22
Page 1 of 22 ECE 4901: Senior Design 1 – Fall 2020 Blast Media Booth Modernization Sponsoring Company: Connecticut National Guard TASMG Groton Airport Primary Contact: Major Douglas Holland – [email protected] Student Team Members: Electrical and Computer Engineering: Nathaniel Burgess – [email protected] Gabriel Zepeda – [email protected] Tyrese Gaffney – [email protected] Mechanical Engineering: Alexandra Buss – [email protected] Oleg Nazarovets – [email protected] Johannah Litchfield – [email protected] Faculty Advisors: Electrical and Computer Engineering: A. F. M. Anwar – [email protected] Mechanical Engineering: Reza Sheikhi – [email protected]

Blast Media Booth Modernization - ecesd.engr.uconn.edu

  • Upload
    others

  • View
    1

  • Download
    0

Embed Size (px)

Citation preview

Page 1: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 1 of 22

ECE 4901: Senior Design 1 – Fall 2020

Blast Media Booth

Modernization

Sponsoring Company: Connecticut National Guard TASMG Groton Airport

Primary Contact: Major Douglas Holland – [email protected]

Student Team Members:

Electrical and Computer Engineering:

Nathaniel Burgess – [email protected]

Gabriel Zepeda – [email protected]

Tyrese Gaffney – [email protected]

Mechanical Engineering:

Alexandra Buss – [email protected]

Oleg Nazarovets – [email protected]

Johannah Litchfield – [email protected]

Faculty Advisors:

Electrical and Computer Engineering:

A. F. M. Anwar – [email protected]

Mechanical Engineering:

Reza Sheikhi – [email protected]

Page 2: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 2 of 22

i. Abstract

The purpose of this senior design will be to modernize the blast media system currently

located at the Connecticut National Guard Air Base. As it stands the pre-existing system is 25

years old meaning that there are many problems including but not limited to the booth

operating in a positive instead of negative pressure, lack of full floor media collection, must be

designed within the building footprint due to FFA and CAA regulations, and general poor

efficiency. These are issues which will be tackled along with the mechanical engineering team

who will be focusing on the floor collection aspect. It will be the aim of the electrical

engineering team to focus on the ventilation of the booth by utilizing newer technologies and

implementing a proper vent control system.

Page 3: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 3 of 22

ii. Table of Contents

i. Abstract...................................................................................................................................................... 2

ii. Table of Contents ..................................................................................................................................... 3

iii. List of Figures and Tables ........................................................................................................................ 4

iv. Nomenclature and Glossary .................................................................................................................... 5

I. Introduction ............................................................................................................................................... 7

• Background .................................................................................................................................. 7

• Challenges .................................................................................................................................... 7

II. Problem Statement .................................................................................................................................. 7

• Statement of need ....................................................................................................................... 8

• Requirements/Specifications ....................................................................................................... 8

• Basic Limitations .......................................................................................................................... 9

• Additional Information ............................................................................................................... 10

III. Approach and Design ............................................................................................................................ 11

• Theory ........................................................................................................................................ 11

• Models ....................................................................................................................................... 13

• Proposed Solution ...................................................................................................................... 14

• Constraints ................................................................................................................................. 14

• Standards and Codes ................................................................................................................. 15

• Final Design ................................................................................................................................ 15

• Simulation Results ...................................................................................................................... 18

IV. Project Management ............................................................................................................................ 20

• Division of Labor ........................................................................................................................ 20

• Budget ........................................................................................................................................ 21

• Project Timeline ......................................................................................................................... 21

References .................................................................................................................................................. 21

Appendices ................................................................................................................................................. 22

Page 4: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 4 of 22

iii. List of Figures and Tables:

• Figure 1: National Guard blasting and paint shop building layout

• Figure 2: Cross draft airflow system

• Figure 3: Armature controlled DC motor model

• Figure 4: Response of uncontrolled DC motor

• Figure 5: System response DC motor unity feedback

• Figure 6: Step response of DC motor controlled by lead compensator

• Figure 7: Simulation of DC motor system (angular position)

• Figure 8: Simulation of DC motor system (motor voltage)

• Figure 9: Project timeline (fall semester)

• Figure 10: Project timeline (spring semester)

• Equation 1: Plant transfer function of DC motor system

• Equation 2: Unity feedback of DC motor plant

• Equation 3: Lead compensator equation

• Equation 4: DC motor controlled by lead compensator

• Table 1: Team member responsibility assignment (RACI chart)

Page 5: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 5 of 22

iv. Nomenclature and Glossary

• Abrasive - (Of a substance or material) Capable of polishing or cleaning a hard surface

by rubbing or grinding.

