MODELING & OPTIMIZATION OF DUAL-BORE OIL DEBRIS MONITORING SYSTEM ECE Team 2016, ME Team 25 Timothy Beacham (ECE), XuDong (Andy) Lu (ECE), Ryan Pyrch (ECE), Gursimran Kainth (ME), Elizabeth Soha (ME) ECE Faculty Advisor: Necmi Biyikli ME Faculty Advisors : Julian Norato Industry Sponsor: Pratt & Whitney Final Presentation 4/27/2020 1
Project Overview | Solution | Constraints | Results | Project Management Agenda ● Project Overview ○ Pratt & Whitney ○ Problem statement ● Solution ○ Dual-Bore ODM ○ Analog Filter ● Constraints Figure 1: 3D Model of a jet engine [1] ● Results ● Project Management ○ RACI ○ Parts List ○ Budget ○ Gantt Chart ● Summary Figure 2: Model of the magnetic field produced 2 by an electromagnet [2]
Project Overview | Solution | Constraints | Results | Project Management Pratt & Whitney ● Pratt & Whitney is an industry leader in the design, manufacturing and service of aircraft engines and auxiliary power units. ● Pratt & Whitney provides aircraft engines that are used worldwide in commercial and military applications. Figure 3: Image of Pratt and Whitney Engine Turbine [3] 3
Project Overview | Solution | Constraints | Results | Project Management Problem Statement Background: ● Senses debris in flow path ○ Indicate the stage of the engine life ○ Detects and prevents engine failure Requirements and Specifications: ● Model magnetic field interactions between ● Need for Dual-Bore ODM stems from failure due to back pressure excitation coils Deliverables: ● Experimental Data ● Determine optimal configuration of the design Figure 4: Model of an ODM configuration [4] 4
Project Overview | Solution | Constraints | Results | Project Management Dual-Bore ODM Setup ● Dual-Bore ODM ● Tektronix TBS1064 ○ Oscilloscope ● Tektronix AFG1022 ○ Function Generator Figure 9: Physical model of the Dual-Bore Figure 8: Completed physical model ODM powered by the function generator of an ODM configuration. Each ODM with the sensing coil outputs displayed on consists of two field coils and a an oscilloscope sensing coil 5
Project Overview | Solution | Constraints | Results | Project Management Excitation Band Pass Filter Purpose: ● Create a smoother excitation voltage ● Remove noise ● Detect particles effectively Figure 10: 125 kHz Band Pass Filter Figure 11: 250 kHz Band Pass Filter Schematic Schematic 6
Project Overview | Solution | Constraints | Results | Project Management Resources ● Tektronix TBS1064 allows a maximum of 2,500 data points per sample ● Inability to sample at Nyquist Rate due to the speed of pulling the particle ● Sampling at 250 Hz Figure 5: Tektronix TBS1000 series Oscilloscope [5] 7
Project Overview | Solution | Constraints | Results | Project Management Quality ● Aliasing ○ Sampling Below the Nyquist Rate ○ Results in a component of the signal Figure 6: Plot showing the effects of aliasing a signal [6] Figure 7: Plots showing the importance of the Nyquist Rate [7] 8
Project Overview | Solution | Constraints | Results | Project Management Physical Model Testing 0.25 in. 2 in. Figure 8: Particle used Particle location prior to being pulled through system Figure 9: Physical Video 1: Pulling particle through physical model 9 Model
Project Overview | Solution | Constraints | Results | Project Management Analog Filter Frequency Response ● 125 kHz Band Pass Filter ○ Designed Peak Frequency at 125.893 kHz ○ 0.7144 percent error Figure 10: 125 kHz Band Pass Filter Voltage vs. Frequency Plot ● 250 kHz Band Pass Filter ○ Designed Peak Frequency at 251.189 kHz ○ 0.4756 percent error Figure 11: 250 kHz Band Pass Filter Voltage vs. Frequency Plot 10
Project Overview | Solution | Constraints | Results | Project Management Dual Bore ODM Experimental Results ● Experimental Setup ○ 3.4 V RMS ○ 250 kHz ○ Particle Pulled through ODM 1 ● Data shows obvious change when particle is pulled through ODM 1 ○ Voltage spiked by 1.88 V RMS Figure 12: Plot of data during pulling particle through ODM 11
Project Overview | Solution | Constraints | Results | Project Management Dual Bore ODM Experimental Results (cont.) ● Particle detected in respective ODM ● Minimal interference ● Insignificant change in sensing coil in ODM 2 Figure 13: Zoomed in plot of pulling particle through the ODM 12
Project Overview | Solution | Constraints | Results | Project Management Schedule 13
Project Overview | Solution | Constraints | Results | Project Management Test Matrix 14
Project Overview | Solution | Constraints | Results | Project Management Obtained Objectives • Built Dual-Bore ODM • EMI Tape to Eliminate Interference Physical Model • Minimal Interference Detected • Detects Particles Within Respective ODM Testing • Supported Initial Claims • Matches ANSYS Simulations Analysis 15
Project Overview | Solution | Constraints | Results | Project Management Roles and Responsibilities 16
Project Overview | Solution | Constraints | Results | Project Management Budget 17
Project Overview | Solution | Constraints | Results | Project Management Sources 1. https://www.researchgate.net/profile/Ihsan_ABaqer/publication/328531263_ROTOR_DYNAMICS/links/5bd2dceea6fdc c3a8da6bc45/ROTOR-DYNAMICS.pdf 2. https://ridingmode.com/how-electromagnets-work/ 3. https://www.americanmachinist.com/news/article/21903188/pratt-whitney-wins-57b-f135-engine-contract 4. https://apps.dtic.mil/dtic/tr/fulltext/u2/p010191.pdf 5. https://www.tek.com/datasheet/digital-storage-oscilloscopes 6. https://www.linkedin.com/pulse/vibration-signal-processing-sampling-aliasing-kishore-kumar-agguna/ 7. http://195.134.76.37/applets/AppletNyquist/Appl_Nyquist2.html 8. https://prattwhitney.com/products-and-services/products 18
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