Sustainable Technology For The Global Market Family of Projects

James BrownRishitha Dias

Casey DillNeranjan Dharmadasa

Kevin KlucherEric MacCormack

Colin Roy

• Underwater use• Advanced tool use

• Advanced controls system

• Use with robotic platform

• Hydraulic •5 fingered hand with wrist motion

• Pneumatic 3 and 5 fingered hand

• Develop high speed camera system

• Integrate modules on D-R compressor

• Design new platform for open source

• Interchangeable propulsion/lighting modules

• Scale and install on compressor

• Simulate sea bed conditions

• Meet load requirements

• Develop modules to fit D-R compressor

• Scale up & develop lab test stand

•Begin testing• Diagnostics

• Wireless monitoring of DAQ

• Make improvements on current test stand

• Energy recovery from D-R VECTRA gas turbine

• Preparation for new compressor arrival

• Reciprocation compressor revamp and interface

•Scale up to D-R expectations

• Integrate robotic arm and optimize design

•Improve existing platform and interface

• Process Improvement Project

•Valueengineering inmanufacturing facility

AY 2009-10

AY 2010-11

AY 2011-12

AY 2008-09

AY 2007-08

• Turbomachinery flow visualization[table top]

Robotic Arm

Robotic Platform

Turbo machinery

Flow Visualization

Thermoelectric Waste

Heat Recovery

Remote Health

Monitoring System

Process Improvemen

t

Preliminary Schedule

2008-2 through 2008-3

Neranjan DharmadasaJames Brown

P09451: Thermo-Electric Module for Large Scale

Systems

Introduction

Thermoelectrics are very simple solid state devices with two basic modes of operation.

• The Peltier Effect, involves the application of current through the module, absorbing heat from one side of the device and emitting from the other side.

• Conversely, the Seebeck Effect can be used for power generation purposes. When a temperature gradient is applied across a TE module an electric current is produced.

Previous Projects

P07442

P08451

Mission StatementThe focus of this project will be to make improvements to last year's power module unit design, perform more extensive testing and address some issues that surfaces from the preliminary testing done last year. This year‘s team will develop a second generation prototype power module that would more closely simulate a power unit that might be deployed on the exhaust stream of a Dresser-Rand Vectra or other turbine. This unit may include the use of air cooling to simulate a power unit serving both as a power generator as well as a recuperator. The team will make improvements in temperature sensor locations to better monitor heat spreading and understand multidimensional conduction which is currently not accounted for in the modeling. The team will also design and implement strategies for max power tracking and the handling of module array mismatch due to differing temperature gradients.

Customer NeedsTest Stand IssuesGUI and data processingTemperature

measurementsSwapping T.E. modulesMax point tracking

(power)Pressure lossesLack of sensors for

multidimensional heat transfer

Test Stand Improvements

More fin optionsDesign for power

requirementsDesign for specific

operating conditionsDesign for

recuperative heating system

Additional “zones”

Staffing RequirementsTeam Member Responsibilities

Team LeaderNeranjan Dharmadasa

Coordinate efforts to complete project, logistics, running meetings, purchasing, resource management and assistance to other team members as required.

Chief EngineerJames Brown

Lead the engineering effort and ensure the final project goals are met by facilitating communication among team as well as carry out mechanical design.

ME-Heat Transfer This student will focus on thermal resistance modeling and heat spreader design for the TE module.

ME-Thermal Modeler This student is responsible for understanding theory behind TE modules and the thermal modeling of their resistances.

EE-Electrical System Designer This student will assist in characterization of voltage current relationships for TE modules and test systems.

