P11251: Side Entry Agitator Test Stand

1. P11251: Side Entry Agitator Test Stand https://edge.rit.edu/content/P11251/public/Home MSD I: System Level Design Review REVISION A: For Reading/Review ONLY (No Formal Presentation Given)

2. Project Team/Attendees Project Sponsor : Richard O. Kehn - "ROK" Senior Technologist - Mixing SPX Flow Technology MSD I, Team Guide: William J. Nowak Principal Engineer, BGO/XIG/XRCW/OSL/Media & Mechatronic Systems Xerox Corporation Team P11251: Kurt Lutz: P.M./(Measurement System w/ Integration) Dennis Beatty: (Fluid-Tight Sealing Structure) Joseph Bunjevac: (Physical Structure w/ Adjustability) Daniel Geiyer: (Measurement System w/ Integration) Gregory McCarthy: Scribe/(Motor/Shaft/Coupling Integration)

3. Meeting Agenda Estimated Time 12:35 - 12:40 12:40 - 12:45 • 12:45 - 1:50 • 12:50 - 12:55 • 12:55 - 1:00 • 1:00 - 1:40 • 1:00 - 1:10 • 1:10 - 1:20 • 1:20 - 1:30 • 1:30 - 1:40 • 1:40 - 1:50 • 1:50 - 1:55 • 1:55 - 2:00 • Mission Statement • Project Description • Review of Customer Needs/Specs • Review of Pairwise, Engineering Metrics, HoQ, Pareto • Concept Sub-System Breakdown • Initial Concept Generation & Selection • Physical Structure • Shaft/Motor/Impeller Integration • Sealing System • Measurement System w/ Hardware Integration • Preliminary Risk Assessment/FMEA • Project Schedule Review (GANTT) • Questions/Comments/Concerns

4. Mission Statement Mission Statement: To create a side entry agitator test stand that allows the user to measure and calculate axial and tangential components of fluid forces, torque, and impeller speed on the motor, impeller, and shaft, incorporating a wide range of adjustable parameters.

5. Project Description • Shaft protrudes through the side wall of the tank • very large, under floor tanks where little headroom is available • less costly than top entry mixers • requires less motor torque to agitate the fluid • three to five times the amount of power as a top entry mixer • Rely heavily on impeller selection • different diameters, physical sizes and blade profiles • Previously developed top entry test-rig • they currently have no way to benchmark these same impellers for side entry agitation • Create a test-rig that allows reliable measurement • through a range of adjustability (Impellers/Speeds/etc.) • similar concepts to the top entry test rig • different array of: bending moments, torque and fluid forces • Very beneficial to our customer • benchmark existing and future impeller designs for side entry applications.

6. Customer Requirements Four Most Important Customer Needs: • Fluid Tight Seal • Calibration Incorporation • Tangential Fluid Forces • Fluid Thrust Force

7. Pairwise Comparison

8. Pairwise Comparison GraphicalRepresentation of Pairwise Comparison

9. Engineering Metrics

10. House of Quality

11. Pareto Analysis of Eng. Metrics

12. Pareto Analysis of Eng. Metrics Power Law Distribution By designing for only 40% of the Engineering Metrics, We’ll gain 65% of the advantages of designing for all the Engineering Metrics Top (5) Most Important Engineering Metrics • Tangential Force Measurement • Thrust Force Measurement • Shaft Rotational Speed • Torque Measurement • Ease of Calibration • Time of Calibration

13. Concept Sub-System Breakdown

14. Physical Structure Sub-System Stand Adjustability • Vertical and horizontal adjustment • Depth into tank • Angle left and right • Angle up and down

15. Physical Structure: Concept Drawings

16. Physical Structure: PUGH Matrix Height Adjustment

17. Physical Structure: PUGH Matrix Horizontal Adjustment

18. Physical Structure: PUGH Matrix Depth Adjustment

19. Physical Structure: PUGH Matrix Vertical Angle Adjustment

20. Physical Structure: PUGH Matrix Horizontal Angle Adjustment

21. Physical Structure: PUGH Matrix System Design

22. Physical Structure: Concept Selection Key Advantages • Removes need for tilt plate • Reduces potential issue with structure height • No limit to step increments on any axis • Possibility for fully automated positioning via stepper motors

23. Shaft, Motor, & Impeller Integration Sub-System Explanation of this sub-system & components: Shaft: Transmits torque & angular velocity via the motor & impeller Coupler: Transmits power between the motor output shaft & shaft Motor: Provides Mechanical Energy to the system Impeller: “Work” horse of the system: agitates the fluid to be mixed Fluid Agitation Impeller Shaft Coupling Motor Tank Wall

24. SMI: System Diagram w/ Impellers 6”Ø: 2” 10Ø: 3” • Given Impeller Dia.: 4.5 – 10” • Off Wall Distance: TYP. 0.5D • <0.4D, Flow Drops Off • >0.5D, Minimal Additional Flow, Adds Cost for Minimal flow benefit • MATL: 316 S.S.

