Identifying & Selecting Problem PSP 1

Analyzing Problem PSP 2

Generating Potential Solutions

PSP 3

Selecting & Planning Solution PSP 4

Implementing Solution PSP 5

Evaluating Solution PSP 6

R1 R2 R3 Y4 Y5 G6

1

Flow through the Bearinghousing is not what wascalculated / Could beobstructed

See "Problem 1:Documentation"

Test plan 4 in place to deduce actual flowwhile rig under full operation. Subject matterexpert guidance will be sought out togenerate correct oil flow requirementsunder dynamic loading

In Progress Anthony

2

Material costs for mountingdesigns are too high [toolsteel]

See BOM, details materialcosts

Run analysis with other steels to see ifdeflection and stress can remain low withnew material

Looking at materialproperties, 1045 steel is areduce in cost with outcompromising strength

Run analysis with 1045 cold drawn steel,further check material selection withexperimental testing before mounting on rig

Since experimetation is not yet possible wewere only able to evaluate the analysis whichwas approved by SME and will be furtherexplored with machine shop In Progess Christina

3

Delfection of mounts with 1045steel is unrealistic

See mounting document Rerun analysis, and have another personcheck analysis

Discuss issues with SME(Dr. Debartolo)

Run analysis with various initial conditions,the error was a flaw in the math model fromsuch small deflections

Various initial conditions provided a betterpicture of displacement of mounts

In Progess Christina

4

Pressure transducer doesn'tproduce a useable signal

Checked transducer withmultimeter to see if itproduced any signal.Checked connection toensure no blockage. Used aPCB and Omega transducerto see if they worked

Old transducer was broken. We looked intopurchasing a new one. See PressureTransducer Document

Chose to purchase PX319-200GV, Documentationhas been completed.Awaiting Purchase 2/9

Part received 2/16/15. Worked throughSOP-0006 to verify calibration of the Omegacalibration sheet

Calibration proved to be within 3%. We will usethe Omega calibration numbers due to sourcesof error in our process (see SOP-0006). Resultsfrom test can be seen in tab titled "Problem 4:PT Cal Results"

Completed Michael

5

Load Cells don't produce auseable signal

Checked load cell with multimeter, looked over manualof meters, contactedtransducer techniques,Meters are AC only unlikewhat manual states,

Contact transducer techniques to fix outputof meters, or purchase new meters

Contacted transducertechniques

Adjusted values inside the meters setup thatallows it to properly interperate the load cellssignals

Both of the 2000 lb load cells are working with acorresponding meters. Notes were taken tohelp problem solve potential calibration issues.Learned that the meters are only capable of 60samples a second which could effect theaccuracy of our load profile. Completed Michael

6

No DAQ program from Alphaprototype

Looked on edge, contactedSteven Lucchesi, contactedLuke with no luck

Create Labview program, ask SME tocreate a DAQ, Renegotiate customer needs

Create our own LabviewProgram

See Labview folder for process. Using theDAQ Assistant node to set up each devicehas problems. The problem seems to becaused by the different methods of datacollection, for example; on demand,continuous etc. The DAQ Assistant doesn'tallow each device to prioritize. This causes abus error. Dr. K and Dr. Kempski advised touse the DAQmx nodes and rewite the codein this fundementalist way. Week 7 had noaccess to a working LabVIEW to code.

In Progress Michael

7

Belt is slipping Belt seems to be slippingbecause of an issue with thejournal. System was takenapart and inspected. Visualevidence of damage to thepillow bearings wasdiscovered. Whencomparing the two pillowbearings one requires muchmore force than the other.Wear on the pillow bearinsouter diameter suggest itwas spinning in place. SeeProblem 7: Images

Damage could be caused by the removal ofthe pillow bearings insert. This process wasdone with the help of Rob from the toolroom. Difficulty was caused by defects inthe journal caused by the set screws thatsecure the journal to the insert. Flats weremilled into the journal to prevent this fromhappening in the future. New bearinginserts were priced through appliedtechnologies at $249.17 a peice. The insertwith new blocks would be $447.00 a peice.When talking with the associate it wasconfirmed that P14453 purchesed one fixedand one free. This explains why there isonly one split clip present. Typically a freebearing would be used in applicationswhere the journal "swells" due to heat andor high rates of rotation. Our systemexperiances neither.

Selected solution is topurchase a new bearinginsert and compared withthe old ones to ensure thatits the cause of theproblem.

Made order and picked up the bearing insertfrom Applied Technologies in Rochester on3/12/15.

Compared it to the two bearing inserts inquestion. When comparing the new insert tobearing insert A, see Problem 7: Images tab,the new bearing was more difficult to rotate.However, the bearings side to side movementwas the same. When comparing the newbearing insert to bearing insert B, the newbearing was easy to rotate and had much moreside to side movement. This side to sidemovment or off axis play allows for the insert toadapt to mis-alignments under 2 degress. Wereassembled the test rig using bearing insert Aand the new bearing insert. Upon completionwe rotated the journal by hand, which felt lessrestricted than before. After running the pumpfor 5 minutes we started the belt drive system.The motor was able to turn the journal withoutrestriction.

Completed Michael

P15453: Dresser Rand Journal Bearing Similarity Test RigMSD II Problem Tracking

ProblemNumber Status Team Member

Responsible

Identifying & Selecting Problem PSP 1

Analyzing Problem PSP 2

Generating Potential Solutions

PSP 3

Selecting & Planning Solution PSP 4

Implementing Solution PSP 5

Evaluating Solution PSP 6

R1 R2 R3 Y4 Y5 G6

8

Load Cell CalibrationProcedure produced resultsthat do not correlate with Tinusolsen

Tinus Olsen cannot hold asteady force. The readingvaries by about 10%. Thereis a change in load by thetime we record the voltageand the applied load.