• Actuator - A device that causes a machine or other device to operate.

• Air compressor - A compressor is a mechanical device that increases the pressure of a

gas by reducing its volume. An air compressor is a specific type of gas compressor, a

pneumatic device that converts power into potential energy stored in pressurized air.

• Blast Media Booth - Room in which the workers at the National Guard blast the

helicopters for cleaning.

• Blaster - Equipment system that is used by the National Guard to clean helicopters.

• CFM - Cubic feet per minute.

• Class II-Division II - Hazardous environment due to the presence of combustible dust,

yet the location in which the hazardous concentrations are handled, processed, or used

are normally in closed containers/closed systems and can only escape in case of an

accidental rupture or breakdown.

• Collection system - A system that retrieves the plastic media after it is used when

cleaning helicopters.

• Connecticut Airport Authority (CAA) - A quasi-public agency established in 2011 to own,

improve, and operate Bradley International Airport and the five state-owned general

aviation airports (Danielson, Groton-New London, Hartford-Brainard, Waterbury-

Oxford, and Windham).

• Cross-draft airflow - How air travels across the room.

• Dust Collector - A system used to enhance the quality of air that is released from

processes by collecting dust and other impurities from either air or gas.

• Federal Aviation Administration (FAA) - A commercial organization. The largest modern

transportation agency and a government body of the United States. The FAA has the

powers to regulate all aspects of civil aviation in that nation and its surrounding

international waters as well.

• FPM - Cross-sectional air-speed.

• Hermetic - (Of a seal or closure) Complete and airtight.

• MATLAB - MATLAB is a proprietary multi-paradigm programming language and

numerical computing environment developed by MathWorks. MATLAB allows matrix

manipulations, plotting of functions and data, implementation of algorithms, creation of

user interfaces, and interfacing with programs written in other languages.

• National Electric Code (NEC) - The National Electric Code, or NFPA 70, is a regionally

adoptable standard for the safe installation of electrical wiring and equipment in the

Page 6: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 6 of 22

United States. It is part of the National Fire Code series published by the National Fire

Protection Association, a private trade association.

• National Fire Protection Association (NFPA) - The National Fire Protection Association is

an international nonprofit organization that was established in 1896, that is devoted to

eliminating death, injury, property, and economic loss due to fire, electrical and related

hazards.

• Negative pressure - When the pressure inside a room is lower than the pressure outside

the room.

• PID - Proportional Integral Derivative.

• PID Controller – A standard controller used in control theory to change the

characteristics of a system to something more desirable.

• Lead Compensator – Like the PID controller it is used to change the characteristics of a

system to something more desirable.

• Plastic magic media - (Of a sand-like material) Used for polishing or cleaning a hard

surface.

• Pneumatic - Containing or operated by air or gas under pressure.

• PSI - Pound per square inch. Force in a certain area.

• Return-on-investment (ROI) - Return on investment is a ratio between net profit and

cost of investment. A high ROI means the investment's gains compare favorably to its

cost. As a performance measure, ROI is used to evaluate the efficiency of an investment

or to compare the efficiencies of several different investments.

• Sensor - A device which detects or measures a physical property and records, indicates,

or otherwise responds to it.

• Simulink - Simulink is a MATLAB-based graphical programming environment for

modeling, simulating, and analyzing multidomain dynamical systems. Its primary

interface is a graphical block diagramming tool and a customizable set of block libraries.

• Transfer function - A mathematical function which theoretically models the device's

output for each possible input.

