Honeywell Powder Amplifier

Operations Manual

Savana Bezdicek Nicole MitichLuke Plumb

Isaac RomeroJacob Setzer

2016-17

Project Sponsor: HoneywellFaculty Advisor: David TrevasSponsor Mentors: Mike McCollum and Mitchell ThuneInstructor: David Trevas

TABLE OF CONTENTS

1. Overview……………………………………………………………….………………………...3

1.1 Project Specifications………………………………………………………………..…...…..3

2. Testing…………………………………………………………………..………………………..4

2.1 Semi-Fluid Characteristics Test……………………………………………….………...……4

2.1.1 Bill of Materials……………………………………………….……………………...…...4

2.1.2 Methodology……………………....……………………….………………………….......4

2.2 Thermal Expansion Test……………………………………………….………...………….....5

2.2.1 Bill of Materials…………………………………………….……………………….…......5

2.2.2 Assembly……………………………………………….………………………….……....5

2.2.3 Methodology……………………………………………….…………………….………..6

2.3 Output Amplification/Stroke Hysteresis Test………………………………………………..7

2.3.1 Bill of Materials……………………………………………….……………..……..……...7

2.3.2 Assembly……………………………………………….…………………………...….….7

2.3.3 Methodology…..…………………………………………….………………………….…8

3. Safety………………………...……………………………………………….…………………....8

3.1 Safety Regarding Nanofluid Composition……………………………………….……….…..9

3.1.1 Nanofluid Safety Hazards……………………………………………….………………...9

3.1.2 Nanofluid Safety Procedures……………………………………………….………….….9

References………………………………………………………………..…………………………10

1. Overview

The Honeywell Powder Amplifier capstone project explores the development of a practical “fluid” output amplifier for use in a magnetostrictive torque actuator. In doing so, it was necessary to determine if a powder of any material could replace commonly used liquids in the amplifier of a hydraulic actuator.

This required intensive research into powders and materials from which the surrounding housing of an amplifier could be fashioned. A conceptual schematic of this idea is provided in Figure 1.

Figure 1: Schematic of Concept

In performing this research and selecting materials for testing, it was essential that the selected materials satisfied the project specifications as provided by the project sponsors, Honeywell. From conducted research, the generation of a nanofluid was pursued and tested to verify its success at satisfying the engineering requirements.

1.1 Project Specifications

Table 1 presents the engineering requirements and specifications corresponding to the provided customer requirements.

Table 1: Engineering Requirements and Specifications

While speaking with the clients, requirements 1, 3, and 4 were identified as the most important to the success of the project. To satisfy these requirements, three tests were designed and the results from each were analyzed.

2. Testing

The purpose of the first test designed and assembled was to test the fluid characteristics of the nanofluid. Following, the second and third tests measured the thermal expansion and the output amplification of the nanofluid, respectively. The following sections detail the materials for the assembly of each test and methodology used to obtain results.

2.1 Semi-Fluid Characteristics Test

The semi-fluid characteristics test was designed for even dispersion of powder and fluid while mixing the nanofluid. This then enabled observation of true nanofluid behavior. To begin the testing process, the applicable materials must be researched and ordered for delivery.

2.1.1 Bill of Materials

Table 2 presents the bill of materials for the semi-fluid characteristics test.

Table 2: Semi-fluid test bill of materials

The first two materials listed in the bill of materials are the contents of the nanofluid, while the last five items were used to properly measure each of the mediums. Because this test did not require any assembly, the assembly section has been omitted. The methodology can be found in the following section.

2.1.2 Methodology

The methodology for the semi-fluid characteristics test was used for mixing the nanofluid and observing the results of each nanofluid with varying volume fraction percentages. The list below details each step of the mixing process.

1. Place weigh boat on balance scale and tare scale to zero.2. Use scoop to transfer nanopowder from bag to weigh boat; monitor scale reading.3. When desired quantity is obtained, remove weigh boat from scale; transfer nanopowder from

weigh boat to measuring cup.4. Use pipette to extract Dynalene from bottle.5. Squeeze pipette bulb with pipette over measuring cup to release Dynalene onto nanopowder.6. Plug in immersion blender.7. Place immersion blender at bottom of measuring cup; turn blender on at slow speed.8. Once combined, increase blender speed to ensure even distribution of powder and Dynalene.9. Repeat for varying solution percentages; compare characteristics.

The resulting solutions from the aforementioned methodology should be carefully analyzed, recorded, and documented using descriptions and photos.

2.2 Thermal Expansion Test

After utilizing the semi-fluid characteristics test to properly mix the nanofluids of various powder volume fractions, the thermal expansion of each mixture should be tested. This ensures that the theoretical calculations match the experimental data, and that the materials do in fact have practical application. To begin the test, the following materials must identified and ordered.

2.2.1 Bill of Materials

Table 3 presents the bill of materials used in the thermal expansion test.

Table 3: Thermal expansion test bill of materials

The 5 mL glass test tubes can be considered disposable, as they are cost-effective and difficult to clean. However, these must be properly disposed of for each trial. Each of the other materials must be properly cleaned and dried for future use. The assembly procedure for this test can be seen in the following section.

2.2.2 Assembly

The items detailed in the bill of materials must be properly assembled and calibrated for accurate test results. The list below provides a guide for the assembly of the test fixture.

1. Turn a hole with diameter of borosilicate glass tube OD into tapered round plug. 2. Fill glass test tube with completely with fluid, removing all air from the test tube.3. Seal glass test tube with tapered round plug; place borosilicate glass tube through plug hole into

bottom of test tube.4. Place graduated glass beaker on stirrer/hot plate, fill with water.5. Insert borosilicate glass tube, test tube, and round plug assembly vertically into center of glass

beaker water bath until water level is just below the top of the test tube; secure with test tube holder.

