03-2012 Report - University of Delaware
Contents
1. 15 Appendix B Force Calculations 44 Appendix C User Manual 45 Appendix D Bill of Materials 56 Appendix E Path Forward Technical Information 60 INTRODUCTION Background and Significance W L Gore is well known for the fabrics they manufacture for a variety of applications One of these families of fabrics is used in industrial air filtration In this application open ended cylindrical bags made of the fabric filter are hung in cages Dirty air is forced through the sides and bottom and clean air exits through the top causing the outside of these filter bags to become caked with particulates To improve airflow compressed air is fired axially down the inside of the bags to dislodge the particulates W L Gore has previously designed a unit to test the life cycle of the filter fabric material in a destructive test which simulates accelerated wear due to firing compressed air However this previous design does not operate as required nor does it include desired functionalities It is also not user friendly and has raised safety concerns Project Scope W L Gore has requested that the senior design team redesign the filter fabric material life cycle testi2. Once in REM mode set the Remote Mode Setting to Run Micro830 Even POU Unheated Valve Opening POU Main Program POU Micro830 Program Major Fault Micro830 Run Controller Mode t Download Upload Secure Click Start Debugging then double click on the program on the left side of the screen to see the debugging results A red line denotes an energized circuit a blue line a de energized circuit View Build Debug Tools Communications Window Help START Ah Ga or Os PL 3 jort EA TAS a h 2y To see the debugging of a User Defined Function double click on the instance of the function block in the debugging mode of the main program see above Click Stop Debugging Mode when debugging is finished see step 4 Put the PLC back into Remote Mode Program see step 3 Make any necessary changes to code the follow steps to download updated code to PLC see DOWNLOADING PROGRAM TO PLC 50 Creating Modifying HMI Human Machine Interface Application In the case that any changes are desired to the HMI application or development of a new application is required the following steps should be followed NOTE Any development must be done on a laptop computer so that troubleshooting the HMI application can be done at the testing device 1 Ensure that Connected Components Workbench is installed on computer If CCW is not installed it can be downloaded free of charge from http ab rockwellau
3. 2 1 0 28 THRU HOLE 40 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG 4 50 Y PROJECT OR CLASS UD SENIOR DESIGN MEEG401 DRAWING TITLE FABRIC FIXURE O RING HALF DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 5 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 19 _ 6 00 0 25 90 25 10 x 24 TAPPED 41 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG 4 50 Y PROJECT OR CLASS UD SENIOR DESIGN MEEG401 DRAWING TITLE FABIRC FIXTURE TAPPED SIDE DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 5 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 20 o NO 5 a c CO amp F c H TI LO N c ON Y Y I _ 54 375 _ 63 750 al PROJECT OR CLASS unes Oihermise SENIOR DESIGN MEEG 401 Notea DRAWING TITLE DECIMAL BOTTOM BOX PIECE XXX 005 ROSES XX 010 X 050 DRAWN BY MICHAEL MARANDO DATE 11 2 12 APPROVED BY TEAM GORE DATE 11 2 12 FRACTIONAL 1 32 MATERIAL 1 8 ALUMINUM QUAN
4. 01 DWG NO XX TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG 30 PROJECT OR CLASS SENIOR DESIGN MEEG 401 DRAWING TITLE TESTING CHAMBER TOP DRAWN BY MICHAEL MARANDO APPROVED BY TEAM GORE MATERIAL 1 8 ALUMINUM SCALE 1 10 BILLING ACCOUNT 2 DATE 10 27 12 DATE 10 27 12 QUANTITY 1 DRAWING NO 3 31 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG PROJECT OR CLASS SENIOR DESIGN MEEG 401 DRAWING TITLE TESTING CHAMBER LID SIDE DRAWN BY MICHAEL MARANDO APPROVED BY TEAM GORE MATERIAL 1 8 ALUMINUM SCALE 1 7 BILLING ACCOUNT 2 DATE 10 27 12 DATE 10 27 12 QUANTITY 2 DRAWING NO 6 Vertical hole distance center to center Vertical measurement for start of window Note can round to 3 6875 3 and 11 16 32 18 000 Horizontal measurement for start of window Window Size 8 x 18 11 00 21 00 lt N a 33 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE INSIDE WINDOW DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL POLYCARBINATE SCALE 1 5 BILLING ACCOUNT D
5. Carr 9888K17 2 485 46 E 2 Tank Bolts McMaster Carr 902714624 8 5 10 Tank Nuts McMaster Carr 91850A190 8 6 92 g or 2 Metal aa AA Cam 4806K39 2 218 80 a Hoses 12 Long 1 NPT Pipe McMaster Carr 44615K546 1 6 28 3 Long 1 NPT Pipe McMaster Carr 44615K456 1 1 65 A Type L G16L44 G Solenoid Valves Magnatrol Valve Corp 24V DC 2 668 00 Ke threaded NPT MoMaster Carr 44615K416 1 1 41 O Ren MeMaster Carr 45375K323 1 73 73 Bushing Air Heater omega com AHP 7561 1 105 00 Heater Insulation McMaster Carr 9364K11 1 9 65 Heater Insulation Wrap McMaster Carr 2587111 1 29 17 Hex Reducing Bushing McMaster Carr 44605K369 1 2 42 3 port ball valve McMaster Carr 4017T14 2 71 66 3 4 FxM Adapter McMaster Carr 44605K313 4 25 76 Component 45 deg Elbow 3 Threaded Pipe PLC HMI Communication HMI Programmable Logic Controller PLC AI Module AO Module TC Module 14 Stranded Wire Black Cable Tie 1 Mount Pad Switch Control Systems DC Paddle Electric Tape Resistor Wire Labels Terminal Block Terminal Block Jumper Ultra Thin Relay Cable Wraps 8 GB Flash Drive Nozzle Bracket Material Fixture Bracket Material Specimen Frame Material Interior Fixtures Specimen Fixture O rings Vendor McMaster Carr McMaster Carr Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Allen Bradley Home Depot Home Depot Home Depot Radio
6. SENIOR DESIGN MEEG 401 D PTIO N TY UNLESS OTHERWISE NO NUMBER Q a MINUM 5 16 1 DRAWING TITLE SIDE BRACKET ASSEMBLY Bracket nn HOLES I DECIMAL 2 Bracket RE 1 2 x 1 2 ALUMINUM 2 ee EP ie DRAWN BY MICHAEL MARANDO DATE 12 8 12 SuppQ ANGLE SUPPORTS CHECKED BY TEAM GORE DATE 12 8 12 FRACTIONAL APPROVED BY TEAM ADVISORS DATE 12 8 12 1 3 3 3 a 5 16 18 SOCKET CAP gt MATERIAL SEE B O M QUANTITY 02 SCREW ZINC PLATED STEEL ANGIR SCALE 1 2 DWG NO 15 0 5 DE 24 BILLING ACCOUNT UN N FE A N QTY Es PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 1 Center ES es Ie 1 DRAWING TITLE CENTER BRACKET ASSEMBLY Bracket SE HOLES ane XXX 005 5 16 18 SOCKET CAP ee A ua DRAWN BY MICHAEL MARANDO DATE 12 8 12 2 Screw No SCREW ZINC PLATED STEEL 4 CHECKED BY TEAM GORE DATE 12 8 12 SONE APPROVED BY TEAM ADVISORS _ DATE 12 8 12 9 1 32 MATERIAL SEE B O M QUANTITY 01 3 Bracket Eee oe 2 ANGULAR SCALE 1 5 DWG NO 13 Support ii BILLING ACCOUNT 25 26 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE FACBRIC FIXTURE ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 2 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DAT
7. are flush with the surface of the fabric fixture b Begin to torque bolts one at a time 3 revolutions per screw in the order of top right corner bottom left top left then bottom right c Repeat the described tightening pattern until the corner of the two plates touch 5 Open testing chamber lid until gas spring on the left side locks into place Place fixture with fabric sample in the fixture brackets 46 TEST SETUP 10 11 12 13 14 15 Prepare and mount fabric sample Adjust fabric fixture brackets and nozzle brackets to desired locations a Remove screws using either a 5 32 or 6mm Allen wrench b Remove plugs from base plate using pliers if necessary c Adjust brackets to desired locations and screw down to baseplate d Put removed plugs in newly vacated holes If only one specimen is being tested close the valves on the three way split in the testing chamber corresponding with the empty fabric fixture slot Close lid of testing chamber by pulling the knob on the left locking gas spring and gently lowering the lid Secure latches when lid is closed Ensure the testing unit is in a location where it will not be disturbed by humans or machinery and in a location where excess noise will not be considered an issue Plug in the onboard Uninterruptable Power Supply UPS to a 120VAC power supply NOTE In the case of a power outage the UPS will provide power long enough to ensure that during a heated test th