• Type 8 plastic magic media - Type of media used specifically for cleaning helicopters.

Magic media comes in different types. The National Guard finds Type 8 media the best

and most sufficient for blasting its helicopters.

• Unity feedback - A closed-loop system configuration is formed to reduce impacts of a

change on a system and cope with a system’s parameter changes.

Page 7: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 7 of 22

I. Introduction

Background:

The Connecticut National Guard TASMG in Groton has tasked our senior design team

with modernizing a blast media booth. This media blast booth is used by the national guard to

conduct abrasive blasting on helicopters. The media blast system uses a special plastic abrasive

to strip the paint off helicopters for maintenance. The current blasting system is over 25 years

old and is now prone to mechanical and electrical failures. Many of the features of the system

no longer work as intended. This system is costing the National Guard lots of time and money

and have decided that they want the whole system to be replaced with a modern system that

can perform the same job better and more efficiently.

Challenges:

The project currently consists of three main things to consider. The first is to select new

equipment for the blast media system. The system has a minimum requirement of including a

blaster, air compressor, and dust collector. The second part of the project is to consider

solutions to the floor collection system for the blast media. The system currently only operates

on two very small troughs which collect the blast media after blasting. The National Guard

wants to consider the possibility of improving this collection system to a full floor collection

system. The last part of the project is to improve the current airflow system. This system has

had notoriously bad airflow for many years which is causing safety hazards for the blasting

booth. The new airflow system needs to be able to maintain negative pressure in the blasting

room during operation.

II. Problem Statement

Statement of Need:

The purpose of this project is to modernize a media blast facility which utilizes 25-year-

old technology. This facility uses highly pressurized hoses which blast the hull of a helicopter

with "Type 8" Plastic Magic Media. When blasted the plastic media will strip the helicopters of

paint making it suitable for maintenance. This plastic media however will accumulate onto the

floor which means the crew will need to pause work and shovel the spent media into the floor

recovery system i.e. a trowel. This trowel leads into a filtration system which will be fed into a

backroom which houses the blast media system equipment. Once the spent plastic media is

deposited into the blast media system equipment, the plastic media will be separated from any

Page 8: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 8 of 22

possible dust particulates collected during the blasting process. This is done through a series of

filters and once filtered will be deposited back into a bin for further use. The other part of this

project consists of improving the airflow in the blasting room. The room should have a cross

draft airflow and should be able to maintain negative pressure during operation.

Preliminary Requirements:

The problems to be addressed throughout this project is to replace their old blasting

system with a new modern system. This is the main task for this project and will be done by

both the ME and ECE teams. The National Guard has made it clear what they are looking for in

the new blasting system. The new system must be able to use type 8 plastic “Magic Media” as

its blasting abrasive. The new system must be able to fit within the buildings blueprint. The

system should also be American made with readily available parts for repair and maintenance.

One task of the electrical engineering team will be to consider power demands for the new

system. Through the utilization of newer technologies, the power demands of the new system

should hopefully be more efficient.

The other main component of this project is to design an electrical/digital system for

controlling airflow in the facility. The current system must be changed to be able to maintain

negative pressure in the blasting room during operation. The system must also have a good

cross draft airflow to ensure proper collection of dust and particles in the dust collector. There

is also a side vent which is currently a manually operated vent which the sponsor would like to

be made into an electro-mechanical system.

The mechanical engineering team is tasked with the development of a more efficient

floor recovery system for the plastic media. The old system is not very efficient and requires the

blast technicians to stop work for several hours requiring them to shovel the plastic media into

the recovery system. A full floor recovery system is preferable to increase work productivity but

may not be achievable due to certain building constraints.

