ryan_palmer mechanical design competition
TRANSCRIPT
Company Sponsor Pacific States Cast Iron Pipe Company
Candidate:Ryan Palmer
CAPSTONE PROJECT
Overview Background Information Customer Needs Concept Generation Concept Selection Testing Results Design
Pacific States Cast Iron Pipe Company
Provo, Utah
• Everyday PSCIPCO produces on average 1500 pipes
• The pipes are about 18’ long and are between 6” and 36” in diameter
• The pipes are cast using the centrifugal method
Problem Statistically, 1 out of 1500 pipes produced a day experiences cracking.
Cracking occurs between casting and annealing stages.
The cracks are of various sizes and are all through cracks.
Yearly, Pacific States loses on average $130,000 in claims due to damages.
Hairline crack in pipe
Project Objective StatementResearch a suitable technology to detect cracks in cast iron pipe and design a crack-detection system for a cast iron pipe production line that will cost less than $20,000 by March 30th, 2012.
Challenges Surface temperature of the pipe (700° F)
Testing speed (4 pipes per minute)
Pipe length and varying diameter (18’ length, 6”-30” diameter)
Environment (noise, humidity, heat)
Surface roughness of the pipe
Concept Selection and ScreeningCrack Detection
Photo Diodes X-rays Pressurized Gas
with Thermal Imaging
Underwater
Submersion
Spraying with water
Pressurized Fluid
Increase Pressure
Thermal Imaging
Improving the seal
Electrical/Magnetism
Magnetic Leak
Detection
Eddie Currents
Electrical Resistanc
e
Resonance/Vibrations
Pinging the Pipe
Ultrasonic
Vibration After Shear Wave
Optical Methods
High-resolution Camera
Thermal Imaging
Visual Inspectio
n
Shining a Bright Light
Unrealistic Ideas
Probes Measurin
g Deflectio
n and Strain
Waterfall
Reduce Pipe
Length to 3"
More Ideas on Separate
Paper
Scoring Based on Testing
Thermal Imaging w/ Pres. Gas Vibration Eddy Current
RatingWeighted
Score RatingWeighted
Score RatingWeighted
Score RatingWeighted
Score RatingWeighted
ScoreSensitivity to surface roughness 20% 5 1 4 0.8 3 0.6 1 0.2 3 0.6Compatibility to op. Environment 20% 3 0.6 2 0.4 3 0.6 2 0.4 1 0.2Adapts to varying diameters 20% 4 0.8 1 0.2 3 0.6 3 0.6 4 0.8Speed of detecting 20% 4 0.8 3 0.6 3 0.6 2 0.4 4 0.8
Reliability/Accuracy - TOTAL 80% 4 3.2 2.5 2 3 2.4 2 1.6 3 2.4Cost (initial) 10% 2 0.2 3 0.3 3 0.3 2 0.2 4 0.4Cost (operating) 10% 3 0.3 3 0.3 3 0.3 3 0.3 4 0.4
Total ScoreRank
Continue?
Vision System Photo Diode
2.10 3.205 2
3.003
2.601 4
Selection Criteria Weight
3.70
Thermal Imaging w/ pressurized air
Testing ResultsGood Pipe
Before Pressurization After 10 Seconds
Testing Results
Before Pressurization After 10 Seconds
Cracked Pipe
Eddy Current
Testing Results
Photo Diode Detection System
Test Results
Oscilloscope detecting light 500 W work lamp on pipe
Failed Tests Automated Visual Detection System (Keyence)
Rough surface finish
Vibrations Detection SystemInconsistency of resonance frequencies between pipes
Failed Tests Electro Magnetic Acoustic Transducer
Too expensive and too slow
X-Ray DetectionToo expensive and too slow
Implementation of Eddy Current
Strategy• Rotate pipe• Translate probes across the surface 1/4”
distance• Adjust to pipe diameter• Use equipment familiar to PSCIPCO• Use as many ready to order parts as possible
Lifting SystemRack and Pinions
End Rollers
Suspension System
Rectangle Tube Beam
Design
Lifting System
Adjustable Mounting Bracket
Pneumatic Cylinder
End Rollers
Steel Roller
End Rollers
Igus Rail and Carriage
Suspension System
Eddy Current SensorSuspension System
Suspension SystemCopper Tubing for
cooling system
Suspension Spring
Phenolic Plate
Steel Roller
Eddy Current Sensor
Hinge
Drawings
Questions