Work Breakdown StructureTeam Member Week 1 Week 2 Week 3

Neranjan DharmadasaTeam Leader

Set up meeting times, assign tasks, establish team values and norms

Ensure access to necessary resources, create specifications, conduct idea generation exercises

Continue project management exercises for concept selection, arrive at final project plan

James BrownChief Engineer

Familiarize team with current test stand and issues, lay out engineering objectives

Prioritize objectives, introduce team to stakeholders, concept generation

Assist Team Leader with final project plan and team with concept selection

ME- Heat Transfer Thoroughly examine EDGE and become familiarized with the past project

Study existing test stand and work closely with Graduate Assistant, concept generation

Update team with concept discussion and make selection

ME- Thermal ModelerThoroughly examine EDGE and become familiarized with the past project

Study existing test stand and work closely with Graduate Assistant, concept generation

Update team with concept discussion and make selection

EE- Electrical Systems Designer

Thoroughly examine EDGE and become familiarized with the past project

Gain understanding of project issues and begin concept generation

Update team with concept discussion and make selection

Team Values and NormsPunctualityOrganizedDevoted/CommittedProfessional and EthicalThorough AccurateMeet GuidelinesMeet Deliverables on Time

Required ResourcesCurrent lab test standMachine shopTime with Graduate AssistanceTime with Faculty Guide, Dr. StevensTime with Dresser-Rand contacts

Staffing requirements will be met throughout course of project

Estimated budget will be provided

Existing test stand can be used and improved for this year’s project

Assumptions

Budget: $ 7500Technical Expertise: Familiarizing students

with TE modules and the current systemTime: All deliverables must be performed within

the allotted 22 week timeframeResources: Time required on machine shop

towards building phase of project.Obtaining TE modules that operate under higher temperatures

Platform: The project must build upon the existing module and test stand

Safety

Constraints

Intellectual Property

Project will be open source, open architecture.

Any information on Dresser-Rand products will be kept confidential

Currently established patents will be researched and taken into consideration with progress of project.

Issues and RisksAvailability of off the shelf TE modules

Delivery of parts on time

Parts exceeding budget

Data inaccessibility or loss

Outstanding ItemsDeliverables over the course of the project

are to be determinedTarget specifications are yet to be

established

2008-2 through 2008-3

P09454: Design and Testing of Centrifugal Pump Components

Project Status Update Project Name

Design and Testing of Centrifugal Pump Components Project Number

P09454 Project Family

Sustainable Technology for the Global Market Track

Turbomachinery Flow Visualization Start Term

2008-2 End Term

2008-3 Faculty Guide

Dr. Stephen Day Primary Customer

Dresser-Rand

IntroductionParticle Imaging Velocimetry (PIV) uses a sheet

laser beam to illuminate particles that cross the sheet.

The particles will diffract the light of the laser and thereby allow for imaging.

Based on the data gathered from imaging these particles, the flow through the system can be visualized.

Starting Point The existing test system was developed for MSD in 2007

-2 & 2007-3 quarters under P08453

The system consisted of a centrifugal pump that sits within an automated and instrumented flow loop.

The apparatus and pump housing will be fabricated from optically clear materials to allow flow visualization within the pump using Particle Imaging Velocimetry

The system was designed and built with a modular construction so that design variations of impellers, diffusers, and housings may be easily exchanged.

Planning

Customer NeedsPerform PIV experiments to characterize

different flows through the pump systemUse as an teaching tool for undergraduate

coursework, projects & labsUse for Graduate research & projects

DeliverablesDesign & manufacture interchangeable

Impellers & Diffusers (3 items each)

Set up & perform PIV measurement on pump system using new Impellers & Diffusers

Mission StatementThe purpose of this project is to design & develop interchangeable impellers and diffusers which will work on the existing PIV system in order to characterize different flows through the pump system. Team will deliver 3 impellers & 3 diffusers for the existing system. Furthermore, team will also be responsible for setting up experiments and performing PIV reading using the new impellers & diffusers

ConstraintsBudget: $7,500Technical Expertise: Not all KGCOE ME

students possess the requisite knowledge in Turbomachinery

Time: All deliverables must be performed within the allotted 22 week timeframe

Resources: Impeller and diffuser manufacturing requires precision machining operation

Platform: The project must build upon the existing PIV system (P08453)

AssumptionsAll roles planned this quarter will be filled

during both quarters

Existing test stand can be used and improved for this year’s project

Existing test stand is in acceptable condition

Outsourcing the manufacture of Impellers and Diffusers will not adversely effect the timeliness of the deliverables

Work Breakdown StructureTeam Member Responsibilities

Team LeaderRishitha Dias

Coordinate efforts to complete project, logistics, running meetings, purchasing, and resource acquisition

