Multidisciplinary Senior Design s7

Multidisciplinary Senior Design Project Readiness Package

Project Title: AATech Universal Oil and Bag System Project Number: P16680 (assigned by MSD) Jim Kalinski – Sr. Engineering Tech (315) 902-5238 [email protected]

Primary Customer: David DeWispelaere - Engineering Team Leader (provide name, phone (315) 902-5249 number, and email) [email protected]

Wanda Crowley - Purchasing (315)-902-5305 [email protected] Sponsor(s): Advanced Atomization Technologies (provide name, phone A Parker Aerospace & GE Joint Venture number, email, and 124 Columbia Street amount of support) Clyde, NY 14433 USA Preferred Start Fall 2015 Term: Faculty Champion: Gary Werth – Adjunct Facility (provide name and (315) 651-0014 email) [email protected] Other Support: As applicable Gary Werth – Adjunct Facility Project Guide: (315) 651-0014 (assigned by MSD) [email protected]

David DeWispelaere and Gary Wort 7/30/15 Prepared By Date

Sarah Brownell 7/30/15 Received By Date

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015 Project Information

* Overview: AATech manufactures fuel injection nozzles for aircraft (figure 1). Before packaging, each nozzle undergoes a procedure where it is attached to a holder and pressurized oil is sprayed through it. This process helps prevent rust during long term storage. More than 300 nozzles are processed each day. The PRP from last year includes background on the existing process which is manual.

Figure 1: Example Fuel Injection Nozzle and Location Schematic

Last year’s MSD team P15680 (https://edge/edge/P15680/public/Home) developed an enclosed test fixture and process to make this test easier and safer for the operator and less wasteful of oil (figure 2). The customer loved the outcome and has asked for more features. For example, the design was hard wired for a specific pressure and duration of oil spray.

The goal of this year’s project is to design and fabricate a system for oil and bagging nozzle assemblies other than the CFM nozzle that the previous MSD project team (P15680) focused on. This new team is tasked with adapting the system to accommodate different size nozzles, add computer controls for oil pressure and spray duration, and, as a stretch goal, automatically bag the nozzle after draining. This new system should have easily interchangeable tooling to support a variety of nozzle assemblies while still meeting the needs of the 2015 project. Each part number has its own fixture and oil spray duration and pressure.

Figure 2: Last year’s Prototype

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015 The desired operating procedure is as follows:  Operator changes over tooling for selected nozzle  Enters part number  Operator loads part into fixturing  System engages oil flush tooling  System turns on pump and flushes nozzle at the required pressure and time duration  At end cycle tooling retracts  part is ready to be removed

* Preliminary Customer Requirements (CR):  Similar footprint to 2015 Project  Mobile  Capable of fixturing the following parts: (List to be supplied by 8/21)  Safely contains oil spray in all directions  Solution must be safe and meet ergonomic requirements of previous CFM Oil & Bag Project o Minimize back bending and wrist twisting o Prevent oil mist from entering human environment o Control noise level (50db or less)  Programming of oil spray duration and pressure automated by part number  System cannot leak  Keep skill level or operator the same  Maintain or improve current system cycle times  For RIT, 110V power is encouraged, but the plant has 3 phase 480V available.  Quick and easy change over to different part numbers  Automate bleeding to prevent operator getting sprayed  Utilize existing programed pressure and duration set points for oil flow  Capture excess oil for recycling  Budget of $10,000

* Preliminary Engineering Requirements (ER):  Footprint to be 2’ x 4’. Height to be set for ergonomic ease of use.  System shall ensure doors are closed prior to being able to start cycle  Test tank and plumbing shall not leak  System shall be capable of fixturing the following parts: (List to be supplied by 8/21)  Cycle time for these part shall be: (Will be supplied by part number with list above)  System shall be PLC controlled so operator can select part number and that will determine pressure and cycle time. Scanning bar codes for this would be an option.  Desired noise level from the system should be 50db or less.

* Constraints:  Power shall be sized for all applications and may be 110Vor 480V.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015  The system shall be portable.  Acrylic chamber should be housed in a par-frame structure. AA Tech will assist with procurement of par-frame ( approx. 4 weeks lead time).  The test chamber will be designed by team and reviewed with AA Tech. Then AA Tech will assist with procurement (lead time is typically 2-3 weeks).  Should be useable by an entry level operator  Total budget shall be $10,000, excluding the cost of the acrylic test chamber and par-frame to be supplied by AA Tech.  Preservation oil used to flush parts will be supplied by AA Tech (Reference Specification MIL-PRF-6081)  Use of an Allen Bradly PLC to remain consistent with other PLCs within the facility.