25. SMI: Shaft Design Selection Shaft Length, (From Tank Wall) = APROX. 2.25 – 5”

26. SMI: Shaft Design Selection PUGH • Best Choice: Solid, Continuously Long Shaft

27. SMI: Shaft Design Prelim. Equations • Static Cantilever Beam Analysis • Mod-Goodman Shaft Analysis • Natural Frequency Ck

28. SMI: Shaft to Shaft Coupling Set Screw Thru-Bolt Gear Disc • All must have high torsional strength, for accurate fluid force & thrust measurement • Minimize parallel mis-alignment (RIGID) for accurate fluid force & thrust measurement • Provide a secure connection between the (2) elements • Long lasting and minimal maintenance/overhaul required Manuf: LoveJoy Req’s: • 1) Required Max Torque 2) Motor Speed/HP Req. 3) Shaft/Motor Shaft Dia.

29. SMI: Shaft Coupling PUGH • Best Choice: Thru Bolt or Set Screw • Thru Bolt for Added Rigidity & Resistance to Torsion

30. SMI: Impeller/Shaft Connection Based on given ID of provided impellers, (3) conditions could exist: • Shaft Dia. < Impeller Dia. - need for a spacing collar • Shaft Dia. > Impeller Dia. - need for a reducer 3) Impeller has threaded spacer that screws onto end of shaft (Similar to 2)

31. SMI: Impeller/Shaft Connection PUGH • Best Choice: Spacing Collar • Method currently being used by industry • OR • Direct connect to shaft, if Shaft OD=Impeller ID

32. SMI: Motor Selection • DC or AC Motor • Variable Drive (per Measurement & Integration) • Highly dependent on “Physical Stand” • Package Size/Weight/Mounting Options • Capable of reaching 1100 RPM under load, with greatest thrust/torque producing impeller • Spec’d based upon required shaft size • Consider Side-Loading Effect on Motor Bearings/Life • NEMA Rating for environment/safety

33. Sealing System: Initial Concepts Concept 1 Concept 3 Concept 2 Concept 4,5,6,7

34. Sealing System: Initial Concepts Concept 10 Concept 11 Concept 12 Concept 13 Concept 8 Concept 9

35. Sealing System: PUGH

36. Sealing System: Final Concept Critical Benefits: • Allows Adjustability • Less parasitic to measured forces • Does not alter tank geometry • Very low leak rate

37. Axial and Tangential Fluid Force Measurement Concept Generation Measurement Technology: Strain Gauge; Donut, Pancake, Canister, or Column Load Cell; or Accelerometer. Location of Measurement Devices: On the motor mount, beneath the coupler, or on the end of the shaft. Motor Mount Design: Parallel Plates, Lever Arms, Shear Support Pins, Load Cell Cocoon, or Parallel Plates with Pointed Pivot. Pictures from www.lcmsystems.com. Picture from www.circuitstoday.com Picture from www.einstein.standford.edu Motor T=(L1/L2)F Pins resist shear effects. Inner and outer support boxes.

38. Axial and Tangential Fluid Force Measurement Concept Evaluation

39. Axial and Tangential Fluid Force Measurement Concept Selection Three Most Critical Criteria: • Resists Affects of Shear • Measuring Sensitivity • Appropriate Time for Setup Low Profile, Tension & Compression Load Cell Mounted to Parallel Plates with Shear Pins optional depending on supporting calculations. Picture From www.lcmsystems.com Side View Isometric View

40. Torque and RPM Measurement Subsystem Slip Ring: • Electrical connection through a rotating assembly • Low speed limitations • Ring wear and dust brushes impede signal transfer • Requires routine maintenance for cleaning

41. Torque and RPM Measurement Subsystem Rotary Transformer: • Tolerates high speeds • Non-contact • More accurate • Requires sophisticated signal condition instrumentation • Less tolerant to extraneous loading conditions (bending moments and thrust forces)

42. Torque and RPM Measurement Subsystem Digital Telemetry: • Software driven allowing changes on the fly • High resolution, sensitivity, and accuracy • More immune to vibration problems • Smaller, lighter, and more compact

43. Torque and RPM Measurement Subsystem Torque Transducer: • Utilizes a system of strain gauges (Wheatstone Bridge) • Uses slip rings or rotary transformers to power and transfer strain gauge data

44. Torque and RPM Measurement Subsystem Torque from Motor Constants: • Ideal for direct drive systems • Only requires measurement of motor current

45. Torque and RPM Measurement Subsystem Critical Criteria • Measurement accuracy and sensitivity • Ease of implementation • Small package size • Allow for multiple shaft diameters • Ease of maintenance

46. Final Integrated Concept Generation

47. Final Integrated Concept Selection • Physical Stand • Tangential & Axial Force Measurement • Shaft, Motor & Impeller Integration • Torque & RPM Measurement

48. Final Integrated Concept Selection • Physical Stand • Sealing System

49. Preliminary Risk Assessment/FMEA https://edge.rit.edu/content/P11251/public/Design%20Documentation

50. Preliminary Risk Assessment/FMEA Key Risk Items • Full range of adjustability • Seal Effects measurement instrumentation & readings • Sensitivity of Measurement Systems • Successful Integration of Sub-Systems • Orientation affects measurements