Chief EngineerKevin Klucher

Lead the engineering effort and ensure the final project goals are met, interchangeability, flow testing, reduced

setup time, and complete test stand

ME-Design Engineer All modeling of structures in relevant programs, and fluid mechanics computation and simulations

ME-Turbomachinery Expert Improvement of the fluid mechanics and flow through the turbomachinery portion of the test stand for better

testing

ME- Systems Integration LabVIEW integration with sensors installed within the PIV system, integration of the flow loop with the PIV unit

Team Member Week 1 Week 2 Week 3

Rishitha DiasTeam Leader

Set up meeting times, inform everyone of their

tasksEstablish team values and

norms

Ensure team members have access to

necessary resources to begin allocated tasks

Oversee the information exchange between all

relevant members

Kevin KlucherChief Engineer

Begin examination of lab test stand and lay out engineering objectives

Develop study plan for engineers to learn the

necessary skills set required for the project

Work with Design Engineer in finalizing the

impeller to outsource

ME- Design Engineer

Thoroughly examine EDGE and become familiarized

with the project & predecessors

Reverse engineer existing and familiarize

with the system

Examine the existing system and identify

components that are critical to the project

ME- Turbomachinery

Expert

Thoroughly examine EDGE and become familiarized

with the project & predecessors

Review/study turbomachinery

technical material related to project

Review/study turbomachinery

technical material related to project

ME- Systems Integration

Thoroughly examine EDGE and become familiarized

with the project & predecessors

Develop study plan for engineers to learn the

necessary skills set required for the project

Examine previous LabVIEW setup & Code

Intellectual Property Considerations

• Project will be open source, open architecture

• Thorough patent research must be carried out prior to starting design phase

Team Values & Norms

• Punctual• Thorough• Accurate• Professional & Ethical• Committed• Good Communication –

Team members should make a conscious effort to keep all members in the team informed with new information, knowledge and project developments, especially the two leaders

Required Resources• Technical learning materials such as Turbomachinery

text books, research papers

• Access to existing (P08453) PIV pump system

• Time with Faculty Guide, Dr. Day

• Access to manufacturing resources: CNC machining, Rapid prototyping or outsourcing

• CAD & Engineering software packages

• EDGE

Concept Development

Customer Needs

• Customers require a upgraded PIV system to perform reading on more sophisticated flow patterns provided by new impellers & diffusers. The new impellers and diffusers must be interchangeable and must fit with the existing pump system.

Brainstorming Questions

• How can the team best familiarize themselves with turbomachinery concepts?

• What material can be used to make the impellers & diffusers?

• Which manufacturing method will be used to make the products?

Target Specifications

• Impellers & Diffusers must be interchangeable

• New parts should work interface with existing PIV system

Risk AssessmentTechnical expertise of ME student might be

inadequate for the design task at hand

Time needed for impeller manufacturing will affect the timeliness of deliverables

Existing PIV module may not function as desired

Risk AssessmentFlow parameters are not met by the design

Design stage leaks over allocated time due to complications

Manufacturing resources at RIT might be inadequate to produce the required parts

Budget might be insufficient to cover outsourcing of manufacturing

Risk ManagementTeam Lead, Lead Engineer will work with

faculty advisor to develop a plan to learn the technical skills required to design turbomachinery

Team lead will look for alternative manufacturing methods to save time, cost

ex: rapid prototyping, outsourcing

Risk ManagementLead engineer designs a study plan with

the assistance of faculty advisor & consultants to learn the required skills

Project lead allocates excess time for manufacturing parts & reallocate labor & resources to expedite other processes.