System Specifications:

The new blasting system must have the same specifications as the old system or better

than the old system. The important specifications to take into consideration are the following:

• Grit Size and Type: Type VIII, Size 30-60 Mesh Plastic Media

• Air Required: 820 Cubic Feet per Minute at 40 Pounds per Square Inch

• Electrical Requirements: 480 Volts / 3 Phase / 60 Hertz

• Exhaust Fan Motor: (Ventilation) 75 HP / 40,000 CFM

Page 9: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 9 of 22

• Exhaust Fan Motor: (Converying) 7.5 HP / 1200 CFM

Basic Limitations:

The current blasting system has been grandfathered in and no longer complies with

building regulations such as the National Fire Protection Association (NFPA) and the National

Electric Code (NEC). Other regulations that will have to be considered is that the new system

will have to comply with Federal Aviation Administration (FAA) and Connecticut Airport

Authority (CAA) guidelines. The building is already along the maximum building line, so external

additions to the building may not be possible. The new system layout will have to comply with

these regulations and be able to fit within the limited space available. Figure 1 shows the

current building layout. It also shows the dedicated room for the mechanical systems. There is

also an opportunity for building an extension on the building in case machinery must be moved

to accommodate the specific codes.

Due to the limitations of the room size that will house the blasting equipment / filtration

components, it is important to consider the explosion proof classification that the room will be

designed in when looking for components. When dealing with abrasives that will be circulating

throughout the system, there is a very real possibility of some sort of fire or explosion if the

abrasive gets into the machinery or electrical equipment. For this reason, it should be

imperative to investigate the volatility of the equipment, explosion proof parts, and whether

the equipment is hermetically sealed. Currently the blasting room being used is a Class II -

Division II meaning that the environment is hazardous due to the presence of combustible dust

yet the location in which the hazardous concentrations are handled, processed, or used are

normally in closed containers / closed system and can only escape in case of an accidental

rupture or breakdown.

Another limitation is that the National Guard does not want to add another transformer

to the existing building, so the overall power draw of the building cannot be increased over the

current building's power capacity.

Page 10: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 10 of 22

Figure 1: National guard blasting and paint shop building layout

Green is blast media bay, Blue is blast media equipment, Red is possible expansion area

Other Data:

The preexisting system was developed by Abrasive Blast Systems, INC which is a

company located in Abilene, Kansas. Unfortunately, as described by the sponsor, the summer /

winter controls did not work when the system was originally designed. This controlled where

and how the intake of the ventilation is processed within the media blast system.

Another issue being faced is the doors during the media blasting. The booth is running in

positive pressure when it should be running in negative pressure. This has forced them to have

to tie down the doors to keep them from force opening during the media blasting.

As for the floor recovery, since the building is on an unusually high-water table this

means that there is only 12 inches of depth to work with when designing a new system. This

floor recovery system should be able to withstand the weight of a 26,000 lb Chinook helicopter.

Page 11: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 11 of 22

Additional Information:

This project utilizes skills in different areas. One large part of this project is identifying if

the system complies with relevant electric codes and building codes. The project also requires

good knowledge of power systems to determine if the new system’s power draw is acceptable

for the building's current power. The ability to determine power draw consumption from each

of the new equipment integrated into the new system. The ability to make an electrical system

to sense environmental factors and adjust system settings to optimize performance. Be able to

read and interpret building schematics and equipment data sheets.

III. Approach and Design

The ECE team will most likely not have to play a role in designing the floor collection

system. It has been determined that this will be the main project for the ME team. This is since

the floor collection system is going to be mostly a mechanical problem and currently does not

have an electrical engineering component to it. The ECE team will still be informed of the

process and design of the floor collection system, however we will not be held responsible for

the actual design.

The amount of blasting done over a given period of time and the number of employees

will be considered. Currently the National Guard has 2-4 employees blast the abrasive but often

takes several hours to clean the abrasive having too shovel into the floor reclamation system.

Therefore, a full floor pneumatic system will be employed which will be covered with a grate

rated to handle the maximum uniform load of a helicopter.

Theory:

A main design component is the airflow system. The most common and economical

method of ventilation is "cross-draft". This means during the abrasive blasting process air is

drawn horizontally across the object being worked on. This air is drawn directly from the booth

environment. Air flow is also determined by the dust collector size or its CFM (Cubic Feet per

Minute) which is calculated by taking the Width of Room x Height of Room x the Cross Sectional

Air-Speed (FPM). Note: The minimum required Cross-Sectional Air Speed for Abrasive Blast

Rooms is 60 FPM for non-steel abrasives and 50 FPM for steel abrasives. For the blast room

used by the Groton National Guard, it is calculated that the dust collector will need to handle a

40,000 CFM capacity. The reclamation system will also add to the total ventilation system and

will require 1200 CFM.

