Detailed Design ReviewMultidisciplinary Senior Design 1Friday, February 15th, 2013

P13051

P13051 – PIV Experiment for Flow Mapping in Lungs

• Customers: ▫Dr. Risa Robinson▫Dr. Steven Day

• Team Guide:▫Michael Antoniades – Chemical Engineering

• Team:▫Kristin Roberts – Project Manager, ME▫Morgan DeLuca – ME▫Brad Demarest – EE▫Ryan Mark – ME▫Jimmy Moore – CE▫Jake Snider – ISE

Agenda•Project Background•Customer Needs & Engineering

Specifications•Component Design & Feasibility

▫Pressure Measurement & Control System▫Pump System▫Lung Tank & Reservoir▫Camera/Laser Positioning System

•Preliminary Test Plans•Risk Assessment

Project Background•The Army Medical Research Lab needs to

validate their CFD models for healthy and diseased lungs

•RIT will perform particle image velocimetry (PIV) on lung models to validate the CFD.

•The senior design team will design and develop the lung models and testing apparatus.

What is PIV?•Used for flow visualization and velocity

measurements•Fluid is seeded with tiny tracer particles•The particles are illuminated using a laser

sheet, and a camera takes pictures of the particles.

•Fluid velocity profiles can be obtained by analyzing particle movement from frame to frame.

Key Customer Needs1. Accommodate various image locations2. Simulate inhalation and exhalation3. Monitor flow rate and pressure4. Control flow at outlets to mimic

boundary conditions of CFD model5. Accommodate imaging with no

distortion6. Create LabVIEW Program and

procedure to run experiment7. Can easily switch between models

Pressure Control SubsystemComprised of:

• T-hose splitter

• Dual flow needle valve

• Amplified voltage pressure transducer

• Powered breadboard

Needle Valve • High resolution, therefore

minor adjustments to flow can be made (5 turns)

• Dual flow capability (allows inhale and exhale simulation)

• Low profile for organization purposes

• Low cost (20$)

T-Hose SplitterReasons for using a T-hose splitter:

• Separate static pressure from dynamic flow

• Allow pressure readings to be taken parallel to flow increasing accuracy

• Organize flow path from model to valve system

Amplified Pressure Sensor• Accuracy (can measure static

pressures +/- 1% with proper calibration)

• Cost (65$ per sensor)

• Compact design (no extensive cables or adaptation, plug into breadboard)

• Easy to calibrate and characterize to increase accuracy

Breadboard Implementation

• Keeps voltage sensors organized and setup compact

• Allows user to adjust voltage getting applied to sensors easily

• Flow from pressure control to DAQ device will be smooth

Pressure Control PathFluid will leave outlet

With steady state conditions fluid will separate due to splitter and apply static pressure on sensor

Flow will be adjusted with needle valve based on logger pro readout compared to desired conditionsBack to

pump

Calibration TechniqueFluke 718 series

• Can use to apply very accurate known pressure

• Output voltage can then be read and adjusted to create new curves accurately matching sensor performance

• Device is on loan from ME Department

Flow Characteristics•Viscosity determined through index

matching, (550 SSU, 109 cP, 0.109 Pa-s)▫Much higher than water (1 cP)

•Flow tested by Army is from 2-10 L/min▫Using Reynolds number matching, 6-32

GPM•Pressure loss through system ranges from

20 psi to 50 psi▫Calculated using Poiseuille flow

Positive Displacement vs. Centrifugal

Conclusion: PD pumps provided better flow control, regardless of pressure and handle high viscosities.

Graph Credit: pumpschool.com

PD Pump SelectionPump Flow Rates Pressures Comments Cost (3 highest)

Gear pump Acceptable,Up to 30 gpm

Acceptable,Up to 50 psi

Common, can be self-priming

2

Rotary Vane Acceptable Acceptable Not really used in our application, better for thin fluids and high pressure differentials

1

Diaphragm Acceptable Acceptable Create pulsing flow, need air supply, cheaper

1

Lobe Pump Acceptable Acceptable Used in Sanitary applications where fragile solids are used, bi-rotational, may be overly complex

3

Image Credit: Wikipedia; Info Credit: pumpscout.com

3 GPM 35 GPM

6 GPM 33 GPM19 GPM

Siewert, 1.6-16 GPM, $2,079

Siewert, 3.2-32 GPM, $2,319

Siewert, 2.3-23 GPM, $2,189

Emerick, 3.3-33 GPM, $2,754

• Max flow rate: 33 GPM• Min flow rate: 3.3 GPM• Max Pressure: 200 psi• Speed Ratio: N/A• Price: $2,745• Shipping not included• Lead time: 3-4 weeks

• Max flow rate: 32 GPM• Min flow rate: 3.2 GPM• Max Pressure: 100 psi• Speed Ratio: 10:1• Price: $2,319• Shipping included• Installation Assistance• Lead time: 5-6 weeks

Emerick Siewert

Inhalation Pipe Schematic

Lung Tank Design• The project team has

decided to go with acrylic siding for the tank, as it is easy to machine and is readily available in the needed sizes.

