John Durfee, Ryan Murphy, Fielding Confer Dan Unger, Katie
Higgins, Robin Basalla Group Members
Slide 3
Agenda General Review 3:00pm Concept Generation Review 3:05
Collaboration of Ideas 3:10 Refining the Concept 3:20 Finalizing
the Design 3:30 Bill of Materials 3:45 Final Drawing 3:55
Calculations 4:05 Risk Assessment 4:15 Testing Procedures 4:25
Production Timeline 4:30 Questions?
Slide 4
General Review
Slide 5
Purpose To design a heat conduction apparatus that can
illustrate fundamental concepts of heat transfer to students new to
hands-on engineering
Slide 6
Keywords To quickly outline the primary goals, follow SAMPLE
Safety- minimal risk of student injury Accuracy- correct
measurements of conductivity Mobility- can be maneuvered in and out
of lab Precision- measurements are easily repeated Longevity-
robust materials and long life span Ease of use- simple assembly,
disassembly, & cleaning
Slide 7
Top Level Function Uninformed Student Partial Assembly Energy
Unknown k Informed Student Hands-on Experience Thermal Energy Known
k Demonstrate Principle of Thermal Conductivity
Slide 8
Functional Decomposition Demonstrate Thermal Conductivity
Creates 1-Dimensional Heat Transfer Minimal heat loss from
boundaries Generates heat flux Provides proper temperature
variation Accepts multiple geometries Accepts multiple
materials/phases Minimizes resistance at heat exchanges Generates
Measurable Data Accurate Precise Manual collection Digital
collection (Labview) Displays rate of heat flux Displays
temperature distribution Enhance Student Lab Skills Requires manual
assembly and disassembly Can be used within given time periods Fits
on the chemical engineering carts Has replaceable components Low
maintenance Durable
Slide 9
Specifications
Slide 10
Slide 11
Concept Generation Review
Slide 12
Fundamental Concept Hot Cold Heat Conduction Energy In Energy
Out A temperature gradient will be produced between a Hot and Cold
regions This gradient will be set across a span of Heat Conduction
The flow of energy will be allowed to reach steady state The Energy
In will be equivalent to the Energy Out The temperature gradient
will be measured with a transmission system Temperature
Transmission
Previous Design Model Electric cartridge heater placed in a
drilled out hole on one end of the specimen Hot Controlled water
temperature connected to the other specimen end with a flow jacket
fitting Cold Cylindrical rod Specimen Probe Thermocouples
Temperature Transmission Fiberglass insulation contained within a
round plastic casing Insulation Horizontal Orientation
Box-Blocks Concept Open for consideration Hot Open for
consideration Cold Oriented more towards a rectangular prism
Specimen A separate thermocouple housing that can be slid in and
out of the device on top the specimen Temperature Transmission
Solid blocked insulation that can be build around the specimen and
fitted together Insulation Horizontal Orientation
Slide 17
Box-Blocks Concept
Slide 18
Box Clamp Concept Open for consideration Hot Open for
consideration Cold Can be fitted for either a bar or a rod Specimen
Thermocouples travel through a lid region and connect to the
specimen Temperature Transmission Solid formed or solid malleable
insulation that holds the specimen on the bottom and is covered by
an insulated lid Insulation Horizontal Orientation
Slide 19
Box Clamp Concept
Slide 20
Hinged Concept Open for consideration Hot Open for
consideration Cold Orientated more towards a rod Specimen
Thermocouples lay in small troughs on one half of the insulation
housing and are covered upon closing the device Temperature
Transmission Solid formed insulation that holds the specimen
between two hinged pieces Insulation Horizontal Orientation
Slide 21
Hinged Concept
Slide 22
Collaboration of Ideas
Slide 23
Benefits of Each System Box-blocks Modular pieces that are
easily constructed Box Clamp Simple, rugged assembly Broad range of
Insulation can be used Open for any type of specimen Hinged Minimal
disturbance to transmitters
Slide 24
Putting It Together Begin with a sturdy platform Seat a solid
block of bulk insulation Include a second block formed to the
specimen Cover it with a malleable slab of insulation Close
everything with a second connected platform
Slide 25
Exploded View Begin with a sturdy platform Seat a solid block