Page 12: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 12 of 22

Return-on-Investment (ROI) of the blast room will be considered. As it stands the Dust

Collector uses 80 air filters which are replaced every 12-18 months. Each full replacement costs

$84,000 meaning that in order to achieve a maximum ROI, the filter must be rated to have an

efficiency of 99.85% on 0.5 micron particles. Another way to increase ROI is the inclusion of the

Reverse Pulse Jet system which will periodically release a pulse of compressed air that reverse

the flow of air on the cartridge and remove excess dust accumulation on the filter. This dust

falls to the bottom and is collected at the bottom of the dust collector hopper.

It should be brought to attention that the current airflow system does not work at all as

it should. The blasting room should be able to maintain negative pressure during operation, but

for many years now it has had positive pressure. After researching this issue and talking to

workers in the facility we have determined that this issue can be due to one or more of the

following:

• Over volume

• Compressed air pressure below 75 PSI

• Timer skipping one or more valves

• Reverse leakage through slide gate

• Dust on clean side of filters from plenum after previous bag failure

• Discharge system bridged, plugged or undersized, allowing re-entrainment to bag

surface

• Other air leaks, piping leaks, door gaskets, etc.

From this list of possible failures, we believe that the most prominent one is due to the

dust collection system not having the same airflow rating that it used to. This may be a problem

that can simply be fixed by implementing the new system with a new dust collector. This should

not be assumed though and research should continue to be conducted to find the source of this

problem.

Page 13: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 13 of 22

Models:

The desired airflow in the blast room is a cross-draft system. A cross draft system can be

seen in Figure 2.

Figure 2: Cross draft airflow system

In Figure 2 we can see the desired airflow through the blasting booth. The air will enter

the room from the vents at the top front of the room. The air will then move down and across

the room. The air will be pulled out the back of the room where the dust collectors intake vents

are.

The vent control system will use a DC motor to turn the crank to open and close the

vents. Figure 3 shows the electro-mechanical model of an armature DC motor:

Figure 3: Armature controlled DC motor model

Page 14: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 14 of 22

In Figure 3 we can see the electrical and mechanical system for the armature DC motor.

The most important parts of this model are the voltage into the motor, v, and the output

rotational position of the motor, 𝜃.

Proposed Solution:

The solution we are planning on following is the second. We are going to try to choose a

dust collector that has a good amount of exhaust airflow (40,000 CFM or more). This will ensure

that exhaust will be greater than intake causing the room to have negative pressure. Then the

intake vents can be opened or closed to adjust the pressure. These intake vents are currently

manually operated via cranks. The National Guard does want these vents to have a better

mechanical solution like a motor to open and close vents at the turn of a dial.

The side vent is currently operated by a manual crank. This is non-ideal as a worker must

get up on a ladder to crank the vents open/closed every time the National Guard wishes to

begin blasting. To achieve ideal airflow during blasting the side vent must be closed or only

slightly open, but when the room is not in operation the National Guard likes to keep the vent

open to allow for fresh air to come into the facility. The sponsor wants our group to update this

to be an electro-mechanical system.

For this electro-mechanical system, we simply need to replace the crank with a motor.

The motor will also need to be controlled by some sort of adjustable dial so that the vent can

be set to the desired state. To control the vent a DC motor is going to be implemented. To

control the DC motor a simple analog control system will be implemented because an

uncontrolled DC motor is an unstable system.

This system will allow the workers to easily open and close the vent to the desired state.

This will allow them to regulate the pressure inside the room which will help to achieve the

optimal cross-draft airflow with negative pressure.

Constraints:

One large constraint is that the current blast room is designed to have a dimension of

62'-10.5'' L x 29'-10' W x 25' H. This room is just large enough to accommodate the blasting of

the CH-47 Chinook among other helicopters being worked on at base. Due to the tight fit of the

helicopters in the blasting room it is not possible to implement a fully automated system for

blasting. Therefore, blasting will have to continue being carried out by the workers.