6. Insert thermocouple adjacent to test tube assembly in water bath.

Once assembled, the test fixture should look identical to that of Figure 2.

Figure 2: Thermal Expansion Test Assembly

Upon completing the assembly of the test, the calibration may be completed. The following section details the calibration steps and testing methodology.

2.2.3 Methodology

Before conducting any nanofluid testing, the results generated by the assembly must be verified. To do so, complete the steps below with water obtained from the sink. Compare the collected results with volumetric thermal expansion curves of water (can be found online).

1. Design a virtual instrument (VI) using LabView for 1 K-Type thermocouple to measure temperature over time.

2. Simultaneously turn on hot plate and VI to monitor temperature increase. 3. Measure height change of liquid in borosilicate tube with ruler; record height measurements and

corresponding temperatures for various times during the test.4. Plot the results in a volumetric thermal expansion vs. temperature curve.5. Ensure the thermal expansion is comparable (< 5% error) to recorded coefficient of thermal

expansion.6. Once results are verified, repeat steps 1 through 5 with nanofluid solutions of various powder

volume fractions.

The resulting solutions from the aforementioned methodology should be carefully analyzed, recorded, and documented using descriptions and photos.

2.3 Output Amplification/Stroke Hysteresis Test

The third and final test was performed to both ensure the nanofluid properly amplified the input stroke by at least 10:1 and that the system experienced no stroke hysteresis. By obtaining a repeatable output amplification displacement of the small piston it is possible to test for hysteresis of the hydraulic medium

being used. Three different hydraulic mediums were used. The first test was performed with just water to validate our test fixture operated correctly. The second and third mediums used were a water/silicon nitride balls mixture and a glass rod/ water mixture.

2.3.1 Bill of Materials

The materials needed to perform this test can be seen in Table 4. The bulk of the materials were ordered from a machining company called Protolabs. These tests were done using a table in the fabrication lab located in NAU building 98C.

Table 4: Output Amplification/Stroke Hysteresis Bill of Materials

An isometric CAD view of the piston assembly can be seen in Figure 3. Each of the first four items in the bill of materials should be assembled to look as such.

Figure 3: Piston CAD Assembly

2.2.2 Assembly

This test system should be assembled on a sturdy table with a level surface. The following details how to properly assemble the test fixture and measure output stroke.

1. Fill the actuator with hydraulic medium a. Open the bleeder valveb. Ensure that the small piston is in the starting positionc. Submerge the actuator in water with the large piston removedd. Insert the large piston into the actuator housing just past the o-ring locatione. Push the large piston in until bubbles escape the bleeder valve

f. Close the bleeder valve g. The actuator is now ready to use

2. Place the actuator in the vise and close the vise so that the actuator is locked in place but the large piston is not being moved

3. The micrometer can now be set parallel to the actuator4. Attach a micrometer to a stand5. Center the micrometer so the tip of the micrometer touches the tip of the small piston6. Turn the vise so that it closes and moves the large piston7. The displacement of the large piston can be measured by looking at the parallel micrometer. It

should be moved 0.003 inches 8. The output stroke measurement can be read from the micrometer touching the small piston

The test system should be identical to those pictured in Figures 4 and 5.

Figure 4: Top View of Hysteresis Test Assembly Figure 5: Side View of Hysteresis Test Assembly

2.2.3 Methodology

Before testing the alternate design solutions the test system needs to be validated. Water can be used to calibrate the system. Once the system has been calibrated, the design solutions can be tested for output stroke. Six tests were performed for each medium. The following list details the methodologies used for this test.

1. Record the initial position of each micrometer 2. Rotate the vise in order to slightly close the jaws 3. The vise should be displaced 0.003 inches4. Record the displacement of the small piston when the needle on the micrometer comes to a rest5. Perform this test until the small piston reaches its limit; reset and repeat until desired number of

trials is met.

By recording repeatable output stroke data it can be proved that the design solutions lead to no hysteresis within the system and that the desired output amplification is met.

3. Safety

To ensure the safety of the team as well as others in the vicinity of the project, several safety precautions must be taken, provided in the following subsections.

3.1 Safety Regarding Nanofluid Composition

The safety recommendations for nanofluid development were detailed by the Occupational Safety and Health Administration (OSHA), providing both safety hazards and procedures when dealing with nanopowders.

3.1.1 Nanofluid Safety Hazards

● If inhaled, the particles may be deposited into the respiratory tract due to their small size. This could lead to health issues in the form of pulmonary inflammation and fibrosis [1].

● Because of the high mass-based potency of the particles, they may be considered an occupational carcinogen [1].

● The particles could penetrate internal cellular walls, damaging intracellular structures and inhibiting cell function [1]..

● Some nanopowders may possess catalytic attributes, generating unexpected reactions and posing a risk for fire or explosions [1].

● Similarly, some nanopowders may be combustible and ignite at lower temperatures, and pose a risk for fire or explosions [1].

.3.1.2 Nanofluid Safety Procedures

To reduce the likelihood or severity of the aforementioned hazards, the following steps may be taken when dealing with the nanopowder.

● Only work with nanopowder in well-ventilated enclosures (i.e. laboratory hood, process chamber, etc.) [1]

● If no enclosure is available, local exhaust ventilation may be substituted and designed to capture air contamination [1].

● Personal Protective Equipment should be worn at all times when handling nanopowder (i.e. masks and latex gloves) [1].

By following the aforementioned precautions, the nanopowder should remain non-hazardous.

References

[1] Occupational Safety and Health Administration, "Working Safely with Nanomaterials", 2017.