MSD P13453Final Project Review

Sean Deshaies (ME)Erin Sullivan (EE)

Michael Gorevski (EE)Brandon Niescier (ME)

Agenda

• Project Goals• Customer Needs• Design Summary– Wired System– Wireless System

• Testing• Expense Report• Project Status• Future Work• Lessons Learned

Project Goals

• Install accelerometers on the compressor– One on the flywheel hub– One on the bearing housing

• Find a solution to wirelessly transmit data from one of the accelerometers

• Data collected in LabVIEW or through standalone software

Customer Needs

Customer Need # Importance Description

CN1 9 Single axis accelerometer mounted to crankshaft (Rotates)CN2 9 Single axis accelerometer mounted inside housing (Stationary)CN4 9 Continuous sensor operationCN8 9 Reliability and accuracy of measurements

CN12 9 Must fit inside of compressorCN13 9 Must fit on shaftCN7 3 Robust design of wireless technology for harsh environmentCN9 3 Interface wth DAQCN3 3 Minimal user intervention CN6 3 Wireless transmission of signal

CN11 3 User manual/Important informationCN5 1 Low cost

CN10 1 Scalable to higher temperature (Internal environment)

Wireless Accelerometer Mounting Location

• CN13 references mounting on the shaft– Accelerometer was too tall for keyway

• Pugh analysis was done to evaluate potential solutions– New mounting location was found on flywheel

hub

Design Summary

• Wired Accelerometer:– PCB Swiveler is able to withstand the oil and

higher temperatures inside the compressor• Wireless Accelerometer:– PCB 660 Series is able to operate on the same low

voltage as the wireless module• Wireless Module:– TelosB module allows for low power, wireless

transmission capabilities

Wired System

Wireless System

Test Fixture

Testing

• Accelerometer verification– PCB Swiveler vs. B&K 4393– PCB 660 Series vs. B&K 4393

• Wireless transmission verification– TelosB module vs. function generator

Accelerometer Test Results

0 500 1000 1500 2000 2500 30000

0.2

0.4

0.6

0.8

1

1.2

1.4

-35

-30

-25

-20

-15

-10

-5

0

5

Transfer Function Magnitude and Phase (PCB 660/ B&K 4393)

Magnitude Phase

Frequency (Hz)

Mag

nitu

de (m

/s^2

/m/s

^2)

Phas

e (d

egre

es)

0 500 1000 1500 2000 2500 30000

0.2

0.4

0.6

0.8

1

1.2

1.4

-35

-30

-25

-20

-15

-10

-5

0

5

Transfer Function Magnitude and Phase (PCB Swiveler/ B&K

4393)

Magnitude Phase

Frequency (Hz)

Mag

nitu

de (m

/s^2

/m/s

^2)

Phas

e (d

egre

es)

Wireless Test Results

0 50 100 150 200 2500

0.5

1

1.5

2

2.5

Wireless vs. Function Generator (50Hz)

Wireless Signal Express Wireless with Scale Factor

Number of Samples

Volta

ge (V

olts

)

Wireless Test Results

Compressor Data

Wireless Data Wired Data

Accelerometer Data Comparison

0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5-1.5

-1

-0.5

0

0.5

1

1.5

Wireless vs. Wired Acceleration Measurement

Wireless Wired

Time (sec)

Acce

lera

tion

(g)

Total Expenses

Team P13453 ExpensesOrder Number Vendor Order Description Total Cost

105-7615249-5268227 Amazon Supply Aluminum Bar and Angle $121.13 3017475-01 McMaster-Carr Steel Bar, Pillow Block Bearings $323.35

55953 Photocraft Encoder, Stub Shafts $208.16 3017475-01 McMaster-Carr Returned Bearings ($252.16)

4389 PowerGate Power Supply $60.93 374572 Bolt Depot Test Rig Hardware $7.24

4002194-01 McMaster-Carr Cable Gland $12.71 2500375331 Allied Electronics USB Extension cord and Enclosure $12.41

PL-121120002 Memsic Wireless Modules $362.00 48997576 Grainger Epoxy $17.60

N/A Anaheim Automation Motor $163.00 N/A McMaster-Carr Coupling $35.77

4547023-01 McMaster-Carr Screws $15.04 2500389198 Allied Electronics Enclosure and Switches $36.76

A233703 Futurlec Header Pins $6.50 N/A PCB Accelerometers and Signal Conditioner $798.30 N/A Lowe's Safety Guard Brackets $3.18 N/A Harbor Freight Hex Key Set and Rubber Mallet $8.98 N/A Jeff Wilczewski Wireless Module Programming $500.00

45448853 McMaster-Carr Helicoil Thread Repair Kit $77.31

Initial Budget: $5,000 Funds Remaining: $2,482

Project Status

• Accelerometers installed successfully– Wired accelerometer integrated into LabVIEW– Wireless accelerometer interfaces through a

standalone program• Data is reliably transmitted wirelessly

Future Work

• Sync the data between wired and wireless accelerometer

• Integrate the wireless accelerometer into LabVIEW

• Mount wireless accelerometer to bearing housing inside compressor

• Improvements to wireless enclosure

Lessons Learned

• There is no viable off-the-shelf wireless solution• Expert opinions are sometimes wrong• Be sure to include all necessary tolerances on

manufacturing drawings• Machinists have the ability to make or break the

project• Communication of customer needs could have

been improved• Need to anticipate the speed of bureaucracy

Acknowledgements

• Bill Nowak – Guide• Jeff Wilczewski – Programming wireless

modules• Rob Kraynik – Machining and installation

assistance• Dresser-Rand – Project sponsor• Markus Holzenkamp – Project assistance• Dr. Kolodziej – Faculty champion/customer

Thank YouP.S. – Bill you owe us all a beer