8. event of pneumatic failure or chamber opening lt 10 Requested by W L Gore Heat Tolerance Heat Tolerance Tolerant above maximum operating test temperature Fabric Fixture Circular ace col 9 To be more comparable to industrial applications Visibility Ergonomic and clear visibility of illuminated specimen Pressure Control I psi Unit fires when tank pressurizes to within 1 psi of set value for test reliability Ease Ease of Cleaning Ease of Cleaning Time required to clean inside of chamber Portability and 1 Person Only one person required for transit and operation Operation Durability 1 000 000 cycles Number of firing cycles before any major maintenance is needed Specimen Heating 120 C Achieve desired specimen surface temperature Specimen Quantity Accommodate two fabric specimens simultaneously Table 1 Prioritized list of metrics and target values CONCEPT GENERATION amp SELECTION Benchmarking In the previous testing unit designed by W L Gore air was taken from the central compressed air distribution system in the production plant and brought to the unit by a hose with a quick release header The air passed through a manual shut off valve followed by a moisture removal unit The airline split to fill two air tanks to specified pressures as controlled by manual regulators The air from the right tank traveled by hose to the right side of the testing chamber where it passed through a heater follow
9. not wired properly for temperature control The testing chamber control unit and pneumatic system were all mounted onto a cart with pneumatic wheels Preliminary Concepts amp Selection This project is a redesign of the old testing unit which calls for the general design to remain the same but for the majority of components to be new and upgraded The component options are presented and selected with justification below Air Shut Off Valve For safety a valve is needed to close off the air supply to the unit The available options were automated ball valves and manual ball valves An electrically actuated ball valve was chosen as it allows for programmed control of the air supply Moisture Separator Removing moisture from the air prolongs the life of the unit The choice was between reusing the old unit s moisture separator which could be restored to full functionality with a maintenance kit or finding a different model with the same specifications It was deemed most cost effective and sensible to reuse the old moisture separator and purchase the maintenance kit Pressure Regulators To control the pressure of the tanks air pressure regulators are needed The available options were manual digital and digital with input and feedback with PLC The final option was chosen as it allows for program control and monitoring of the pressures with high accuracy Tanks The capacity of the tanks did not significantly influence the
10. the fact that the program is dysfunctional could not be properly tested Before integrating the ball valve with the control system programming it is suggested that the ball valve be tested by forcing an output through the debugging mode see Appendix C for details on debugging mode 60 VO Location Device Description DI 00 PLC Backplane DO 00 PLC Backplane DO 01 PLC Backplane Closure Sensor EABV Close EABV Open DO 03 PLC Backplane Solenoid Valve 1 DO 04 PLC Backplane Solenoid Valve 2 DO 05 PLC Backplane Lights COM 0 PLC Backplane Common for DI 00 CMO PLC Backplane Power Supply for DO 00 CM1 PLC Backplane CM2 PLC Backplane Power Supply for DO 01 Power Supply for DO 02 through DO 05 AJ 01 IF4 Module Pressure Sensor 1 Monitor A1 03 IF4 Module Pressure Sensor 2 Monitor AO 00 OF2 Module AO 01 OF2 Module Pressure Regulator 1 Command Pressure Regulator 2 Command COM OF2 Module Pressure Regulator 1 Command COM OF2 Module Pressure Regulator 2 Command Table E Current system I O locations and descriptions 61
11. was deemed ideal to fabricate all new components to more easily allow for the desired configuration and accommodation of two specimens e Control System The control system options were reusing the entire control system scavenging the PLC and some components or completely rebuild the control system The sponsor requested a new PLC and Human Machine Interface HMT as the old PLC was not deemed user friendly Components of the old system namely the control box power converter terminal blocks and relays were reused The new PLC will also allow for the requested alarm system functionalities in the event of chamber opening or pressure loss e Cart Researched carts come in many shapes and styles ranging from widths of 24 to 36 and lengths of 18 to 60 Cart heights were relatively consistent but a variety of handle types allow for different ergonomics A cart 30 wide x 48 long x 36 tall with locking wheels and floor brake was chosen for expected stability due to its wide base locks and dimensional accommodation of the testing chamber FINAL DESIGN Overview In the testing chamber of the redesigned unit one or two fabric specimens can be mounted for life cycle testing The fabric specimen s can be subject to one of two tests a test that includes cyclically fired air from one or both sides or a test that includes constant heated air from one side and cyclically fired air from the other The exact test to be run and relevant
12. which will be addressed by intensive testing One such component that could be damaged is the heater which will blow out if the solenoid valve is closed off while heater is operational Programming the control unit to supply air to the heater until it has cooled will mitigate this risk Another possible failure is the overheating of the solenoid valves due to the heater This risk has been lessened by selecting solenoid valves with high enough ambient and media temperature specifications and placing a PTFE fitting between the solenoid and heater to reduce heat conduction The unit is not equipped to handle a power outage so an uninterruptable power supply should be provided however this issue was identified too late in the design process to fully address Testing e Preparation time The sponsor requested that the specimen mounting preparation was timed Specimen mounting consists of placing the fabric specimen between the two brackets tightening all four screws and placing in the testing fixture An individual with a single precut piece of fabric set of frames and screws and Allen wrench was timed by a second person with a stopwatch The result was 44 seconds which implies that the preparation is simple and easy e Operation noise While the unit was operating at 50 psi a decibel meter was positioned at a 3 ft distance to measure the maximum sound intensity the unit produces over multiple valve firings The measured value was 110 dB which m
13. 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 APPROVED BY TEAM ADVISORS MATERIAL SEE B O M DWG NO XX 22 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE BASE PLATE ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 8 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 11 ITEM PART i 1 4 ALUMINUM Interior PLATE 5 16 18 1 Base TAPPE PES Bracket O 3 Fixture S EE 2 AssembligSY TAPPED INCLUDES 2 Cente CI ANGLE SUPPORTS SideaP zle 1 4 Anto STEEL PLATES 5 1 OBracket DIAMETER SLOTS 2 Assembly 1 06 HOLES 5 16 18 SOCKET Screw CAP SCREW ZINC 16 PLATED STEEL 1 4 ALUMINUM F ri PLATES VITON O abric RING 1 4 20 2 Fixture TAPPED HOLE W SCREWS TOLERANCES PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 UNLESS OTHERWISE NOTED DRAWING TITLE BASE PLATE ASSEMBLY DECIMAL XXX 005 XX 010 h o 050 DRAWN BY MICHAEL MARANDO DATE 12 8 12 CHECKED BY TEAM GORE DATE 12 8 12 ERGE APPROVED BY TEAM ADVISORS DATE 12 8 12 1 82 MATERIAL SEE B O M QUANTITY 01 ANGULAR SCALE 1 8 DWG NO XX 0 5 DEG BILLING ACCOUNT 23 ITEM PA RT TOLERANCES PROJECT OR CLASS UD
