=0.1, 4 magnets Pull force (normal force) required is ~2.5 lb Pull force is expected to be >10 lb per magnet 22

23 Electrolysis Experimentation (1 of 3) 23 ASME WATER TABLE MET WATER CHANNEL Flow over a plate w/ electrolysis

24 Electrolysis Experimentation (2 of 3) 24

25 Electrolysis Experimentation (3 of 3) 25 Pulsing circuit Pulses the electrodes if desired. Range of operation: Fully on through pulses of 5s off / 5s on

26 Depth (in) Operating Range of Table (Flow Rate) Flow Rate (gpm) fortest Section Width of 10 in Speed (in/s) *Water is the working fluid *Max Flow Rate 93.5 GPM *Typical operation would be at 3 inches depth = expected flow rates 26

27 Test Piece Characteristic Length (in) Operating Range of Table (Re Number) Reynolds Number Speed (in/s) E E+05 1E E+05 1E+05 1E E+05 1E+05 1E E+05 1E+05 1E+05 1E+05 = expected Re #s *Intended flow speed of 12 in/s maximum *Typical operation would be at a characteristic length of 2-5 inches 27

28 Depth (in) Operating Range of Table (Fr Number) Froude Number for Test Section Speed (in/s) *Froude number is the ratio between channel velocity and wave speed of the free surface *Fr>1 = supersonic flow analogy 28 = supersonic analogy = expected Fr #s

29 Testing Plan (1 of 2) 29

30 Testing Plan (2 of 2) 30 *Testing plan also includes sampling size (where applicable), data analysis required, and person responsible. [Not pictured in slides, but available on EDGE]

31 Risk Management Update (1 of 1) 31

32 Risk Management Update (2 of 2) 32

33 Initial MSD II Phase Plans 33 3 Week MSD II Plan: Tank Assembly Build Time: 3/4/13-3/8/13 (Week 1) Person Responsible: John Harrington Cart Assembly Build Time: 3/4/13-3/12/13 (Week 1 Beginning of Week 2) Person Responsible: Tim Jordan Electrical Components Build Time: 3/8/13-3/15/13 (End of Week 1 Week 2) Person Responsible: Dan Abdeen Piping Assembly Build Time: 3/13/13-3/21/13 (Mid-Week 2 Week 3) Person Responsible: Andrew Nauss Week 3 Customer Demonstration Future Targets: Testing/Debugging (Week 4 Week 7) Week 6 Customer Demonstration Week 9 Final Demonstration

34 Questions/Comments/Concerns 34 Thank you for attending our Detailed Design Review!

35 FEA Analysis of Cart (Backup Slide) 35