Risk ManagementTeam Lead & Lead Engineer assigns a plan

and adequate labor to ensure that the existing PIV system will meet required levels of operation

Team Lead & Lead Engineer will reevaluate and prioritize design goals to ensure timeliness of deliverables

Risk ManagementLead engineer will reevaluate design to

ensure that products can be manufactured using resources at RIT (while meeting specifications)

ORProject Lead and Lead Engineer will work

towards outsourcing the manufacturing to outside vendors

Risk ManagementProject Lead will work with Faculty Advisor

to reevaluate the budget ORReevaluate the scope of the deliverable to

meet the existing budget

Eric MacCormack (IE)Colin Roy (IE)

Project Status UpdateP09457 – Process

Improvement Project

Project Status Update Project Name

Process Improvement Project Project Number

P09457 Project Family

Sustainable Technology for the Global Market Track

Process Improvement Innovations Start Term

2008-2 planned academic quarter for MSD1 End Term

2008-3 planned academic quarter for MSD2 Faculty Guide

Professor John Kaemmerlen Faculty Consultant

Dr. Kuhl, choice for simulation Faculty Consultant

Dr. Carrano, choice for manufacturing processes Primary Customer

Dresser-Rand with the point of contact being Dennis Rice at the Olean facility

Mission Statement The mission of the Process Improvement Project is to

implement lean principles into the piping and packaging line at Dresser-Rand Corporation’s Olean facility.

Goal: reduce cycle time by 30%. Approach: improve the flow of products, warehousing

of parts, visual controls, and reduce the waste within the line.

Current Layout

Piping Assembly & Packaging

Assembly

Test

Parts

Customer Needs Reduce Cycle Time

Improve Flow of Product Visual Controls System Standardize Work Processes Accurate Drawings

Free Up Floor Space Maintain High Level of Safety

Staffing RequirementsName Discipline Roles/Skills

Professor John Kaemmerlen Faculty Guide

Will work closely with the team on an on-going basis to facilitate success.

Colin Roy I.E. Project Manager, Point of contact for Dresser-Rand. Construct and submit deliverables. Lead in Simulation and Factory CAD software.

Eric MacCormack I.E. Chief Engineer, Focus direction of work. Assist in any necessary tasks. Lead in lean.

I.E. Student (TBD) I.E. Engineer, Strong background in the fields simulation, lean and ergonomics.

I.E. Student (TBD) I.E. Engineer, Strong background in the fields simulation, lean and ergonomics.

M.E. Student (TBD) M.E. Engineer, Skills for work with parts family assessment and part number consolidation. Custom tooling. Set-up reduction opportunities.

Work Breakdown Structure

P – D – C – A

Work Breakdown StructureMember Week 1 Week 2 Week 3

ColinTour the Facility. Bring all group members up to speed with Customer Needs

Direct each team member/obtain data on current state

Monitor and facilitate each team member in their active roles

EricTour the Facility. Bring all group members up to speed with Customer Needs

Acquire all current data D-R has on the current process.

Reiterate current state value stream map

IETour the Facility. Bring all group members up to speed with Customer Needs

Begin Factory CAD analysis on current D-R CAD layout.

Continue on Factory CAD analysis on current D-R CAD layout

IETour the Facility. Bring all group members up to speed with Customer Needs

Begin preliminary current state simulation model.

Continue on current state simulation model.

METour the Facility. Bring all group members up to speed with Customer Needs

Become familiar with the various parts that are used in the assembly process

Evaluate ways part drawings can become more accurate to the products

Risks and ConstraintsRisks

Quality – Tradeoff of quality vs. speedWorker resistance to changeDisruption to other processesIncreased cost to production

ConstraintsFactory distance (Olean plant 2 hour drive)22 week improvement periodCameras not allowed in facilityD-R staff availability

Resources Required

Personnel

Professor KaemmerlenDr KuhlDennis RiceDan Krenn

EnvironmentSenior Design LabISE/ME Computer LabsOlean Facility

EquipmentArena SoftwareFactory CAD Software

DeliverablesCurrent State Value Stream MapFuture State Value Stream MapDetailed Current State LayoutFuture State LayoutFactory CAD Drawings and AnalysisSimulation Models and AnalysisCost-Benefit AnalysisVisual Control System

Team Values

Punctual

Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one teammate prior to the expected absence. An absent team-member should confirm that a teammate has received their message.

Thorough

Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person

Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow.

Timely Each team member will fully complete their tasks at or before the due date for the deliverable.

Professional and Ethical

Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers.

Committed Each team member will contribute an equal share to the success of the project

Teamwork Each team member will be supportive of one another. All must realize we are working to achieve a common goal. If any conflicts are to arise during problem solving or execution they shall be resolved professionally and timely. If necessary, mediation will be provided by group leads.