14. 652 Class A 2 x24 x48 7454A24 9425K14 4138T57 99129A051 1530A51 8 32 Thread 3 8 Length SPCAR2CL 500RM 92210A249 90480A011 Schmersal AZ 16 ZVRK Sxhmersal AZ 15 16 B6 8982K871 M5 0 8 mm x 20 mm countersunk M5 0 8 mm 1967A3 MS 0 8 mm x 16 mm 1863A16 91772A126 904804006 10 24 Thread 3 8 Length 55015K28 Leviton 70046 75 W Soft White Bulbs 6 32 Thread Quantity 1 6 sheets 2 18 0 5 x24 x48 sheet 20 20 10 10 1 168 00 588 27 21 37 57 85 14 47 3 40 7 08 3 54 243 00 8 70 1 72 79 00 22 00 9 62 3 92 2 70 6 46 0 98 5 72 6 36 1 59 1 18 64 00 12 90 1 54 0 32 Component Vendor Part Number Quantity 57 Box Trim Home Depot EPDM Rubber tape 2 16 74 _grey 20ft Teflon Tape McMaster Carr 4591K12 2 4 62 Electrically Actuated Ball B600F 4IS0 Valve Control Resources Inc 024AC DC 1 210 28 7 Pipe NPT McMaster Carr 44615K194 3 8 55 F T20C Moisture Removal Unit Beach West Filters KIT20 1 61 20 Maintenance Kit 4 Pipe NPT McMaster Carr 44615K464 1 1 22 Tee Joint McMaster Carr 44605K154 1 1 89 5 Pipe NPT McMaster Carr 44615K474 2 2 82 3 Pipe NPT McMaster Carr 44615K454 3 3 00 Hose 2ft McMaster Carr 5304K39 2ft 1 17 28 90 deg Elbow NPT McMaster Carr 68115K21 3 9 48 Die ae Air Control Inc OBATFEEO80 2 1 500 00 Regulators ES Tanks McMaster
15. 72 4 U Na LONG B KRO mber 1 4 ALUMINUM gt SHEET WELDED NS ssembly Base Plate 2 x1 5 x2 25 WOOD A Support eres Lid SEE LID ASSEMBLY 7 Assembly DRW ATTACHED TO BOX Closure BY INTERNAL sensor SCREWS 9 Lid Hinge STRAP HINGE 2 10 Hinge 5 16 8 THREAD 4 Screw 1 2 LENGTH TOLERANCES PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 UNLESS OTHERWISE NOTED DRAWING TITLE EXTERNAL ASSEMBLY DECIMAL XXX 005 ogee le DRAWN BY MICHAEL MARANDO DATE 12 8 12 CHECKED BY TEAM GORE DATE 12 8 12 FRACTIONAL APPROVED BY TEAM ADVISORS DATE 12 8 12 1 32 MATERIAL SEE B O M QUANTITY 01 ANGULAR SCALE 1 15 DWG NO 25 0 5 DEG BILLING ACCOUNT MO PARTNUMBER DESCRIPTION QTY 1 Cart 48 x30 x36 cart 2 Tank 10 gallon tank 2 3 Regulator to Tank 3 pipe 90 deg 2 Pipe elbow 7 pipe 4 Pressure Regulator Aoo pesue 2 o 2 5 pipes 90 deg 5 Piping sbon 2 hose 1 pipe Moisture Seperator moisture filter 7 3 in Pipe 3 pipe 2 Electrically 8 Actuated Ball Valve PaA vave l 9 Control Unit PLC TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 4 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS Senior Design Team W L Gore DRAWING TITLE External Components Assembly DRAWN BY ToniLynn Yavorski CHECKED BY Team W L Gore APPROVED BY Team Advisor MATERIAL Various SCALE 1 10 B
16. ATE 12 8 12 DATE 12 8 12 DATE QUANTITY 02 DWG NO XX 21 00 11 00 34 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE OUTSIDE WINDOW XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG DRAWN BY MICHAEL MARANDO DATE 12 8 12 CHECKED BY TEAM GORE DATE 12 8 12 APPROVED BY TEAM ADVISORS DATE 12 8 12 MATERIAL POLYCARBINATE QUANTITY 02 SCALE 1 5 DWG NO XX BILLING ACCOUNT 35 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG401 DRAWING TITLE FIXTURE BRACKET DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 2 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 02 DWG NO 16 0 78 HOLE DEPTH 5 00 6 00 36 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 ANGULAR 0 5 DEG lt H 1 63 2 00 PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE CENTER FIXTURE BRACKET DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL ALUMINUM SCALE 1 2 BILLING ACCOUNT DATE 12 8 12 D
17. ATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 14 9 000 3 000 3 500 12 000 _L 0 250 37 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG 6 000 PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE NOZZLE BRACKET UPRIGHT WITH HOLES DRAWN BY MICHAEL MARANDO DATE 11 15 12 APPROVED BY DATE MATERIAL ALUMINUM QUANTITY 02 SCALE 1 5 DRAWING NO 23 BILLING ACCOUNT 2 1 3 418 8 000 RO 166 2 000 12 000 0 916 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG 38 0 250 _ 5 000 PROJECT OR CLASS UD SENIOR DESIGN DRAWING TITLE NOZZLE BRACKET BOTTOM PLATE DRAWN BY MICHAEL MARANDO APPROVED BY MATERIAL ALUMINUM SCALE 1 5 BILLING ACCOUNT 2 DATE 11 15 12 DATE QUANTITY 02 DRAWING NO 22 4 750 0 250 4 750 ml 39 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE ANGLE BRACKET DRAWN BY MICHAEL MARANDO DATE 11 15 12 APPROVED BY DATE MATERIAL ALUMINUM QUANTITY 04 SCALE 1 2 DRAWING NO 24 BILLING ACCOUNT
18. Code B WE Model number EL20 e When replacing light bulbs use only 60W incandescent e To adjust the sensor closure key open the chamber and find the adjustment screw on the sensor key The adjustment screw is the visible flat head socket screw Using a 5 64 or 2 mm Allen wrench adjust the key to the required angle Loosening the adjustment screw brings the angle closer to 90 degrees while tightening it makes the angle smaller e Solenoid valve diaphragms should be replaced after roughly 1 million cycles at continuous operation with 30 seconds between intervals 1 million cycles will be reached in 1 year Contact Magnatrol for replacement information Model number is Type L G16L44 G 24V DC 54 Troubleshooting Problem Solution Pressure Loss Alarm is occurring Ensure that the pressurized air is being supplied to the unit Check if any parts are loose and may be causing pressure loss and tighten component Ensure that electrically actuated ball valve is open Check that pressure parameters are not set too high above 60 psi Ensure that total cycles parameter is above 0 Lid opening alarm is occurring Make sure lid is closed properly and the lid is latched If lid is not closing or contact sensor is not registering that the lid is closed adjust the key accordingly see Maintenance section page 10 Test will not start when Start button is pressed Light is not turning on Make sure that the P
19. E 12 8 12 QUANTITY 02 DWG NO 17 ITEM NO PART NUMBER Fabri SN VITON O RING 3 16 THICKNESS 3 7 O D Screws 1 4 20 THREADS 5 8 LENGTH NOTE SCREWS GRINDED FLUSH W PLATE N 27 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE FABRIC FIXTURE ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL SEE B O M SCALE 1 2 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 02 DWG NO 18 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG 28 PROJECT OR CLASS UD SENIOR DESIGN DRAWING TITLE NOZZLE BRACKET ASSEMBLY DRAWN BY MICHAEL MARANDO APPROVED BY MATERIAL STEEL SCALE 1 3 BILLING ACCOUNT 2 DATE 11 15 12 DATE QUANTITY 02 DRAWING NO 21 29 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE BOTTOM CHAMBER ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL 1 8 ALUMINUM SHEET SCALE 1 10 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY
20. Final Design Report Filter Fabric Material Life Cycle Testing Unit Team W L Gore Michael Marando Robert McGrath Michael Pfeiffer ToniLynn Yavorski Sponsor W L Gore Advisor Dr Jennifer Buckley PhD MEEG401 Senior Design Department of Mechanical Engineering University of Delaware Newark DE Submitted 12 12 2012 Table of Contents INTRODUCTION cit AAA cence silanes AAA ce ones AA 1 Backeround and Significante a id is 1 Project SCOPE AA AA AAA Ge ae eg 1 Needs Wants amp Constraints 1 Design MEES A siasat A RAE A AA SARA Aber 2 CONCEPT GENERATION amp SELECTION 3 Benchmarkih SE NR A 3 Preliminary Concepts amp Selection 3 FINAL DESIGN osse SE DAA SORA 5 Dee stede 5 Desten Details ASA AAA AS AGS AA 5 User Ee KI EO EE ER EE asses asseta 9 Corluka OS ES SR EES RE Re Se Es 9 DESIGN VALIDA TION iss ee N EE EG Ge Go Ee Ge ree OG Ge een 10 F ilure GE OER xg os sense vies oa OR is nisin sin EE OE ONE 10 ER ET OR AE 10 Validation ROSUUS A A N GR ee We Ee ai SN 11 CONCLUSION Sopa Gen 12 Design Evald GOM A SP See Ee De di se ndo 12 Deliverables iss neer EE tease de ts onts ed NG GE a a Ge Ed GR ENE de vee dese 12 Path Forward da 12 APPENDICES EA ge ves oy vis ee Ge Ge se vai Ge RR 14 Appendix A Drawing Package
21. ILLING ACCOUNT DATE 12 12 2012 DATE 12 12 2012 DATE 12 12 2012 QUANTITY 1 DWG NO 26 19 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE CHAMBER ASSEMBLY DRAWN BY MICHAEL MARANDO DATE 12 8 12 CHECKED BY TEAM GORE DATE 12 8 12 APPROVED BY TEAM ADVISORS DATE 12 8 12 MATERIAL SEE B O M QUANTITY 01 SCALE 1 10 DWG NO 02 BILLING ACCOUNT 20 TOLERANCES UNLESS OTHERWISE NOTED DECIMAL FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE LID ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL SEE B O M SCALE 1 10 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 10 5 GASES DESCRIPTIONS YGTY 1 Lid Too 1 4 ALMINUM S a 1 2 Lid Side 1 4 ALUMI HEET 2 3 lid Handle O M EE aa 4 PE SG PLEXIGLASS gt NOTED E ide N aa a 5 Windo O X 050 6 Winday 5 16 18 THREAD 1 5 20 Scr LONG 5716 18 THREAD 1 2 KG ar are TE TO ANGULAR 8 5 16 ee EES 21 PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE LID ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE SCALE 1 10 BILLING ACCOUNT DATE 12 8