• The tank will be 24” x 16’’ x 16’’, which will hold slightly less than 27 gallons worth of liquid.

Lung Tank Design• The case will be made

watertight using silicone gel, and then made more structurally sound using L-brackets along the side.

• 8 holes will be drilled along the bottom of the side panels for the multi-tube connectors

• A single hole on the top of the case will allow liquid to be pumped in to the model.

Tank Wall Deformation Analysis• ANSYS Workbench was

used to analyze wall deflection due to hydrostatic pressure (P=ρgh).

• Original choice of 1/8” thick acrylic resulted in 1.868” outward deflection.

• Needed to find appropriate wall thickness that would not affect PIV results

1/8”

5/16”

Tank Wall Deformation Analysis•Treated tank wall as a

simply supported beam•Able to calculate

deflection and slope of deflection

•Calculate angle between laser and perpendicular𝜃1= tan− 1(𝜃𝑠𝑙𝑜𝑝𝑒)

(𝑠𝑙𝑜𝑝𝑒)

Tank Wall Deformation Analysis•Used Snell’s Law to

calculate the angle of the laser after it enters the tank (θ2).

•We can then calculate the error associated with refraction using the distance the lung is from the wall.

θ2

Error

Distance to model

)(distance)

Tank Wall Deformation AnalysisPanel

Thickness (in)

I (in4) Max P (psi) (q)

Max Deflection (approx)

Max Slope (Magnitude) θ1 (deg) θ2 (deg)

Distance to Model

(in)

Error due to

refraction (in)

Error due to refraction

(mm)

0.25 0.0208 1.0595 0.2441 0.0347 1.9885 1.3344 8 0.1863 4.7333

0.3125 0.0407 1.0595 0.1250 0.0178 1.0184 0.6835 8 0.0954 2.4240

0.4375 0.1117 1.0595 0.0455 0.0065 0.3712 0.2491 8 0.0348 0.8835

0.5 0.1667 1.0595 0.0305 0.0043 0.2487 0.1669 8 0.0233 0.5919

0.6875 0.4333 1.0595 0.0117 0.0017 0.0957 0.0642 8 0.0090 0.2277

0.9375 1.0986 1.0595 0.0046 0.0007 0.0377 0.0253 8 0.0035 0.0898

1 1.3333 1.0595 0.0038 0.0005 0.0311 0.0209 8 0.0029 0.0740

Tank Wall Deformation Analysis

For a 16”x24” acrylic panel, 7/16” thick

Reservoir Design•Similar design to

Lung Tank•1/8” thick acrylic

will be fine since tank is not used for PIV – only 0.17” deflection.

•12”x12”x12” box•Holes cut for

connection to pump system

Omega Multi-tube Connectors

•Can handle 10 tubes per connector. Will allow easy connection/disconnect when we switch out models.

•Allows for thru-wall connection to simplify the tank and tube interface.

Lung Holder•Used to hold lung

in tank•Put rubber

between holder and lung model to ensure a tight and secure fit

•Can rapid prototype in clear Watershed XC 11122 for ~$300

Lung Holder Drawing

Labview – Data Acquisition•NI-USB-6225, Screw

Terminated▫80 Analog Input Ports▫Compatible with

Labview▫$1749

•This will output to the Labview program which will collect the pressure data and display it to the user.

Labview Code•Not fully

completed ▫Need all

components before testing and construction can occur.

Positioning System•Need: Ability to take PIV pictures of all

branches and bifurcations•XYZ Stages alone are not the answer

▫Used for low travel, high resolution▫Very expensive for more than one

•Optics rods and clamps also too expensive & precise

•Make it ourselves – 80/20

Design•Essentially a square arch

that translates•L-Handle brakes to keep it

in position•Strong frame – no vibration•Drop-in T-studs allow for

camera movement •When combined with a

rotation allows for all angles

Result•Contacted Bob Proscher at Ralph W. Earl

Co.•Developed a kit including all requested

machining▫Quote: $243.75

•Mount an optical stage (5 – 10 mm) ▫$600 - $1,000

•Refractive index (RI) of fluid must match that of the model.▫Model will be made using RedEye

Veroclear n = 1.47

•Fluid used will be made from glycerin.▫85% Glycerin, 15% Water

n = 1.45 While RI may not be matched exactly, the

difference is negligible.