Another large constraint is the available space for the machinery. For the blasting booth

we must be able to fit all the machinery into a very limited space, as seen in Figure 1. This may

be difficult due to conflicting national codes.

Page 15: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 15 of 22

Standards and Codes:

There are not too many standards and codes to consider in this project. Mainly we must

consider two national codes when designing the mechanical systems for the blast booth. First,

we must consider the National Electric Code (NEC). This code lays out electrical standards that

must be complied to when working with electrical systems.

The second main code to consider is the National Fire Protection Association (NFPA).

This must be considered as the machinery we are working with is in proximity and they are

handling a flammable material. The blasting booth has lots of small particles that could create

an explosion if not properly handled.

Final Design:

From the DC motor model in Figure 3 we can derive a transfer function the electro-

mechanical system. The plant transfer function is derived to be:

Equation 1: Plant transfer function of DC motor system

Using this transfer function in Equation 1 we can plot the system response to an

arbitrary step input. To carry out this simulation MatLab will be used as it has a good built-in

function for systems analysis. The response of the uncontrolled DC motor system can be seen in

Figure 4.

Figure 4: Response of uncontrolled DC motor

Page 16: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 16 of 22

The system in its current state is not usable for our application. What we want is to be

able to set a desired position for the motor. This will allow us to use a dial to command the

motor to move the vent to a certain position. To get the transfer function we want we can

apply unity feedback to the plant which yields the transfer function in Equation 2.

Equation 2: Unity feedback of DC motor plant

With this system we can input our desired angular position of the motor and it will go to

that position. We can see the response of this new system by using MatLab.

Figure 5: System response DC motor unity feedback

Figure 5 shows the response of the system to a step input of 1. From this we can see

that the system does stabilize at the desired value, but the problem with this system is that it

takes too long to stabilize. The system takes over 40 seconds to stabilize to the final angular

position. In order for this design to work well this response must be quicker. Making the

response quicker will ensure that the ventilation system is responsive to user input on the dial.

To speed up this unity feedback system we can implement a controller. For this specific

problem we are between using a PID controller or a Lead network. The advantages of these two

Page 17: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 17 of 22

systems is that they are very easy and accessible to implement. A lead network was chosen as a

lead system that is very easy to build with minimal analog components. A lead compensator

can be represented by Equation 3.

Equation 3: Lead compensator equation

Using this H(s) from Equation 3 we can apply a simple feedback control scheme with the

plant. This will result in a closed loop system. To design the Lead compensator, we can analyze

the bode plot of the plant function. From the bode plot we can determine a crossover

frequency that will result in the desired settling time. This can then be used to evaluate the

values of w1 and B in Equation(x). After all the values have been determined a final system can

be derived from a simple feedback control scheme seen in Equation 4.

Equation 4: DC motor controlled by lead compensator

Using Equation 4 we can use MatLab to plot the step response of the final system. From

this we can evaluate the controller used.

Figure 6: Step response of DC motor controlled by lead compensator

Page 18: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 18 of 22

From Figure 6 we can see that the response time has been greatly reduced. One

observation is that the system now has overshoot, but this should not be a problem as this

system has a limiting factor of the motors saturation voltage. Due to this system now having a

good response we can go forward with this design of the DC motor and conduct some

simulations using this design.

Simulation Results:

From the transfer function in Equation 4 we can conduct some realistic simulations as if

someone were turning the dial. To do this Simulink was used to construct a model for the

system. Then a simulation profile was created to simulate someone turning the dial from

completely off to the max setting over about 1 second. This resulted in the system response

shown in Figure 7 and Figure 8.