22. LC is in Run mode Make sure air is supplied to system and the electrically actuated ball valve is in the open position Ensure the PLC is in RUN mode Check to see if light bulb needs to be replaced Air is continuously firing out of heated side if not desired Make sure heater is off on testing parameter page 55 Appendix C Bill of Materials D E OD Ep d Un O Ei I DA nA A WwW N 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Component Testing Chamber Acoustic Insulation Adhesive for insulation Locking Gas Spring Gas Spring Gas Spring Nuts Hinges Hinge Screws and Nuts Window Material Window Screws Window Nuts Closure Sensor Sensor Key Sensor Attachment Bracket Sensor Attachment Screws Sensor Attachment Nuts Handle Handle Screws Latches Latch Screws Latch Nuts Other Latch Screws amp Nuts High Temp Metal Duct Light Sockets Light Bulbs Light Nuts Vendor Sheet Metal Contracting Soundproofcow com McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr Home Depot Professional Plastics McMaster Carr McMaster Carr Wolf Automation Wolf Automation McMaster Carr Home Depot Home Depot McMaster Carr Home Depot McMaster Carr McMaster Carr McMaster Carr Home Depot McMaster Carr Sears Home Depot Home Depot 56 Part Number T 3
23. TITY 1 SCALE 1 15 DRAWING NO 8 ANGULAR 5 DEG BILLING ACCOUNT 4 3 2 1 42 43 TOLERANCES Unless Otherwise Noted DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 5 DEG PROJECT OR CLASS SENIOR DESIGN MEEG 401 DRAWING TITLE BOTTOM BOX PIECE LIP BEND RADIUS DRAWN BY TEAM GORE APPROVED BY TEAM GORE MATERIAL 1 8 ALUMINUM SCALE 1 10 BILLING ACCOUNT 2 DATE 11 2 12 DATE 11 2 12 QUANTITY 1 DRAWING NO 9 Appendix B Force Calculations The fired compressed air was modeled as a turbulent jet as shown in Figure B 1 The input parameters are pipe diameter and exit velocity found using compressible air flow tables plane of lt orifice u z r Umax EXP 3 1 Uns 5d RE aa Qnrdr H TR u 2rrdr gt l 4o 2R 50r u t r Umax xpl apr 52 entrainment of ambient fluid i aa TT Professor Cushman Roisin Environmental Fluid Dynamics Professor Cushman Roisin Environmental Fluid Dynamics Figure B 1 Model and equations of a turbulent jet The velocity profile at distance x with radius r is a Gaussian distribution The average velocity was calculated for a range of distances An equations to find the force of the air was derived and is shown in Figure B 2 Q v m pQ pvA F mv F pv A Figure B 2 Derivation of force equation The total maximum force at various distances was calculated and is sh
24. cMaster Carr McMaster Carr Sheet Metal Contracting Home Depot Home Depot Home Depot DC Graves Co Inc McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr Home Depot N A omega com McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr Part Number 91263A556 47065T224 47065T222 8711K19 9277K38 T 3654 5 16 18 Thread 1 Length 5 16 18 Thread 3 8 High 3 16 Zinc AW24 BK B3 F3 3310T241 91263A553 9246K 13 1756A3 44605K344 2 pin hinge AHP 7561 1530A51 8822K51 85985K 13 85985K12 8266K19 9464K61 Quantity 10ft 1 pack 1 pack 1 ft 12 12 31 68 10 48 460 00 0 68 0 48 0 56 451 00 22 80 6 88 20 11 9 66 2 49 2 47 56 52 105 00 3 54 3 90 5 00 4 70 25 69 9 38 Figure A Project bill of materials by project category The last category is components purchased but not used in the final design The total is the total cost for the entire project 59 Appendix E Technical Information for Path Forward The pressure regulator exhaust air can be vented into the testing chamber by inserting the male end of a 4 NPT hose into the exhaust port of the regulator A 3ft hose McMaster Carr 5304K39 3ft 18 48 is recommended for the right side and a 4ft hose McMaster Carr 5304K39 4ft 19 68 is recommended for the left side Hole
25. e PDF s supplied on flash drive titled Micro800 and CCW Getting Started Guide and Micro830 User Manual or navigate to the built in help menu by double clicking on the Micro830 icon on the left and then Help Project Organizer X Micro830 Even POU Uni val ning POU Main Program POU A Name New Revision Gore 2 Program Major Fault FRI Mm 0830 Micro830 an Diiconnected 2 icre Mi 830 Run Controller Mode E Es Programs t B o am Download Upload Secure Manuals Hel a fr Main Program p m Local Var 2080 LC30 24QWB Global Variabl T A Gore Fabric Sample Testing Apparatus s DataTypes ES User Defined Functior 3 fr Unheated Valve vw Local Var CREATING A NEW PROGRAM To create a new program follow the instructions in PDF Micro800 and CCW Getting Started Guide supplied on flash drive starting on page 14 In program help function will supplement this publication 48 DOWNLOADING PROGRAM TO PLC 1 Plug control cabinet into power source and open cabinet door 2 Ensure PLC is in either PRG or REM mode via the toggle switch locations shown below 11 1 RUN REM PRG 3 Connect to the PLC by following the pictorial procedure below EE v 7 X Micro830 Even POU Unheated_ Valve Opening POU Mein Program POU x Name New Revision Gore 5 Program Major Fault Micro830 Disconnected Micro830 Run Controller Mode B Program
26. e heater will not blow out Ensure the proper HMI application is loaded If not see RUNNING ANOTHER APPLICATION LOADED ONTO HMI on page 10 of the user manual Attach quick release hose from central air supply to testing unit Insert exhaust tubing into top of the testing chamber and turn on exhaust vacuum external component not included in system Input testing parameters into HMI a On the main screen select Input Testing Parameters b On the Testing Parameters screen select input pressure valve opening time time between left and right pulses and total cycles If the test is desired to be unheated ensure the heater is OFF d Ifthe test is desired to be heated i Set the heater to ON in the testing parameter screen ii Set the desired temperature on the testing parameter screen Hi Set the desired temperature on the temperature control unit to the left of the HMI NOTE Instructions for setting temperature control unit will be provided during follow up independent study during next semester of UD academic year Click start test when ready Click Lights On Lights Off on HMI to turn lights on or off NOTE Do not leave lights on if not vlewing sample Click Stop Test to interrupt test a Ifa resumption of test is desired click Start Test to resume from current cycle count b Iftestis desired to be reset press Reset Counter and follow instructions to start a new test NOTE Ensure testing parameters are still as desired o
27. e side of the box will distort the closing of the lid e When opening lid make sure gas spring is locked before letting go of handle e When closing lid pull knob on left gas spring before lowering lid e Secure latches before operation e Ensure three way ball valves inside testing unit are open or closed per testing requirements e Note that at least one of the valves in the testing chamber must be open or failure will occur e Do not leave the light on in the testing chamber unless viewing sample e Do not touch heater or adjacent pipes when in operation e Do not open box while in operation If necessary stop test first then open testing chamber e Do not open control cabinet while test is running e Only open control cabinet if changes to electrical wiring or programming are necessary e Do not change wiring unless the unit is powered OFF e Ensure air supply is disconnected if program changes are being made e Instructions for PLC coding and HMI applications will only work with Windows Operating System SAMPLE PREPARATION 1 Cut a4 25 x4 25 11cm x11cm portion of fabric to be tested 2 Remove screws holding fabric fixture together 3 Lay fixture half with o ring down on flat surface and center fabric on top stretched out as much as possible 4 Reattach fabric fixtures with the four screws Tighten screws according to the following steps until corners of the plates touch a Screw in all four screws one at a time until each
