Team Members Joe Savino Mechanical Engineer Adam Remick
Electrical Engineer Andrew Hintermeier Mechanical Engineer
Slide 3
Expansion Joints Bolted between pipes Made of Rubber, Fabric
and Metals Diameters of 2 to 130 Factors that contribute to
failure: Axial Displacement Wear Pressure/Temperature
Slide 4
Benchmarking No system in the market Difficult to measure
composite/rubber degradation Multiple reasons for degradation
Current method is regular preventative maintenance Visual
Inspection Qualitative data no quantitative data
Slide 5
Our Goal Deliverables Sensor package for EJs 4in and larger
Collect and Store data Measure axial displacement, pressure and
temperature Stretch Goals: Mountable on any type of EJ Measure
difference in vibration across EJ Integrate with previous software
groups package
Slide 6
Customer Requirements Customer Rqmt. # ImportanceDescription
CR11Monitor Temperature, Pressure, Displacement CR21Withstand
working environment CR31Easy data access CR42Compatible with
existing hardware CR51Alterations must not significantly affect the
strength of the EJ CR61Fit on the EJ CR71Capture data for 3-6
months
Slide 7
Engineering Requirements rqmt. #ImportanceSource Engr.
Requirement (metric)Unit of Measure Marginal Value Ideal Value
S15CR1Measure Pressure PSI 11 S25CR1Measure Temperature F 400450
S35CR1Measure Axial Displacement in 24 S45CR2/CR5Temperature cycles
to Fail cycles500750 S55CR2/CR5Pressure cycles to fail
cycles10001500 S65CR2/CR5Mechanical cycles to fail cycles30004500
S72CR6Small Size in24 S84CR4Sensors connect to old system Binary11
S93CR6Easily Mountable number of steps81 S103CR3Analog Votage
outputBinary11 S115CR7Battery LifeDays90180 S125CR7Data
StorageDays90180
Slide 8
Functional Decomposition Detect EJ Failure Sense EJs Current
state Sense Localized Defect Sense General Wear Process Data
Collect Data Determine Dangerous Conditions
Slide 9
Actively Monitoring of Sensor Data Active monitoring on EJ
mount: Real time measurements of pressure, temperature, etc, for
warning about exceeding limitations of EJ Could be based off time
(ex: temperature over limits for 1 sec may be ok, but 10 sec is
not) LED or other signal visible to passersby to show error
Difficult to reset In addition to data capture
Slide 10
Event Triggered Monitoring If the EJ is subjected to a harmful
environment, start collecting data Faster sample rate Collect for a
smaller period of time Show warning LED Would be used to gather a
smaller amount of data then send to Garlock for analysis
Slide 11
Block Diagram of Electrical System Temperature Sensor 1
MicroProcessorLED DisplayPressure SensorDAQ Device Memory Storage
Displacement Sensor MicroProcessor
Slide 12
Data Storage Requirements Assuming: Rate of 1 sample/second 16
bits/sample Required 3 to 6 months of data 6 months would take
240MB Easily obtainable
Concept Development Measure Pressure Measure Temperature
Measure Axial Displacement Mount sensors to EJ Diaphragm (strain)
sensor Thermocouple (Grounded) UltrasoundBuilt into EJ Diaphragm
(capacitance) sensor Thermocouple (ungrounded) Laser sensorGlued on
outside Diaphragm (piezoelectric) sensor Thermocouple (Exposed)
Linear Potentiometer Zip Ties LVDTBracket Infrared Metal insert
String Potentiometer
Slide 15
Axial Displacement Linear Potentiometer/LVDT Water/Environment
Accelerometer eliminated due to effects from vibration Ultrasound
was picked for measuring wear, worried about interference
Slide 16
Axial Displacement Ultrasonic Laser
Slide 17
Axial Displacement Infrared String Potentiometer
Slide 18
Displacement LVDT Linear Potentiometer Accuracy : High Water
proof, shock and impact ressistant Price : $495 Accuracy: +/-0.0001
in Vibration/impact Price: $395
Slide 19
Displacement Laser Utrasonic Accuracy: Diffracts too easily