One solution would be to set up the TinusOlsen applied load output screen in thesame frame as the mulitmeter and video thetest. Then gather data points by pausing thevideo

In Progress Molly

9

V-belt hardware does notmount to the oil pump

The oil pump has anirregular drive shaft. It is an11'16" notched taperedshaft. Surplus Center andGrainger do not carry anybushings or pullys that havea 11/16" notched taper

1. Buy a H-Bushing that has a 0.5" innerdiameter and then use bortrax to vut thetaper. Use the two diameters and lengthcom come up with the angle. Onlyprobablem could be the mount. This couldbe mixed by using flat head screws.2. Purchase a different pump that has astandard shaft

Selected Option 1 Purchased 1/2" taper from amazon. Machinetaper, slot and counter bore with Rob's help.See Problem 9 documentation.

Vbelt pulley mounts to oil pump without anissue. See Problem 9 documentation.

Completed Michael

10

EMA's are larger than werespecified in MSD 1. Mountsneed to be redesigned toadjust for this difference. X-axis mount could pose aproblem because of how far itneeds to hang off the surfaceof the table In Progress Christina

P15453: Dresser Rand Journal Bearing Similarity Test RigMSD II Problem Tracking

ProblemNumber Status Team Member

Responsible

1/26/2015

2/6/2015

2/5/2015

2/9/2015

2/19/2015

3/5/2015

Problem 1: Documentation

Date Problem Analysis Images from the first dissasembly

Emails - Steven Luchessi, project manager from last year was contacted. He said"Reviewers stated it would be gallons, but I don’t recall any calculations we actuallydid to prove that."

Emailed Scott Delmontte who stated: "Our published data for this particular framespecifies a flow rate of approximately 2.5 to 3 gallons per minute of oil flow for thecomplete machine at 360 RPM. Considering that this flow is shared between the twomain bearings and the connecting rod bearing, I would say an estimate of 0.8 to 1gpm for each of the bearings is realistic. I haven’t crunched the numbers but this flowshould be representative of a single plain bearing. "

Initial Testing at o load and 0 rpm showed flow rate being on the order of drops perminute not gallons. Our value was 0.001585 gpm

Dr. Boedo was contacted who confirmed he did no flow calculations for last yearsteam. He provided us with the equations needed to determine the flow theoretically.His numbers were for 0.0165 gal/min to 0.0575 gal/min. Which were high comparedto ours

To figure out the difference we looked into the actual clearence of the journal andbearing which was about 32 microns instead of the 45um that was specificed. It wasalso discovered that the oil being used was SAE30 not SAE10 which was originallyassumed because of the box of oil that was in the lab. SAE30 was mentioned one inthe assembly instruction to lubricate the journal before its placed in the bearinghousing. This changed the dynamic viscosity from 79cP to 300cP. To ensure that thepressure value was correct a test was done to aquire the pressure drop from the feedhole in the bearing. This was found to be 20psi. With these corrected values pluggedinto Dr. Boedo's equations the range became 0.0009gpm to 0.0022gpm. Thereforeour tested value now correlates with the theory

To try and spec out a flow meter that would work for our application, we asked Dr.Boedo to run analysis on what the flow would be under dynamic loading. He ran hisanalysis with viscosity values of 0.3 Pa-s and 0.005 Pa-s and obtained flow values of9.04e-4 gpm and 0.1081 gpm respectively. The lower viscosity value of 0.005 Pa-swas used because Dr. Boedo assumes that the viscosity will drop due to thetemperatures rise that he expects within the bearing. So with that value he gives usan upper bound no flow. To validate his numbers we will run another test to measureoil flow, we will measure the flow with a bucket, stopwatch, and a digital thermometerwhile the machine is running.

Date of Test 3/7/2015

Name of Tester Michael Bush

Model of Trans PX319-200G5V

Pressure (Psi) Shop Air Omega Difference

Voltage (V) Pressure (psi) 0 -4.3358 0 4

0.00 0 10 386.2642 401.74 15

0.42 10 20 776.8642 803.48 27

0.67 20 30 1167.4642 1205.22 38

0.92 30 40 1558.0642 1606.96 49

1.17 40 50 1948.6642 2008.7 60

1.41 50 60 2339.2642 2410.44 71

1.64 60 70 2729.8642 2812.18 82

1.89 70 80 3120.4642 3213.92 93

2.11 80 90 3511.0642 3615.66 105

100 3901.6642 4017.4 116

Slope (psi/V) 39.06 110 4292.2642 4419.14 127

Y-Intercept (V) -4.34 120 4682.8642 4820.88 138

130 5073.4642 5222.62 149

140 5464.0642 5624.36 160

Voltage (V) Pressure (psi) 150 5854.6642 6026.1 171

0.001 0 160 6245.2642 6427.84 183

2.489 100 170 6635.8642 6829.58 194

4.977 200 180 7026.4642 7231.32 205

2.492 100 190 7417.0642 7633.06 216

0.003 0 200 7807.6642 8034.8 227

Slope (psi/V) 40.20 84365.4 2430

Y-Intercept (V) -0.09

Problem 4: Pressure Transducer Calibration Results

Theoretical Based On Linear Fit

Calibratin with shop air Excitati

Calibration by Omega Excitatio

Sum% Difference 0%

Bearing Insert A (V-belt side) Bearing Insert B (Encoder side)

Problem 9: Machine of Slipt H Taper and Results