28. e used for the life cycle test At least one nozzle set should be open for any test The testing chamber is closed and the latches are engaged See Appendix C for complete users manual Cost Analysis The final design costs a total of 9 214 59 of the 10 000 budget The cost of each item is displayed in the Bill of Materials in Appendix D The most expensive components in descending order were the two digital pressure regulators 1 500 the fabricated aluminum testing chamber 1 168 the HMI 687 the two solenoid valves 668 and the sound insulation 588 Every other component s price was under 500 The components are divided into five categories based on where they fit into the design The pneumatic items had the largest cost as they were the most important features of the design The testing chamber is the second most expensive It required the most individual parts but almost half of its cost came from the fabricated testing chamber Table 2 Cost of each project category and total cost DESIGN VALIDATION Failure Analysis The most likely design failure is in the wiring and programming of the control system due to the lack of expertise in the team In wiring the components there is the risk of damaging internal circuitry which will be mitigated by seeking outside help and intensive testing In programming the control system there is the risk of the program being dysfunctional and damaging components as a result
29. eans that the design is operating above OSHA regulations e Displacement A displacement dial indicator was positioned against the side of the cart to measure the side to side displacement A video was taken of the dial reading while the testing unit fired at 30 psi The measured maximum displacement was 0 001 when unit fired meaning that the unit is very stable e Alarm for Pressure Loss To simulate air pressure loss the air supply pressure was lowered below the set pressure of the tanks at the start of a test The time until the testing unit activated the alarm response was timed at 30 second This observed response time confirms that the program properly signals an alarm when the tanks have not filled to the set pressure in 30 seconds e Alarm for Lid Opening To test the alarm for the opening of the lid the testing chamber lid was unlatched and lifted until the closure sensor disengaged The testing unit s response was closely observed The solenoid valves instantaneous ceasing to fire confirms that the alarm operates as desired 10 Pressure Control For life cycle test reliability the solenoid valves are supposed to fire when the tanks are within 1 psi of the set value To test this the difference between regulator feedback pressure and set pressure at firing was visually inspected on the computer s program interface It was observed that the metric was met Visibility The illuminated visibility of the surfaces of the mo
30. easured operating displacement of 0 001 is well under the design metric of 0 5 Both alarm functionalities operate as desired meeting the design metric The fabric mounting brackets 11 allow for the desired exposed area and the design is capable of accommodating multiple samples Furthermore specimens are visible from both windows The pressure control target value of 1 psi was passed as well as the metric of requiring only one individual to transport and operate However the ease of cleaning metric of 5 minutes was not met but satisfactory cleaning can be expected in a reasonable amount of time The durability of the testing unit could not be tested due to the program not being completed and the infeasibility of testing to the target cycle count Furthermore the heat tolerance and specimen heating could not be tested due to the present temperature control unit not functioning in conjunction with the PLC as required CONCLUSION Design Evaluation The testing unit did not satisfy the original scope as the program is not functional and as a result fabric life cycle testing cannot be run All electrical components of the design are functional except for the electrically actuated ball valve which has been alternatively operated in manual mode As the temperature controller did not function as necessary for the project fabric heating and temperature tolerance could not be tested but testing chamber components are all heat tolerant to sp
31. ed by a thermocouple to monitor the temperature It then passed through a nozzle held in place by a nozzle bracket to fire a constant flow of heated air at the right side of the specimen The air from the left tank traveled by hose to the left side of the testing chamber where it was fired cyclically using a solenoid valve at the left side of the specimen The fabric specimen was secured between two frames which left a square area exposed and the fabric fixture slid into upright fixture brackets One of these frames had vertical metal bars which simulated the cage in a filter bag The fixture brackets and nozzle brackets could be repositioned along the tracks inside the testing chamber SS Chamber 1 ET Acoustic Insulation bP Closure Sensor ANY N Fo N 4 Thermocouple Lib y BE Nozzle Brackets 7 Solenoid Valve Valve Pressure Regulators Av Moisture Separator Figure 1 Front view of previous design Figure 2 Interior of testing chamber The previous testing chamber was constructed of wood had a single window on the front and had multiple cabinet latches to lock it The interior was lined with low density foam to dampen sound There was a sensor on the chamber to ensure that the unit operated only when the chamber was closed but it was not operational A programmable logic controller PLC controlled the firing of the solenoid valve and the heater however the heater and thermocouple were
32. fects to the application usage and can be ignored if troubleshooting or developing a new application For example if a display box is not linked to a variable the rest of the application will still function as desired 5 Ifchanges are made in CCW re upload application to HMI and restart validation procedure 6 Once validated save application in browser environment and close window 7 Unload the application from the Dashboard by clicking stop sign Applications Name PVcApplication1 Location Internal Mode Editing Touch sasen and communication are disabled Initial_T6T Yes Internal PVcApplication1 Yes Internal PVcApplication2 Yes Internal 53 RUN APPLICATION ON HMI 1 On the HMI Configuration Screen click File Manager on the left 2 Select the desired application from the list 3 Select Run at Startup in order to set as default loading application then click run RUNNING ANOTHER APPLICATION LOADED ONTO HMI 1 If an application is currently running click Goto HMI Config 2 Click File Manager on left side of HMI configuration screen NOTE Clicking Goto HMI Config may bring up the File Manager 3 Select the desired application to be run from the list Click Run to unload the current application and load the new application Maintenance e Replace desiccant filter on moisture removal unit every three months Order from http www beachwestfilters com Merchant2 merchant mve Screen PLST amp Store
33. functionality of the design so the choice had to be based on other factors The chosen tanks were the same capacity as the previous unit s tanks However the shape was chosen to be shorter in length than the previous tanks in order to better fit on the cart necessary port sizes were also taken into consideration Solenoid Valves There are a variety of specifications available for solenoid valves NPT inlet and outlet sizes orientation of inlet and outlet 180 or 90 normally closed or open medium and ambient temperature tolerance activation voltage 120V or 24V AC or DC The specifications chosen were 1 NPT for ideal air flow 180 orientation for simplicity of piping normally closed for safety tolerant of at least 120 C and 24V DC for simplicity of electrical wiring Air Heater A new air heater was needed as the old unit s was broken After product research it was determined the old unit s model is the only option found for this application s specifications Thermocouple and Sleeve To monitor the air temperature a thermocouple and sleeve are required It was determined that the old unit s thermocouple Omega Type K and sleeve should be utilized as it is fully functional and intended for the selected air heater model Testing Chamber The testing chamber could be constructed using wood sheet metal or plastic The decision was to have a 1 8 aluminum chamber lid and bottom fabricated by a machine shop as it was rec
