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ME Senior Design Danfoss Turbocor: Stator Insertion

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Presentation on theme: "ME Senior Design Danfoss Turbocor: Stator Insertion"— Presentation transcript:

1 ME Senior Design Danfoss Turbocor: Stator Insertion
Team 8 ME Senior Design Danfoss Turbocor: Stator Insertion Gregory Boler Jr. Matt Desautel Ivan Dudyak Kevin Lohman Figure 1: Compressor Housing

2 Overview Danfoss Turbocor Background/Introduction
Product Specification Design Approach Initial Expansion Calculations Experiment 1: Verifying Linear Expansion Heat Transfer Calculations Design Concept Design Details Cost Analysis Conclusion Future Work

3 Cutting Edge Compressors
Outstanding Efficiency Totally oil-free operation Extended life with minimal scheduled maintenance Onboard digital controls and electronics Exceptionally quiet operation Compact Environmentally responsive Danfoss Turbocor technology advancements enable new advantages for the HVACR industry Outstanding energy efficiency: The Turbocor family of chillers' competitive full load and outstanding part load efficiency enables HVACR OEM's to exceed ASHRAE 90.1 and California Title 24 energy efficiency requirements. Totally oil-free operation: No oil management hardware, controls or downtime costs. Improved heat transfer efficiency. Extended equipment life with minimal scheduled maintenance: Solid-state electronics, no lubrication and no metal-to-metal contact of rotating components. Onboard digital controls and power electronics: Enables effective monitoring, control and self-diagnosis/correction of system operation. Eliminates some traditional OEM control and power panel costs. Exceptionally quiet operation: 70dBA (conversation level) sound with virtually no vibration. Compact: 50% less footprint and 1/4 to 1/5 the weight of traditional compressors. The actual operating weight is only 265 pounds while conventional screw compressors can weigh over 1000 pounds. Environmentally responsive: Optimized for CFC-free HFC-134a, plus high-energy efficiency means reduced greenhouse gas emissions. ETL Listed Figure 2: Turbocor Compressor

4 Introduction Background
Heating of an aluminum housing to allow thermal expansion of the material Once expanded a stator is inserted into the housing The housing cools in ambient conditions locking the stator in place through an interference fit

5 Product Specification
Current method Large oven requiring extensive floor space Lengthy heating time ~ 45 minutes High final temperature ~ 300°F Four units per cycle Long cooling time before the technicians can continue assembly ~ 30 minutes Figure 3: Current Oven

6 Product Specification
Current method Stator inserted at a secondary station after heating cycle Precise position required for pneumatic actuator Additional floor space required for the secondary station Figure 4: Stator Insertion Station

7 Product Specification
Engineering Requirements Reduced heating time, < 8 min. Lower final temperature Smaller size Thermal expansion must allow for 60 microns clearance at maximum material conditions

8 Design Approach Spring Events Problem Specification
Preliminary thermal expansion calculations to determine the housing temperature to reach the desired clearance Construction of heating unit proof of concept Experimental measurements of housing expansion in a thermal chamber Final design and prototype of heating unit Calculation of heat input needed to achieve the desired temperature using hot air Experimental testing and design adjustment Design concept and component selection based on analysis Final Product Evaluation

9 Initial Expansion Calculations
Sliding fit at maximum material condition 60 microns clearance Linear Expansion Equation 60 μm 85.86 °C Figure 5: Linear Expansion Relationship

10 Experiment 1: Verifying Linear Expansion
Steps: Heat housing Take diameter measurements at various temperatures Plot experimental data versus theoretical data Data analysis Figure 6: Bore Gauge (

11 Where to measure? Linear expansion equation
Dimensionless linear expansion Figure 7: Compressor Housing Cross-Section

12 Figure 8: Experiment 1 Data Analysis

13 Initial Heat Calculations
How much heat input to reach 85 °C? Closed system with no work output kJ 85.86 °C Figure 9: Change in Temp w/ Heat Input

14 Heat Transfer Analysis
Q loss Heat Transfer Analysis 1 W Heat input to system 2 from heater Q21 Heat transferred from system 2 to system 1 Q loss Heat lost from system 2 to outside environment Q21 2 W Figure 10: Heat Transfer System

15 System 1 First Law System 1 1 System 2 First Law System 2 2 Q21 Q loss
Figure 11: Heat Transfer Systems

16 Coupled System of Ordinary Differential Equations
Initial Conditions MATLAB 84.6 °C 7.56 min Figure 12: System Temperature vs. Time

17 The Design Concept Re-circulating air over a heater coil within an insulated unit to heat housing Cooling cycle opens lid to hood and activates a blower to circulate ambient air around outside of housing Figure 13: Convection Concept Sketch

18 The Design Concept Consists of: An insulated table and hood
Re-circulating fan Heater Cooling fan Figure 14: Provisional Design

19 Table Selection Requirements: Design chosen: Heating unit
Hot air recirculation Housing locator Temperature sensors Design chosen: Utilizes an exterior blower Has built in return ducts for hot air recirculation Figure 15: Lower Design Section

20 Figure 16: Electric Heater
Heater Selection Heater chosen: MSC 5600 watt electric portable heater 84.6 °C 7.56 min Figure 16: Electric Heater ( Figure 4: Housing Temperature vs. Time

21 Hood Selection Requirements: Design chosen:
To retain heat within unit (insulated) To allow easy insertion and removal of the part in and out of the machine An opening lid to allow for a cooling cycle Design chosen: Has two doors, one inlet and one exit Contains a cooling fan Figure 17: Interim hood Design

22 Nozzle Selection Various nozzles are to be tested on their performance of these goals Even heat distribution Turbulent flow High heat transfer Testing method Smoke generator is used to blow smoke through each nozzle into a clear cylinder for observation Testing will start next week Figure 18: Nozzle A Figure 19: Nozzle B Figure 20: Nozzle C

23 Table 1: Convection Heater Cost Analysis
Part Description Supplier Unit Price ($) QTY Total Price ($) Electric Heater 5600W 100 CFM MSC 138.09 1 Flange Mount Blower 250 CFM 112.59 2 225.18 Polycarbonate 96" x 48" x 3/8" 381.57 Expanded Sheet Metal 1/2" x 12" x 24" 18 Gauge Lowes 9.37 18.74 Ultra Flex Hose 5' Length 4" ID 74.24 80/20 Extrusion 25 Series Mono Slot Bar 6m TBD 48.00 4 192.00 80/20 Hardware Misc. Hardware 100.00 Total

24 Conclusion Exploded View Housing Heater Hood Exhaust Fan Table
Heater Fan Shroud Nozzle 1 8 7 6 2 5 3 4 Figure 21: Concept Exploded View

25 Planned Future Work Build and test nozzle designs
Proof of concept testing (Fall Semester) Begin building prototype (Spring Semester) Figure 22: Electric Heater w/ Shield removed

26 Acknowledgements Turbocor Famu/FSU College of Engineering Rob Parsons
Dr. Lin Sun Kevin Gehrke Famu/FSU College of Engineering Dr. Juan C. Ordóñez Dr. Kareem Ahmed Dr. Rob Hovsapian Dr. Srinivas Kosaraju

27 Questions?

28 References "Aluminum A356 T6 Properties." N.p., n.d. Web. 15 Nov <>. "Linear Expansion." N.p., n.d. Web. 15 Nov <>. Engineering Tool Box. N.p., n.d. Web. 15 Nov <>. Cengel, Turner, Cimbala. Thermal Fluid Sciences. New York: McGraw Hill, 2008

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