Sponsor: Carrier CorporationAdvisor: Dr. H. El-Mounayri

May 3, 2007

Design Team: Mike Abel Braden Duffin Simon Marin Joe McGuire

Presentation OutlinePresentation OutlineBackgroundRequirementsDevelopmentFinal DesignEvaluationRecommendationsQuestions

Design ObjectiveDesign ObjectiveDesign a custom cyclic corrosion device for

testing material samples. The device must replicate conditions

encountered in actual furnace applications.Environmental conditions include hot air,

chemical exposure, and humidity.

Performance RequirementsPerformance RequirementsControlled temperature range of 70-

400° FahrenheitHumidity: 85%Corrosive Chemical ExposureControllable and variable cycle

transitions (30-60 sec. transitions)Other (weight, cost, size, power,

safety)

DevelopmentDevelopmentConcepts generation included QFD, functional

flow analysis, function-concept mapping, decision matrix, etc…

Designed housing concept using ProEngineerResearched commercially available

components (heat element, fan, valves, chemical pump, etc…)

Performed analyses to determine necessary component performance

Redesigned housing to fit suitable components

Final Design (Front View)Final Design (Front View)

HeatChamber

Heating fan

Cooling Fan

ValvesFume hoodRepresentation

Final Design (Rear View)Final Design (Rear View)

Chamber Vent

Drain Pan

Chemical / Water spray inlets

External Cover

Final Design (Internal View)Final Design (Internal View)

TestSamples

Chemical NozzleWaterNozzle

Design EvaluationDesign EvaluationVerification of the requirements was

obtained from: Procured component specifications ProEngineer model geometry Part weights and dimensions Computational Fluid Dynamics (CFD)

simulations

CFD Model and BoundariesCFD Model and Boundaries

HeatingElement

Heating Fan

Heat side valve

Cool sidevalve Cooling

Fan

Vent

Requirements VerificationRequirements VerificationCFD Analysis

Temperature range requirement: 70-400ºF Temperature range achieved: 70-500ºF

Temperature transition time requirement: < 60 seconds

Actual time to heat chamber: > 200 seconds Actual time to cool chamber: 25 seconds

Steady-state heating simulationSteady-state heating simulation

Flow streamlines colored by

temperature

Demonstrates capability to exceed temperature requirement

Internal temperature is 475-500 ºF

Cooling time simulationCooling time simulationDemonstrates

cooling time capability

Simulation time is 25 seconds

Internal temperature drops from 500 to 80ºF

Heating time simulationHeating time simulationDemonstrates

heating time capability

Simulation time is 200 seconds

Final Internal temperature is 340ºF

Needs optimization

Requirements VerificationRequirements VerificationHumidity: 85% (predicted, not verified)Uniform Chemical Vapor Spray (based on

procured nozzle and pump specs.)

Requirements VerificationRequirements VerificationSafe to be handled (warning: some heated

surfaces and ventilation)System maintenance and cleaning: All parts

exposed to chemicals are stainless steel. All individual part weights are below 60 lbs.

Fits in hood dimensions (verified by ProE model)

Holds 6 coupons (Target: 2)

Requirements VerificationRequirements VerificationPowered by 110 V (based on procured

components specs.)System can be automated (All parts can be

electrically controlled)System Cost $2799 - $8389 depending on

valve choice (Target: $3000)

Heat Cycle RecommendationHeat Cycle RecommendationObjective: decrease time to heat chamberCurrently using preheated air to facilitate heatingIncrease amount of preheated air:

Increase volume of heat chamberIncrease surface area of heat stripAdd heat stripAdd second heat chamber

Optimize air flow Entry ventsExit vent

Valve RecommendationValve RecommendationObjective: Meet initial budget requirements,

minimize long term costsXomox butterfly valve: $3345 each

Highest quality heat and corrosion resistance2” long

McMaster swing check valve: $550 eachLower quality heat and corrosion resistance6” longLikely requires regular replacement

Design custom valve in house?

QuestionsQuestions