Figure 7: Simulation of DC motor system (angular position)

Page 19: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 19 of 22

Figure 8: Simulation of DC motor system (motor voltage)

From the simulation in Figure 7 we can see the dial input of the desired angular position

of the motor (blue line). We can also see the response of the DC motor system as the output

angular position (yellow line). This shows that the DC motor system can follow the user input

very well. Figure 8 shows the DC motor’s voltage during this simulation. From this we can see

that the motor starts up and saturates at its max input of 90 volts. It stays at 90 volts until the

motor reaches the desired position. After the motor reaches the desired position the voltage

drops back to zero. It is important to note that this simulation was carried out using the

specifications from a general purpose 1 HP 90-volt DC motor. We also assumed that the vent’s

crank would pose a load of about 30 kg. This is most likely way more load than the motor will

experience opening and closing the vents, but it is important to design for the worst-case

scenario. For this system it is not uncommon for the vents hinges to get clogged with the plastic

media, so the motor must be able to overcome this.

Page 20: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 20 of 22

IV. Project Management

Division of Labor:

Table 1: Team member responsibility assignment (RACI chart)

Figure 2 shows a RACI chart which defines the responsibilities of each of the team

members for the different tasks this project includes.

Project Timeline:

Figure 9: Project timeline (fall semester)

Figure 10: Project timeline (spring semester)

This project is mainly a design project, so much of our time will be spent researching and

designing our solution to this project. We are currently aiming to have the project completed by

Page 21: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 21 of 22

March. This will give us time at the end of next semester for any issues or slowdowns in the

researching and designing of the various systems.

Budget:

As this is mainly a design project there will be no need for our group to have a budget

since we will not be building any physical system. There are some economical things we must

take into consideration though. Currently the National Guard would like to allocate somewhere

between 3 - 5 million dollars when they carry out the implementation and purchasing of the

new blasting system. This should be taken into consideration when completing a bill of

materials for the National Guard when they decide to move forward with implementing the

system.

V. Summary

The National Guard has tasked our group with redesigning and modernizing their

blasting booth. They have also been very clear on what they expect from us when the project is

finished. Currently they expect this to be a design project. We are tasked with conducting a

study on what the best components are for making a long lasting and efficient system. This

means researching different styles of systems and finding the best fit for their needs. Then

determining the size of the system and where the different components can be placed within

the facility. It also includes bringing their ventilation system up to more modern standards.

After our design is complete the National Guard plans to hand off our designs to a professional

design team which will investigate the feasibility of implementing our system while also

considering the necessary codes required for the actual construction process.

References

[1] Singh, G., 2013, “Modeling, Analysis, Evaluation and Experimental Investigation of Abrasive Blasting process. Thapar University, India.

[2] A. B. Systems, “Blast Room Ventilation,” Abrasive Blast Systems, by ABS Blast, 27-Oct-2015. [Online]. Available: https://absblast.com/room-to-vent/.

[3] “Abrasive Blasting,” American Galvanizers Association. [Online]. Available:

https://galvanizeit.org/design-and-fabrication/fabrication-considerations/abrasive-blasting.

Page 22: Blast Media Booth Modernization - ecesd.engr.uconn.edu

Page 22 of 22

Appendices:

Senior Design Project Checklist

Project name: Blast Media Booth Modernization

Sponsor: Connecticut National Guard TASMG Groton Airport

Team members (majors/programs):

Nathaniel Burgess (ECE), Gabriel Zepeda (ECE), Tyrese Gaffney (ECE), Alexandra Buss (ME), Oleg

Nazarovets (ME), and Johanna Litchfield (ME)

Faculty advisor(s):

A.F.M. Anwar (ECE) and Reza Sheikhi (ME)

Skills, Constraints, and Standards: (Please check (√) all those that apply to your project.)

Skills: (√) Analog circuit design and troubleshooting √ Digital circuit design and troubleshooting Software development/programming Embedded Systems/Microcontrollers Web design RF/wireless hardware Control systems √

Communication systems Power systems √ Signal processing Machine shop/mechanical design √ Other (please specify): Constraints: Economic (budget) √ Health/safety √ Manufacturability Environmental (e.g., toxic materials, fossil fuels) Social/legal (e.g., privacy) Standards: List standards/electric codes that you used (e.g.,

IEEE 802.11, Bluetooth, RS-232, VHDL, etc.) If applicable, list the name or # here: National Electric Code, National Fire Protection Association,