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

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

7. Customer Needs

8. Engineering Specifications

10. Functional Decomposition

11. Functional Architecture Heating Element Cooling Element Temperature Sensors Insulation Data Acquisition Provide a constant heat source to the specimen Provide a constant heat sink to the specimen Provide a means for measuring temperature Minimize the amount of heat loss 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. HeaterJacketed CoolerJacketed Temp SensorThermo Cp InsulationAir OrientationHorizontal Set-upEasy Design 1

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

20. HeaterDisk CoolerJacketed Temp SensorThermo Cp InsulationAir OrientationVertical Set-upMild Design 2

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 HeaterDisk CoolerPlate Temp SensorThermo Cp InsulationSolid or packed OrientationVertical Set-upmed-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. HeaterDisk CoolerPlate Temp SensorThermo Cp InsulationMuti OrientationVertical Set-upmed-hot Design 4

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. 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 Physical Architecture

28. Critique of Designs

30. Data Collection - Design #1 DAQsCostInterface (to PC) Arduino~60USB/Other Ni Equipment>600USB/Other Labjack~110USB/Other NeedsManual Data Collection Digital Data Collection Effective For Students of Various Learning Styles33 Utilization is complex enough to involve 3-4 students in the allotted time 11 Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles 3- Allows for manual Data Collection9- Allows for Digital Data Collection-9

31. Data Collection - Design #1 (Digital Only) NeedsManual Data Collection Digital Data Collection Effective For Students of Various Learning StylesN(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 N(3)- Allows for manual Data CollectionN(9)- Allows for Digital Data Collection-9

32. Data Collection - Design #2 (Analog Version) NeedsManual Data Collection Digital Data Collection Effective For Students of Various Learning Styles3N(3) Utilization is complex enough to involve 3-4 students in the allotted time 1N(1) Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles 3- Allows for manual Data Collection9- Allows for Digital Data Collection-N(9)

33. Data Collection Design #3 NeedsManual Data Collection Digital Data Collection Effective For Students of Various Learning Styles33 Utilization is complex enough to involve 3-4 students in the allotted time 11 Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles 3- Allows for manual Data Collection9- Allows for Digital Data Collection-9

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 Δ T = 120 K Chosen Parameters: T0 = 273 K, D = ¾”, L = ½’

35. Feasibility Analysis h 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 Analysis h T1T2 T3 T4 T5

37. One Dimensional Transient Analysis h T1T2 T3 T4 T5

38. One Dimensional Finite Difference Steady State Analysis h T1T2 T3 T4 T5

39. Simulation Parameters Copper Rod Parameters Density (kg/m 3 )8940 Thermal Conductivity (W/m*K)401 Specific Heat (J/kg*K)394 Length (m)0.254 Diameter (m)0.00635 Stainless Steel Parameters Density (kg/m 3 )7820 Thermal Conductivity (W/m*K)43 Specific Heat (J/kg*K)490 Length (m)0.254 Diameter (m)0.00635

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

51. Project Schedule for Quarter GoalWeek Completed Revise System Design based on Review feedbackWeek 6 Create assembly plansWeek 7/8 Create test plansWeek 7/8 Write BOMWeek 9 Order materialsWeek 9/10 Hold Detailed Design ReviewWeek 10/11

52. Questions?