Artificial Limb Project

By Casey Dill

Mission Statement

This project will improve upon existing plans for an artificial arm with the same capabilities of a human arm. Extensive work will be done to study the motions of the human hand, the forces acting on the parts and the effects of scaling up and down; all on various designs that reproduce human motion acurately.

Staffing Requirements

ME Lead – To lead the team and make sure all the goal of the project are met and on time.

ME1 – To work on computer models and to do mechanics analyses.

ME2 – To work on computer models and to do mechanics analyses.

EE1/CE1 – To program a controls systems. EE2/CE2 – To work on a software interface

package or to create a human interface.

Intellectual Property Considerations

There are many patents for robotic designs that are still in effect. There are 5 for robotic arms that perform maintenance and 12 that have to do with medical procedures. None of these arms mimic the movement of the human anatomically, probably due to the fact that no one can patent human motion.

Source: http://patft.uspto.gov/

Preliminary Work Breakdown Structure

Person Week 1 Week 2 Week 3 Week 4

ME Lead

Familiarize with past projects’ accomplishments and challenges. Meet with faculty guide to talk about goals and concepts. Brainstorm concepts for development. Become a team.

Initial design concepts for the wrist and forearm.

Continue designs for accurate motion. Work on CAD models.

Feasibility of budget analysis for prototype

ME 1 Scaling up analysis

ME 2 Scaling down analysis

EE/CE 1

Design for position controls

Design for human interface.

Scaling up analysis

EE/CE 2 Scaling down analysis

Team Values and Resources

Team Values and Norms Professional and Ethical, Committed,

Demonstrates the core RIT spirit, Thorough, Accurate and Punctual

Required Resources Access to The RIT Library’s resources for

research Access to CAD programs, control programs, etc. Meeting space

Customer Needs Customers:

Dr. Lamkin-Kennard – Faculty guide Past Senior Design Team Medical Industry Dresser Rand in the future, if enough is proven possible

Needs: The project needs to add to the value of the roadmap

Proof of concept CAD model with the mechanics worked out, of the whole arm Should demonstrate tool usage and natural range of motion Structural analysis for scaling up and down

An interface system with a computer model and a real robotic arm Simple and well documented

(if funding is found) a prototype arm demonstrating wrist motions The project should be interesting for senior design students

Target Specifications By the end of the first quarter CAD models of several different

designs for a robotic human arm are to be developed. They should be accurate with respect to human motion, and include designs from past groups and include wrist, forearm and elbow motion. Designs to improve motion sensing should also be completed.

By the end of the second quarter, if no funding for a prototype is found, a complete analysis for scaling, up and down should be completed. If funding is found, then a prototype demonstrating the wrist design concepts will be developed. Overall improvement to the controls system should be made.

Issues & Risks Risk Management Table

Description of Risk Possible Consequences

Probability of Risk (H/M/L)

Severity of Risk

(H/M/L)

Overall Risk

(H/M/L) Contingency Plan

Money is not found for prototyping

Not able to build prototype

H L LAlternate path a for more rigorous engineering analysis is followed.

Because most of this work will be done on the computer, there is always the potential of data loss

Lost time and work M M MDaily back up on EDGE server

EDGE server has down time

Not able to retrieve work off of EDGE

L H MKeep work in progress backed up on local machine

The school computer could crash with too detailed CAD work with too many parts

Model not renderable H L LWork with parts of a model at a time.

Not enough programming knowledge to support efforts

Too much work would be placed on those who do know programming

M H M

See help from another faculty guide able to help with the programming & teach it.

Concept DevelopmentOption 1 Option 2 Option 3 Option 4

Knuckle

1 DOF

Pin joint Flexible material

Ball and socket

Floating

Knuckle

2 DOF

Ball and socket

Two pin joints Gyroscope Flexible connector

Wrist Two pin joint Ball and socket

Two ball and socket joints

Flexible connector

“Bone” material

Steel Aluminum Hard plastics Titanium

Position Sensing

3D position sensing

Joint angle monitoring

Tendon length monitoring

Control system calculations

Forearm Two “bones” that wrist

Load-bearing bearing

Rotate at elbow

Concept Development

Questions?