1. P13623: Conductive Heat Transfer Lab Equipment
System Design Review
April 5th, 2013

2. Project Participants Dr. Karuna S. Koppula
Project Sponsor : RIT KGCOE, Chemical Engineering Dept.
Dr. Karuna S. Koppula
Mr. Paul Gregorius
MSD 1 Team Guide: Michael Antoniades
Project Members:
David Olney - (ChemE) Project Manager
Todd Jackson - (ME) Project Engineer
Alysha Helenic - (ChemE) Documentation Engineer
Edward Turfitt - (ChemE) Design/Concept Engineer
Charles Pueschel - (ChemE) Data Acquisition Specialist
Ian Abramson - (ChemE) Customer Liaison

3. Agenda Overview of project
Design specifications, needs and constraints
Customer needs
Engineering specifications
Project deliverables
Functional decomposition
Design process
Concept generation
Functional architecture
Physical architecture
Design generation and assessment
Initial concepts
Pros and cons
Final proposed design
Final design assessment
Benefits and limitations
Feasibility
Risk
Project planning
Project schedule
Deliverables
Quarter goals
Questions

4. Heat Transfer and Thermal Conductivity
Heat transfer can take place from three methods (Conduction, Convection , Radiation).
The most valuable method to calculate a constants for one specific mode of heat transfer is to reduce or eliminate the other two modes.

5. Project Overview Problem Statement:
Build an apparatus that can demonstrate thermal conductivity reliably to students for educational purposes.
Resources:
The only limitation we have is the set budget for the project.
(space, cart, current lab equipment, donations) excluded from budget.
Expectations:
The purpose of this review session is for constructive criticism, recommendations, and validation by the customer for some of our current designs that we have derived.

6. Design Process Flow Problem Definition Define Requirements
PRP
Functional Decomposition
Problem Definition
Engineering Matrix
House of Quality
Constraint Criteria
Define Requirements
Define Constraints
Power Source
Temperature Sensors
Heating Element
Cooling Element
Insulation Methods
Data Collection
Contact Resistance
Interchangeability
Define Systems
Research Systems
Develop Solutions
Concept Generation
External
Assess Solutions
Pugh Matrix
Design 1
Design 2
Design 3
Design 4
Generate Designs
Assess Designs
Pro/Con List
Final Design
Final Design
Design assessment
Customer Specifications review
Risk Assessment
Cost Assessment

7. Customer Needs

8. Engineering Specifications

9. Engineering Specifications

10. Functional Decomposition

11. Functional Architecture
Heating Element
Provide a constant heat source to the specimen
Cooling Element
Provide a constant heat sink to the specimen
Temperature Sensors
Provide a means for measuring temperature
Insulation
Minimize the amount of heat loss
Data Acquisition
Provide a means for collecting data
Power Source
Provide a means for power heating element

12. Concept Generation

13. Criteria Generation

14. Pugh Matrix: Heating and Cooling

15. Pugh Matrix: Insulation

16. Pugh Matrix: Sample Container

17. Pugh Matrix: Data Measurement and Display

18. Design 1 Heater Jacketed Cooler Temp Sensor Thermo Cp Insulation Air
Orientation
Horizontal
Set-up
Easy

19. Pros & Cons of Design 1 Pros Simplicity Cheap Visual
Compatible with different samples
Easy to set up
Cons
Inconsistent insulation

20. Design 2 Heater Disk Cooler Jacketed Temp Sensor Thermo Cp Insulation
Air
Orientation
Vertical
Set-up
Mild

21. Pros & Cons of Design 2 Pros Pressure can be applied to the heater
Cheap
Visual
Compatible with different length samples
Cons
Hard to swap different diameter samples
Potential air leaks because of water supply connections.

22. Design 3 Heater Disk Cooler Plate Temp Sensor Thermo Cp Insulation
Solid or packed
Orientation
Vertical
Set-up
med-hot

23. Pros & Cons of Design 3 Pros No convection
Compatible with different length
Pressure can be applied on both the heater and cooler
Solid insulation adds support
Cons
Complex
Longer set up times
Not completely visible

24. Design 4 Heater Disk Cooler Plate Temp Sensor Thermo Cp Insulation
Muti
Orientation
Vertical
Set-up
med-hot

25. Pros & Cons of Design 4 Pros Limits convections Visual
Compatible with different length and diameter samples
Pressure can be applied on both the heater and cooler
Compatible with multiple insulations
Cons
Complex
Longer set up times
More expensive

26. Boat Design
Removable caps allow liquid , gases, and pastes to be inserted into the boat.
Temperature sensors will be placed at set lengths within the boat so that they do not move.
The ends will be made out of a conductive medal to minimize leakage.