34. interface with the new PLC so a new temperature control unit is required The control system must be wired appropriately to accept the retransmitted thermocouple reading from the new temperature control unit The electrically actuated ball valve also is not currently functioning An H bridge circuit has been constructed but has not been tested due to dysfunction of program A possible failure point was identified late in design process where if a heated test was running and a power failure occurred the heater would blow out when the solenoid valve closed due to loss of power The addition of an Uninterruptable Power Supply will help to mitigate this failure point See Appendix E for technical details on path forward 13 APPENDICES Appendix A Drawing Package 15 RE TOLERANCES A UNLESS OTHERWISE NOTED DECIMAL XXX 005 XX 010 X 050 FRACTIONAL 1 32 ANGULAR 0 5 DEG PROJECT OR CLASS UD SENIOR DESIGN MEEG 401 DRAWING TITLE CART ASSEMBLY DRAWN BY MICHAEL MARANDO CHECKED BY TEAM GORE APPROVED BY TEAM ADVISORS MATERIAL SEE B O M SCALE 1 20 BILLING ACCOUNT DATE 12 8 12 DATE 12 8 12 DATE 12 8 12 QUANTITY 01 DWG NO 01 TEM PART DESCRIPTIONIQTY NUMBER Q 48 x48 x32 STEEL Cart CART W WHEEL LOCKS Base Platel sce s sNYLATE Assembly AS Y DRW Cart EENS 18 CAP 4 Screw NY SCREW Nut N 5 1618 NUT 1
35. ion 8 5 Save all changes when finished 51 Downloading Application to HMI GENERAL INSTRUCTIONS In order to install and run a new application the application must first be downloaded to the HMI and validated See below for detailed instructions for connecting and downloading to the HMI CONNETING VIA ETHERNET 1 2 3 4 S Remove the screws holding the HMI panel in place Open HMI panel and connect CATS cable from computer to HMI Set the LAN IP address on the laptop to 192 168 1 10 and the subnet mask to 255 255 255 0 On the HMI navigate to the communications page button will be on the left side of the screen from the Configuration Menu If an application is loaded navigate to the main screen of the application then select Goto HMI Config then Communications Set the static IP address of the HMI to 192 168 1 11 and ensure DHCP is disabled DOWNLOADING PROJECT TO HMI l OS ONDE 10 Follow directions in CONNECT VIA ETHERNET section and ensure that the HMI is connected to the laptop via Ethernet cable Start either Internet Explorer Version 8 or earlier or Firefox Enter the HMI IP address 192 168 1 11 into the address bar NOTE Internet Explorer Version 9 is not supported Firefox will display a warning saying Version Not Supported if using a version greater than v4 Press OK and the HMI web portal will load anyway Once logged into HMI controls on browser click File Transfe
36. ircular area of 9 in as requested by the sponsor e Visibility The testing chamber is to allow a clear ergonomic and lighted view of the surfaces of the mounted fabric specimen through two windows e Ease of Cleaning The inside of the redesigned testing unit chamber is to have more rounded corners and edges and fewer crevices than the previous design The unit should be able to be cleaned quickly and efficiently with a vacuum and or a damp rag e Portability and Operation The unit is to require no more than one individual to transport and setup for operation and will have wheels for transportation e Durability Major components of the system should not require maintenance before 1 000 000 cycles e Specimen Heating The ability to heat a fabric specimen to 120 C is requested e Specimen Quantity The ability of the testing unit to accommodate two fabric specimens simultaneously is requested Constraints 1 Air Supply Limited by Gore s central compressed air equipment 600 gallon tank 75 hp screw 105 psi 1 inch air headers and 100 200 ft of hose before testing unit 2 Exhaust Vacuum Testing chamber will have an air hose compatible with Gore s industrial vacuum with a 2 75 diameter port to remove air born particles Design Metrics Description lt 85dB Must meet OSHA regulations Displacement lt 0 5 For safety cannot move during operation Alarm System 30 seconds For safety shuts down test In the
37. n Testing Parameter screen When finished with testing unplug the testing unit from power supply and air supply and remove exhaust tube Turn off exhaust vacuum and store testing unit in a location where unit will not be damaged 47 16 Creating Modifying PLC Program In the case that any changes are required for the control system program or a new program is needed on the PLC the following steps should be followed NOTE Any development must be done on a laptop computer in order to download and troubleshoot code using the debugging tool built into Connected Components Workbench CCW Ensure that Connected Components Workbench is installed on computer If CCW is not installed it can be downloaded free of charge from http ab rockwellautomation com Programmable Controllers Connected Components Workbench Software In the code and HMI application provided from University of Delaware Senior Design Team Pressure Regulator 1 and Solenoid Valve 1 refers to the unheated side while Pressure Regulator 2 and Solenoid Valve 2 refer to the heated side MODIFYING EXISTING CODE 1 Start CCW and navigate to the project folder Project folder should be contained in the CCW folder stored under Documents on the C drive if the project was developed on the computer in use 2 Open the desired project The provided code from the UD Senior Design Team has a file name of Gore Senior Design ccwsln 3 Modify code as desired For more instructions se
38. nd four screws left The fixture brackets hold the fabric fixtures in place right An Allen Bradley Micro830 PLC was selected and configured to provide the correct number of inputs and outputs I O both analog and digital for the control system I O was determined based off solutions to all other needs and wants The control system allows for the operator to select either a heated or a non heated test and input testing parameters such as pressure valve opening times total number of cycles and time between cyclic firings The operator can stop the test when desired and resume until total cycle count is reached or reset the counter to zero and begin a new test If a pressure loss occurs in the system and the valves do not fire for 30 seconds the system will go into an alarm mode venting the tanks and pausing the test Ifthe lid of the testing chamber is opened the valves will not fire until the lid is closed Temperature Controller Figure 8 Control System User Instructions Prior to operation the exhaust duct is inserted into the industrial vacuum the unit is plugged into a 120V AC power source and the plant air supply line quick release is attached to the air inlet The nozzle brackets and fabric fixtures are adjusted to the desired positions The fabric specimen s are secured into the fabric fixture s and slid into the fixture brackets The 3 way ball valves must be opened or closed in accordance with the nozzle set s to b
39. ng unit to their specifications This will allow for W L Gore employees to conduct accelerated life cycle tests of existing filter fabrics and use these results as a benchmark for the development of new filter fabrics Needs Wants amp Constraints The team constructed a prioritized list of needs wants and constraints and a list of metrics for evaluation These were presented to the sponsor and approved after several iterations The prioritized needs wants and constraints are as follows Needs amp Wants highest to lowest priority e Noise Reduction The previous design operated above the limits of OSHA regulations and was a nuisance to operators The new design should be quieter and meet OSHA regulations e System Stability For safety the new design should have no significant movement during operation due to the forces exerted from the firing of compressed air e Control System The new design will have a revised control system with components from the old unit and new components to allow for desired functionalities A new control system is required in order to integrate an alarm system as requested by the sponsor e Cost The sponsor requested that the redesigned unit cost less than 10 000 to develop e Heat Tolerance The testing chamber and all internal components must be able to withstand the temperature of a heated test which could be as high as 120 C e Fabric Fixture Redesign The redesigned fabric fixture should expose a c