* Project Deliverables: Minimum requirements:  All design documents (e.g., concepts, analysis, detailed drawings/schematics, BOM, test results)  System that is near production ready after review and check by AA Tech(fixtures, tooling, programs)  Training on how system works (can be done during runoff)  Technical paper

Additional required deliverables:  poster  All teams finishing during the spring term are expected to participate in ImagineRIT

† Budget Information:  $10,000 materials  AA Tech will procure chamber and all par-frame material with guidance from team

* Intellectual Property: All legal markings need to be honored.

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015 Project Resources

† Required Resources (besides student staffing):

Faculty list individuals and their area of expertise (people who can provide specialized knowledge unique to your project, e.g., faculty you will need to consult for Initial/ more than a basic technical question during office hours) date Gary Werth Environment (e.g., a specific lab with specialized equipment/facilities, space for very large or oily/greasy projects, space for projects that generate airborne debris or Initial/ hazardous gases, specific electrical requirements such as 3-phase power) date 3-phase power and Preservation oil (Reference Specification MIL-PRF-6081) Equipment (specific computing, test, measurement, or construction equipment that Initial/ the team will need to borrow, e.g., CMM, SEM, ) date Sample nozzles Materials (materials that will be consumed during the course of the project, e.g., test samples from customer, specialized raw material for construction, chemicals that must Initial/ be purchased and stored) date Oil to be supplied when requested for test – flushing of nozzles, chamber (per RIT Team Design) and par-frame Initial/ Other date N/A

† Anticipated Staffing By Discipline:

Dept. # Req. Expected Activities BME CE EE 2 Motion controls, system logic and operator interface (or ME’s with strong controls background) ISE 1 Cycle time, safety, ergonomics ME 3 Fixture, tooling, machine interface requirements, process design Other

* Skills Checklist: Indicate the sills or knowledge that will be needed by students working on this project. Please use the following scale of importance: 1=must have 2=helpful, but not essential 3=either a very small part of the project, or relates to a “bonus” feature blank = not applicable to this project

Mechanical Engineering

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015 ME Core Knowledge ME Elective Knowledge 1 3D CAD Finite element analysis Matlab programming Heat transfer 2 Basic machining Modeling of electromechanical & fluid systems 2D stress analysis Fatigue and static failure criteria 2D static/dynamic analysis Machine elements Thermodynamics Aerodynamics 3 Fluid dynamics (CV) Computational fluid dynamics 3 LabView Biomaterials Statistics Vibrations Materials selection IC Engines 2 GD&T 1 Linear Controls Composites Robotics Other (specify)

Electrical Engineering EE Core Knowledge EE Elective Knowledge 1 Circuit Design (AC/DC converters, regulators, amplifies, analog filter design, FPGA logic design, Digital filter design and implementation sensor bias/support circuitry) Power systems: selection, analysis, power budget 2 Digital signal processing 2 System analysis: frequency analysis (Fourier, Laplace), stability, PID controllers, modulation 2 Microcontroller selection/application schemes, VCO’s & mixers, ADC selection 1 Circuit build, test, debug (scope, DMM, function Wireless: communication protocol, component generator selection Board layout Antenna selection (simple design) Matlab Communication system front end design PSpice Algorithm design/simulation

Programming: C, Assembly Embedded software design/implementation 3 Electromagnetics: shielding, interference Other (specify)

Industrial & Systems Engineering ISE Core Knowledge ISE Elective Knowledge Statistical analysis of data: regression Design of Experiment Materials science Systems design – product/process design Materials processing, machining lab Data analysis, data mining Facilities planning: layout, mat’l handling Manufacturing engineering 1 Production systems design: cycle time, throughput, DFx: manufacturing, assembly, environment, assembly line design, manufacturing process sustainability design 1 Ergonomics: interface of people and equipment Rapid prototyping (procedures, training, maintenance) Math modeling: OR (linear programming, 3 Safety engineering simulation) 2 Project management Other (specify) Engineering economy: Return on Investment Quality tools: SPC Production control: scheduling

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015 ISE Core Knowledge ISE Elective Knowledge Shop floor IE: methods, time studies Computer tools: Excel, Access, AutoCAD 3 Programming (C++)

RIT – Kate Gleason College of Engineering Multidisciplinary Senior Design Project Readiness Package Template Revised Jan 2015