Detailed Design Review P13465 Water Table February 8 th , 2013 H E - PowerPoint PPT Presentation

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 ”

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

Today’s Agenda 3 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

Project Description – Water Table 4  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

Main System Capabilities 5  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)

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

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

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

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

Tank Assembly Procedure (Part 3 of 3) 10 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 Alternate Possible Design 2 Alternate Possible Design 1

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.

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 Step #5- Mount support Step #6- Attach handle post/box board

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- 40-150 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

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

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

Budget / BOM (Part 1/2- Mechanical)

Budget / BOM (Part 2/2- Electrical) *Projected budgeted for $2000 *Estimated total cost of project is totaled at $1959.70 *Conservative estimate for shipping costs 17

Feasibility Analysis and Experimentation 18 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

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* Δ P)  Nominally Δ P=1.1psi  Step 3: Calculate Major Head Losses  Nominally Δ P=5.8psi  Step 4: Compare pump head needed to pump power/efficiency and pump curves

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

Drain/Flow Calculations 21  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

Magnet Calculations 22  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

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

Electrolysis Experimentation (2 of 3) 24

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