40. ommended by specialists in acoustic insulation will be temperature tolerant and will shorten the total assembly time Sound Insulation There is a variety of sound dampening foams but few that are heat tolerant After researching foams the only option that was heat tolerant to specification was melamine foam The thickest option of 2 with a Mylar facing for easy cleaning was chosen Windows The window options were dictated by available transparent and heat tolerant materials which narrowed down the choices to glasses or transparent polymers Glass is temperature resistant but it is heavy and not effective as a sound dampener Clear plastics like Plexiglass Lexan and polycarbonate are better sound dampeners Doubled sided abrasion resistant 0 5 polycarbonate was chosen for the windows which will be double paned for additional acoustic insulation e Lighting The sponsor requested that the testing chamber have interior lights The options for lights were LEDs incandescent bulbs halogen bulbs and fluorescent bulbs After research it was determined that LEDs and fluorescent bulbs will not operate properly under high temperatures and halogen lights get too hot Incandescent bulbs with heat tolerant ceramic sockets were chosen e Chamber Interior Components The choice was between reusing single specimen components from the old unit while adding compatible new components to accommodate two specimens or fabricating all new components It
41. onsor s specifications The cost metric of 10 000 was met with a total project cost of 9 214 Deliverables e Filter fabric material life cycle testing unit will be delivered upon completion of follow up project for independent study or upon earlier request by sponsor Drawing Package See Appendix A User Manual See Appendix C Flash drive with component manufacturer manuals Spare parts and remnants of old testing unit if requested Bill of Materials See Appendix D Path Forward see next section and Appendix E Path Forward Several aspects of the project scope were not met by the project deadline Noise levels were much higher than OSHA regulations allow for continuous operation without hearing protection One reason for this was the pressure regulators operating differently than the team initially thought by venting excess air through the side It is suggested that additional hoses be purchased and installed to vent excess air into the testing chamber Addition of 1 of extra foam to the inside of all surfaces of the containment chamber could help with reduction of noise but it is recommended that the unit should be operated either in an environment where hearing protection is already required or operated in a soundproof room The control system requires updates The control system as it stands is not capable of running a 12 test as desired The temperature control unit used from the old design does not have the capability to
42. own in Graph B Force vs Distance O e NU T 2 m lt al x v o Sam 6 LL a N m lt N Co 00 Distance inches Graph B Forces based off varying distance from 1 to 8 5 and a pipe diameter of 1 44 APPENDIX C USER MANUAL Material Lifecycle Testing Unit Please read through all warning and instructions before using the testing unit to ensure proper procedure is followed and all safety instructions are adhered to TABLE OF CONTENTS Test Operation IL 2 Warnings EE AN 2 Sample Preparation LA oe olin les Coe hoa shea leon hon soa EE hrs leon bon dato 2 Test Setup ne ae EO ee mR AO ON OOR OOR OE EE N 3 Creating Modifying PLC Program 3 33 4 Modifying Existing Code U U aaa aaa aaa 4 Creating New Program O aala 4 Downloading Program to PLO C O aaa 5 Debugging the Program Ee 6 Creating Modifying Human Machine Interface HMI Application Ee 7 Downloading ApplicationtoHMI ss 8 General Instructions 11111111 Connecting Via Ethernet mms aaa aa 8 Downloading Project to HMI _ e a es 8 Validating Application MA 9 Run Application on HMI eb 10 Running Another Application Loaded on HMI 1 10 Maintenance 10 Troubleshooting I os hh ts oh hk hth ad 11 45 Test Operation WARNINGS e Do not move testing unit while in operation e Do not disconnect any pipes or tubing while system is pressurized or has an air supply connected e Open and close lid at handle Opening or closing from th
43. parameters such as air temperature fired air pressure and sequence and total cycles of test are set in the control system using the HMI The control system will have an alarm system programmed that pauses testing in the events of pressure loss or testing chamber lid opening Design Details In the redesign of the testing unit air is taken from the central compressed air distribution system in Gore s production plant through a hose with a quick release header The air passes through an electrically actuated ball valve followed by a moisture removal unit The airline then splits to supply two digital regulators with digital feedback that will control and monitor the pressures of the two air tanks in conjunction with the PLC The 10 gallon capacity tanks the same size tanks in the old unit were deemed sufficient due to the tank size not influencing the initial and maximum force of the fired air The air in the tanks is to be released by solenoid valves and directed through two sets of nozzles mounted inside the testing chamber The nozzles to be fired should be set with the 3 way ball valves Between the nozzles the fixture brackets will hold the fabric fixtures so that a circular area of the filter material is exposed to the air fired orthogonally at the surface from both sides One of the frames has vertical bars to replicate the air filter cage See Appendix A for drawing package The testing chamber is composed of 1 8 aluminum sheet metal wi
44. r at top of screen Click new transfer Under Select file source click My Computer then click Next Under Select file type to transfer click Application then click next Under Select file navigate to application directory on the computer select the application and click Open NOTE The application should have a file extension of cha Under Select file destination select Internal Storage then click Transfer When a dialog box saying Transfer Complete pops up click OK then return to the Dashboard to validate the application See instructions below 52 VALIDATING APPLICATION 1 Once the application has been downloaded to the HMI navigate back to the Dashboard on the HMI web portal 2 Select the newly added application from the list and click edit A new window will pop up so ensure pop up blocker is off 3 The application will show up in a new window that looks similar to the CCW programming environment Click the validate application button Settings Communication v Sak ABa e1 1 Main Screen 2 2 Parameters Current Cycle Air Temperature 4 lia gt x Startup Screen 1 v 4 If project has errors they can be fixed directly in the web browser or in CCW a NOTE Any changes made in the web browser environment will not be carried over to the project in CCW environment b NOTE Some errors may not cause negative ef
45. s t 9 _ la TES Download Upload Secure Manuals H i Eg veo Program Y Autobrowse Refresh 2 2 Workstation MIKE HP Glas Linx Gateways Ethernet 3 49 AB_VBP 1 1789 A17 A Virtual Chassis i m o R server Micro830 Micro830 has no password o Gl 49 Right click Micro830 on the left side of the screen then click Build A build dialog box should display at the bottom of the screen If there are any errors with the program they will be displayed and must be fixed When fixed rebuild the program Once successfully built right click Micro830 again at the left of the screen and click download If the PLC is in REM mode a dialog box may appear asking if you want to set the PLC to Program Mode Click yes Once the program is finished downloading if it is in REM mode a dialog box will ask if you want to set the controller back to run mode Click yes if you would like to start debugging the program or no if you would like to debug later DEBUGGING THE PROGRAM 1 2 3 4 File Edit ia HMI Application Language E CCW has a built in debugging tool to assist in finding errors in a program To take advantage of this feature first ensure the correct code is loaded on the PLC and that the PLC is connected to the laptop see instructions for connecting under DOWNLOADING PROGRAM TO PLC above Set the PLC mode to REM via the toggle switch See DOWNLOADING PROGRAM TO PLC step 2