Index Matching Fluid

Complete Test SetupPositioning System

Lung TankPump System

Reservoir

Subsystem CostTanks and Containment $1207.46Camera Positioning $191.45Pumping System $2,597.91 Common Header $266.62Pressure Control and Measurement $11,703.00

Total: $15,966.44

Budgetary Overview

Part Price/Unit

Quantity Cost

Acrylic Sheet, 48"x24", 7/16" thick $132.39 2 $264.78 Multitube Quick Coupling Set $64.00 8 $512.00 Perforated framing, zinc-plated steel, 4ft each, pkg qty 12 $8.78 1 $8.78 Plain Steel Square Head Low Strength Bolt 5/16"-18 Thread, 1" Length, pkg. 25 $5.59 2 $11.18 18-8 SS Type A USS Flat Washer 5/16" Screw Size, 7/8" OD, .06"-.11" Thick, pkg. 25 $5.60 2 $11.20 Plain Grade 8 Steel Hex Nut 5/16"-18 Thread Size, 1/2" Width, 17/64" Height, pkg. 100 $4.28 1 $4.28 Steel Perforated Flat and Angle Framing Hardware: Zinc-Plated Steel Bolts W/Nuts & Washers $7.42 1 $7.42 Zinc-Plated Steel Machine Screw Hex Nut 2-56 Thread Size, 3/16" Width, 1/16" Height, pkg. 100 $1.21 1 $1.21 316 SS Pan Head Phillips Machine Screw 2-56 Thread, 1/2" Length, pkg. 50 $6.18 1 $6.18 Acrylic Sheet, 12"x12", 1/8" thick $8.63 6 $51.78 All-Seal Sealant for Wet and Oily Surfaces, Clear, 10.2 oz $18.27 1 $18.27 Standard Pipe Thread Sealant 1-1/4-Ounce Stick $3.46 3 $10.38 Lung holder – rapid prototype in Watershed XC 11122 $300 1 $300

Total: $1207.46

Tanks and Containment

Part Price/Unit

Quantity

Cost

1515 Profile $13.99 5 $69.95Drop-in T-studs $2.14 5 $10.70 Single Flange Linear Bearing $38.60 2 $77.20Hidden Corner Connectors $7.25 2 $14.50 L-handle Brake $9.55 2 $19.10

Total: $191.45

Camera Positioning

Pump SystemPart Price/

UnitQuantity

Cost

H75M Gear Pump$2,319.00 1 $2,319.00Variable Frequency Drive

MotorTubing, 1'' ID $2.45 5 $12.25Tubing, 1/4'' ID, 3/8'' OD $0.71 25 $17.75Tubing, 1.5'' ID $4.22 10 $42.20Tube clamps, 1.5'' 10 $7.22Tube clamps, 1'' 10 $7.07Tube clamps, 3/8'' 20 $5.67Tube to pipe, adapter, 1'', 1'' $8.32 1 $8.32Pipe to tube, adapter, 1.5 , 1.5 5 $8.73Tube to pipe, adapter, 1/4'', 1/2'' 10 $4.97Pipe to tube, adapter, 1/2, 1'' 10 $8.48Valve, ball, 1.5'' $44.56 1 $44.56Valve, ball, 1/2'' $9.84 1 $9.84Valve, ball, 1'' $22.31 1 $22.31Pipe, 1-1/2'', 4'', Male-Male $3.18 2 $6.36Reducer, 1'', 1 /2'' $32.46 1 $32.46Coupling, 1 1/2'' $6.37 2 $12.74Bulkhead, 1'' $6.05 2 $12.10Cap, rigid plastic, tubing, 1/2'' $0.06 100 $5.50Stopper, rubber, 1-1/2'' $0.87 12 $10.38

Total: $2,597.91

Common HeaderPart Price/

UnitQuantity

Cost

Manifold, 10 outlets, 1 inlet 23.1 8 $184.80Fitting, wye, t-t-t, 1/4,1/4,1/4 4.91 1 $4.91Plug, tube, 1/4 0.97 1 $0.97Tubing, polyurethane, 1/4'', 1/8'', 100' 24.7 1 $24.70

Total: $266.62

Pressure Control and MeasurementPart Price/

UnitQuantity

Cost

Minature Voltage Sensor $65.00 81 $5,265.00 Needle Valve $15.00 81 $1,215.00 Urethane Hose 50 ft $15.00 10 $150.00 Hose Connectors $188.00 6 $1,128.00 Polycarbonate sheet $50.00 6 $300.00 Data Acquisition Device $3,000.00 1 $3,000.00 Powered Breadboard $90.00 3 $270.00 T splitter $5.00 75 $375.00

Total: $11,703.00

Risk Assessment

Questions?