27. Heat conduction apparatus
Physical Architecture
Components
Subsystem
System
Heat conduction apparatus
Power source
Electric variable power generator
Temperature sensor
Thermocouple or silicon based temperature sensor
Heating element
Plate heater
Cooling element
Cold plate
Insulation
Variable insulation method
Data Collection
DAQ
LCD
Contact resistance
Screw cap (pressure)
Multi-material
Boats

28. Critique of Designs

30. Data Collection - Design #1
DAQs
Cost
Interface (to PC)
Arduino
~60
USB/Other
Ni Equipment
>600
Labjack
~110
Needs
Manual Data Collection
Digital Data Collection
Effective For Students of Various Learning Styles 3
Utilization is complex enough to involve 3-4 students in the allotted time 1
Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles -
Allows for manual Data Collection 9
Allows for Digital Data Collection

31. Data Collection - Design #1 (Digital Only)
Needs
Manual Data Collection
Digital Data Collection
Effective For Students of Various Learning Styles
N(3) 3
Utilization is complex enough to involve 3-4 students in the allotted time
N(1) 1
Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles -
Allows for manual Data Collection
N(9)
Allows for Digital Data Collection 9

32. Data Collection - Design #2 (Analog Version)
Needs
Manual Data Collection
Digital Data Collection
Effective For Students of Various Learning Styles 3
N(3)
Utilization is complex enough to involve 3-4 students in the allotted time 1
N(1)
Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles -
Allows for manual Data Collection 9
Allows for Digital Data Collection
N(9)

33. Data Collection Design #3
Needs
Manual Data Collection
Digital Data Collection
Effective For Students of Various Learning Styles 3
Utilization is complex enough to involve 3-4 students in the allotted time 1
Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles -
Allows for manual Data Collection 9
Allows for Digital Data Collection

34. Temperature In Sample versus Length
Assumptions: Steady State, No conduction or convection from the air on the sample.
q = Q/A =-k(dT/dx)
Given Targets: Q = 500 W, Target ΔT = 120 K
Chosen Parameters: T0 = 273 K, D = ¾”, L = ½’

35. Feasibility Analysis One Dimensional Transient Analysish T1 T2 T3 T4 T5
One Dimensional Transient Analysis
One Dimensional Finite Difference Steady State Analysis
T1 and T5 will be known temperatures
The length of the rod and properties will be known

36. One Dimensional Transient Analysish T1 T2 T3 T4 T5

37. One Dimensional Transient Analysish T1 T2 T3 T4 T5

38. One Dimensional Finite Difference Steady State Analysish T1 T2 T3 T4 T5

39. Simulation Parameters
Copper Rod Parameters
Density (kg/m3)
8940
Thermal Conductivity (W/m*K)
401
Specific Heat (J/kg*K)
394
Length (m)
0.254
Diameter (m)
Stainless Steel Parameters
Density (kg/m3)
7820
Thermal Conductivity (W/m*K) 43
Specific Heat (J/kg*K)
490
Length (m)
0.254
Diameter (m)

40. Copper Rod Results
After 1 minute
After 2 minutes

41. Copper Rod Results
After 3 minutes
After 4 minutes

42. Stainless Steel Rod Results
After 5 minutes
After 10 minutes

43. Stainless Steel Rod Results
After 20 minutes
After 40 minutes

44. Stainless Steel Rod Results
After 60 minutes

45. Feasibility Conclusion
Copper rod reaches steady state much quicker than the stainless steel rod.
In order to reach thermal equilibrium quicker, the length of the specimen can be diminished.
The lab can be conducted within the allotted time.

46. Means for Calculating Thermal Conductivity – Steady State
Where:
Rs = thermal resistance of sample
F = heat flow transducer calibration factor
Tu = upper plate surface temperature
Ti = lower plate surface temperature
Q = heat flow transducer output
Where:
K = thermal conductivity
d = thickness of sample

47. Means for Calculating Thermal Conductivity –Transient

48. Risk Assessment

50. MSD I and MSD II Goals and Deliverables Project Organization
Define Customer Needs and Specs
Develop Concepts
Create System Level Design
Create Detailed Design
Hold System Design Review
Revise design based on Review
Create test and assembly plans
Write BOM
Order Materials
Hold Detailed Design Review
Update Project Plan
Design Verification
Write Technical Paper
Create Poster
Final Presentation
Create test plans
Build system
Verify design through testing

51. Project Schedule for Quarter
Goal
Week Completed
Revise System Design based on Review feedback
Week 6
Create assembly plans
Week 7/8
Create test plans
Write BOM
Week 9
Order materials
Week 9/10
Hold Detailed Design Review
Week 10/11

52. Questions?