46. s should be drilled in each side of the bottom of the testing chamber to fit a compression tube fitting adapter 50915K328 Standard Brass Compression Tube Fitting Adapter for 1 2 Tube OD X 1 2 NPTF Male Pipe 4 57 each This will secure into the wall of the testing chamber and provide an attachment point for the female side of the hoses to vent the air into the chamber To enable the operation of a heated air test a new temperature controller and external solid state relay are needed The CNil654 DC Omega 260 is 1 16 DIN and therefore should fit into the control system panel and provides the necessary analog output for temperature reading to the PLC However this unit requires an external solid state relay to provide power to the heater which is already present in the unit From a programming aspect it is the team s opinion that the program should be completely scrapped and restarted The current program has a bug that causes unpredictable outcomes Table E below lists the current wiring of I O for the PLC and program A follow up Independent Study is currently planned to finish the project up the project during University of Delaware spring semester should the sponsor request it If the sponsor wishes to have their design engineers finish the project the Senior Design team will make delivery of the unit to W L Gore along with extra material from the build The electrically actuated ball valve EABV has been installed but due to
47. shack Radioshack Radioshack Radioshack McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr McMaster Carr 58 Part Number 68115K32 44615K455 1761 CBL PM02 2711C T6T 2080 LC30 24QWB 2080 1F4 2080 OF2 2080 TC2 50 ft white black and green 4 Black UV resistant cable tie 40 pack X1 UV black mounting pads 100 pack SPST SUBMINI SW SW LED 12V 30A 20 5 pack 560 OHM 1 2 W 8668T 13 7641K51 7641K15 8262T11 2652K35 12075T6 6544K25 9008K741 89155K24 9464K173 57 80 687 24 309 00 149 00 89 00 109 00 39 66 2 38 9 98 7 38 7 98 2 99 1 19 20 29 3 42 13 86 59 72 22 59 14 47 234 55 151 98 38 94 5 72 79 80 81 82 83 84 85 86 87 Miscellaneous 95 96 8 97 5 si 98 x m 5 99 100 101 102 Component Specimen Fixture Screws End Fixture Bracket Stand Middle Fixture Bracket Stand PTFE Sheets Tapered Plugs Base Plate Base Screws Base Nuts Washers Cart Control Cabinet Brackets 1 4 Screws Aluminum Sheet Drop Leaf Brace Bushing Brace Hinge Shipping Through University Dysfunctional Heater Extra Hinge Unused Aramid Strip Unusable Plugs U nusable Plugs Unusable Insulation Wrap Unusable O Ring Vendor McMaster Carr McMaster Carr McMaster Carr M
48. th an interior lining of sound dampening Mylar coated 2 melamine foam The testing chamber is dimensioned to accommodate a nozzle to fabric distance from 1 up to 8 5 on one side if desired as determined by force calculations See Appendix B and 2 of foam with at least an inch of extra space for additional foam if needed To provide clear visibility of the specimens the front and back of the testing chamber lid are sloped with double pane abrasion resistant polycarbonate windows Two incandescent bulbs mounted inside the lid will provide illumination and can be turned on or off via the HMI The testing chamber has an exhaust duct to remove air born particles which is compatible with the industrial vacuum at Gore s production plant All components of the testing unit are mounted on an industrial cart which has dimensions chosen to accommodate the testing chamber with locking wheels and a floor brake Closure Sensor Control Cabinet Figure 3 The redesigned testing unit Figure 4 Piping amp Instrumentation Diagram Electrically Actuated L Ball Valve N Regulators me I W 4 Air Supply Quick Release Attachment Figure 5 Back view of unit showing pneumatic components Specimen G Fixture Insulated E gt Light Bulbs nn J 7s M 3 Way Ball I Valve Thermocouple Solenoid Valve Figure 7 The fabric fixtures are composed of two frames one with vertical bars a
49. tomation com Programmable Controllers Connected Components Workbench Software Start CCW click Open and navigate to the project folder Project folder should be contained in the CCW folder stored under Documents on the C drive if project was developed on the computer in use Open the desired project The provided code from the UD Senior Design Team has a file name of Gore Senior Design ccwsln Make any desired changes to the application once opened For additional help with HMI application development see PDF s supplied on flash drive titled PanelView Component Application Guide and PanelView Component User Manual or navigate to the help menu by double clicking on PVc1 Application on the left of the screen then clicking Help under the HMI Settings tab Project Organizer X HMI Settings HMI Screens 1 1 Main Screen Micro830 Micro830 VAR Unheated Valve Opening VAR Main Program POU Name New Revision Gore 2711C T6T Local Var T gt f 9 af communication creen ecuri anguages 5 RB Reset ENTIRE SEE DELE T Local Var 39 Even U Local Var 5E oas T Local Var Protocol a Pr peer Serial Allen Bradley CIP zj E Ethernet Allen Bradley CIP Load Last Saved Driver Configuration O Alarms E Driver USB Ethernet B Recipes L Use Ethernet Encapsulation led Screens Startup Scree PanelView C Settings 1 1 Main sen Write Optimizat
50. unted fabric specimens through both the front and back windows was judged It was determined that both windows provided visibility of both sides of the two fabric specimens in the fixture s right most and left most positions Ease of Cleaning A stopwatch was used to measure the duration of a damp rag cleaning and a vacuum cleaning of the interior of the testing chamber To simulate the particulates that will dislodge from certain fabrics the interior surfaces were coated in baby powder The interior surfaces include the Mylar coated sides of the sound insulation the portion of the exhaust hose inside the chamber light bulbs windows interior surface base plate specimen fixtures and brackets nozzle brackets and pneumatic components The surfaces were mostly cleaned with a damp rag in 5 minutes and not as well cleaned with a vacuum in 5 minutes and 30 seconds Many crevices of the fixtures brackets and base plate still contained powder post cleaning While the metric of 5 minutes is not met a full cleaning with a damp rag and vacuum should not take more than 10 minutes Portability amp Operation One individual familiar with the unit s operation attempted to bring the testing unit from the senior design studio through the machine shop navigate through doors and around corners and bring the unit into the elevator with a width of 55 This person then tried to take the unit out of the elevator go down the hall turn around in the 7
51. wide hallway and retrace the route back to the senior design studio This is to simulate bringing the unit from Gore s production floor up the elevator and up to the sound proof room The individual then attempted to setup and run a test followed by preparing the unit for transport and or storage One individual was successfully able to complete the tasks previously described with relative ease This test confirms that the portability and operation design metric of one individual was met Specimen Quantity The unit was judged as to whether it could accommodate either one or two specimens Due to the adjustability of the 3 way ball valves and the specimen fixtures accommodation of either one or two mounted specimens the unit was determined to have successful specimen quantity accommodation Fabric Fixture To validate the exposed surface area provided by the specimen mounting brackets calipers were used to measure the diameter of the cutout The measured diameter was 3 41 in which means the area is 9 13 in This passes the design metric of 9 in Validation Results The final design does not have a fully functional PLC program and only one valve could be fired cyclically The program was modified to be able to test most of the metrics however not all metrics could be tested The design operated at a measured noise level of 110 dB which is an improvement upon the old unit s 116 dB reading but does not meet the 85 dB metric The m
Download Pdf Manuals
Related Search