Customized Cyclic Test Device ME 462

1
Customized Cyclic Test DeviceME 462

• Sponsor Carrier Corporation
• Advisor Dr. H. El-Mounayri
• May 3, 2007
• Design Team Mike Abel
• Braden Duffin
• Simon Marin
• Joe McGuire

2
Presentation Outline

• Background
• Requirements
• Development
• Final Design
• Evaluation
• Recommendations
• Questions

3
Design Objective

• Design a custom cyclic corrosion device for
  testing material samples.
• The device must replicate conditions encountered
  in actual furnace applications.
• Environmental conditions include hot air,
  chemical exposure, and humidity.

4
Performance Requirements

• Controlled temperature range of 70-400
  Fahrenheit
• Humidity 85
• Corrosive Chemical Exposure
• Controllable and variable cycle transitions
  (30-60 sec. transitions)
• Other (weight, cost, size, power, safety)

5
Development

• Concepts generation included QFD, functional flow
  analysis, function-concept mapping, decision
  matrix, etc
• Designed housing concept using ProEngineer
• Researched commercially available components
  (heat element, fan, valves, chemical pump, etc)
• Performed analyses to determine necessary
  component performance
• Redesigned housing to fit suitable components

6
Final Design (Front View)
7
Final Design (Rear View)
8
Final Design (Internal View)
9
Design Evaluation

• Verification of the requirements was obtained
  from
• Procured component specifications
• ProEngineer model geometry
• Part weights and dimensions
• Computational Fluid Dynamics (CFD) simulations

10
CFD Model and Boundaries
11
Requirements Verification

• CFD Analysis
• Temperature range requirement 70-400ºF
• Temperature range achieved 70-500ºF
• Temperature transition time requirement lt 60
  seconds
• Actual time to heat chamber gt 200 seconds
• Actual time to cool chamber 25 seconds

12
Steady-state heating simulation

• Demonstrates capability to exceed temperature
  requirement
• Internal temperature is 475-500 ºF

Flow streamlines colored by temperature
13
Cooling time simulation

• Demonstrates cooling time capability
• Simulation time is 25 seconds
• Internal temperature drops from 500 to 80ºF

14
Heating time simulation

• Demonstrates heating time capability
• Simulation time is 200 seconds
• Final Internal temperature is 340ºF
• Needs optimization

15
Requirements Verification

• Humidity 85 (predicted, not verified)
• Uniform Chemical Vapor Spray (based on procured
  nozzle and pump specs.)

16
Requirements Verification

• Safe to be handled (warning some heated surfaces
  and ventilation)
• System maintenance and cleaning All parts
  exposed to chemicals are stainless steel. All
  individual part weights are below 60 lbs.
• Fits in hood dimensions (verified by ProE model)
• Holds 6 coupons (Target 2)

17
Requirements Verification

• Powered by 110 V (based on procured components
  specs.)
• System can be automated (All parts can be
  electrically controlled)
• System Cost 2799 - 8389 depending on valve
  choice (Target 3000)

18
Heat Cycle Recommendation

• Objective decrease time to heat chamber
• Currently using preheated air to facilitate
  heating
• Increase amount of preheated air
• Increase volume of heat chamber
• Increase surface area of heat strip
• Add heat strip
• Add second heat chamber
• Optimize air flow
• Entry vents
• Exit vent

19
Valve Recommendation

• Objective Meet initial budget requirements,
  minimize long term costs
• Xomox butterfly valve 3345 each
• Highest quality heat and corrosion resistance
• 2 long
• McMaster swing check valve 550 each
• Lower quality heat and corrosion resistance
• 6 long
• Likely requires regular replacement
• Design custom valve in house?

20
Questions