Durability: IP54 not dust resistant, water resistant Price: $377
Accuracy: Heat/wind Durability: Splash/shock/impact Price:
$250
Slide 20
Displacement Infared String Potentiometer Accuracy:+/- 0.04 in
Durability: IP67 Dust protected, Water proof Price: $305 Accuracy:
+/- 0.025 in Durability: Water Proof Impact/shock resistant Price:
$247
Slide 21
Pugh Chart for Axial Displacement
Slide 22
Temperature Measurement Thermocouple Exposed Benefits
Previously tested successfully Fits between layers within EJ
Difficulties Calculating temperature difference between inner layer
of EJ and fluid
Slide 23
Temperature Grounded Faster Response time, Vulnerable to noise
Ungrounded Slower Response, Reduced Noise
Slide 24
Pugh Chart for Temperature
Slide 25
Pressure Regular sensor with heat dissipation stem $350-$500
Simple non insulated straight pipe High Temperature sensor High
Price Custom made
Slide 26
Mounting Options Spacer addition Potentially one per side
Allows access to fluid without altering EJ Use with Pressure Sensor
and potentially vibration sensor Outside Mount Used with
displacement and thickness sensor Inside Mount Used with
Thermocouple Already been tested by previous iteration
Slide 27
Mounting Black RTV With nut Mounting Plate Threaded
inserts
Slide 28
Engineering Analysis Simulated an EJ under compression and
tension in ANSYS Workbench Displacement of 1 inch Used to determine
where stress concentrations will be Helps to determine sensor
placement
Slide 29
Compression
Slide 30
Tension
Slide 31
Engineering Analysis Avoid areas in the middle of EJ and areas
right below or above flanges Embed sensors in between these areas
Minimize risk of EJ leaking after sensors are embedded
Slide 32
Engineering Analysis-Insert
Slide 33
Temperature Isolation of Pressure sensor May not be able to
find a pressure sensor that can withstand the temperature EJ does
Can use a tube protruding from EJ to dissipate heat A stainless
steel tube would need to extend at least 6 in out for our
applications
Slide 34
Schedule Week 1Week 2Week 3Week 4Week 5Week 6Week 7Week 8Week 9
Week 10 Week 11 Week 12 Week 13 Week 14 Week 15
TRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRSTRS Create Problem
Definition Create Customer Needs Create Engineering Specs Create
Interview Questions Interview Customer/Garlock Visit Create
Functional Decomposition Concept Development Create Pugh Charts
Risk Assesment Benchmarking Sensor Research Basic ANSYS Model
Engineering Analysis (1st Order) Engineering Analysis (2nd Order)
Sensor Selection Test Plans Created Custom Parts Designed Order
Sensors Presentations Problem Definition Presentation System Design
Review Subsystem Design Review Fourth Presentation DDR
Presentation
Slide 35
Questions?
Slide 36
Back Up Slide
Slide 37
Risk Analysis IDRisk ItemEffectCause Likelihood Severity
Importance Action to Minimize Risk 1 Weaken EJ Doesnt past test
cycles Poor design implementation 339 Consult Garlock design
Engineers 2Sensors fail early Does not measure failure criteria
Sensors not rated for EJ requirements133 Pick sensors with high
safety factor 3Scope too large Not able to accomplish all
requirements More goals than team is capable of224Discussed with
customer 4Parts ordered too late Not enough time to build and
testLate deign choices133 Identify and order long lead time parts
early in design process 5Poor team work ethic Do not complete work
on time Poor communication/motivati on122 Bonding activities/high
communication 6Not sensing local failure Failure to measure failure
criteriaInsufficient research339 Research rubber failure
degradation thoroughly 7Mounting failure Ease of mounting/cycle
failure/ doesnt measure failurePoor construction236Consult Garlock
Engineers