of bulk insulation Include a second block formed to the specimen
Cover it with a malleable slab of insulation Close everything with
a second connected platform
Slide 26
Moving Forward Considering previous decisions, i.e. The Hot
Side will use a cartridge heater The Cold Side will use a liquid
refrigeration unit The Temperature Transmission will use
thermocouples
Slide 27
Moving Forward New subsystems needed to be identified Heating
Connection Cooling Connection Transmitter Connection
Slide 28
Moving Forward The cartridge heater can be placed inside the
specimen The refrigerated fluid can cool the specimen with an
external jacket The thermocouples can be tacked to the
specimen
Slide 29
Summarizing Previous subsystems can be used to help categorize
new elements A new list of subsystems has to be generated
Slide 30
Categorized Subsystems Hot Side Heat Source Heating Connection
Cold Side Cold Source Cooling Connection Housing Top Bottom
Connection Transmission Transmitter Type Transmitter Connection
Insulation Upper Middle Lower Sections Specimen Geometry
Slide 31
Refining the Concept
Slide 32
Current Benefits Modular design Simple assembly Rugged, easily
replaceable components Minimal stress on transmitter connections
Well insulated energy exchange
Slide 33
Current Issues Need an appropriate method to tack thermocouples
No feasible material was found for the upper insulation (soft
forming) Unshielded insulation can be damaged Housing connections
need to be addressed
Thermocouple Connections Pros Solder Accurate Solid Connection
Adhesive Patches Simple Modular Thermal Epoxy Accurate Drilled
Holes Accuracy Modular Cons Solder Dangerous Messy Adhesive Patches
Inaccurate Thermal Epoxy Time Intensive Trades cost for accuracy
Messy Drilled Holes Permanent Added Processing
Slide 36
Upper Insulation Options Rigid Formed (like middle) Soft
Fiberglass or alternative Combined Structure
Slide 37
Upper Insulation Pros Rigid Simple Durable Fiberglass Cheap
Modular Combination Works best with ideas Partially modular Cons
Rigid Needs processing Less modular Fiberglass Less durable Messy
Combination More complicated Needs processing
Slide 38
Housing Insulation can be contained within a boxed housing Did
not require much decision making Slots can be made for the
thermocouple wires (as opposed to a long section) Openings will
also be needed on both the Hot and Cold Ends
Slide 39
Housing Connection Options Hand screws Buckles Structural
Offset
Slide 40
Housing Connection Pros Hand Screws Rugged Solid Closure
Buckles Simple Use Solid Closure Structural Offset Simple No
Processing Needed Less Expensive Cons Hand Screws Needs processing
Can be over worked Buckles Needs processing Less durable Structural
Offset Less Solid Closure
Slide 41
Selections Thermocouple Connections Drilled Holes Upper
Insulation Rigid and Formed Housing Box Enclosure Housing
Connection Structural Offset
Slide 42
Finalizing the Design
Slide 43
Still Need to Include Hot Side Energy Measurement (power
source) Cold Side Coolant Carrier (tubing) Cooling Fluid
Temperature Transmission Data Collection Hardware Data Collection
Software Housing Construction (screws) Used Specimen Container
Slide 44
Used Specimen Container Holds each specimen after they have
been heated and measured Isolates heated material from students Can
be moved away from testing area Uses the same material as the
housing device
Slide 45
Final List of Subsystems Hot Side Energy Management Heat Source
Heating Connection Cold Side Cold Source Cooling Connection Coolant
Tubing Transmission Transmitters Connection Data Collection
Hardware Data Collection Software Specimen Geometry Insulation
Upper Middle Lower Housing Material Connection Fasteners Used
Container Material Insulation Fasteners
Slide 46
Bill of Materials Handout
Slide 47
Final Drawings
Slide 48
Full Draft
Slide 49
Characteristic Dimensions Housing (21x8x8)in box 1in thick
Insulation 6x(19x6x1)in 2 milled sections Specimen 18in long 1in
diameter Heater 3/8in diameter 1in length Cooling Jacket 1in
diameter 1.24in depth Thermocouples 5 total Begin 3in down spec.
3in apart
Slide 50
Cross Sections Hot SideCold Side
Slide 51
Calculations
Slide 52
Needed Values Proper length for rod Manageable specimen
Reasonable time for Steady State Thermal Conductivity Bread and
Butter of experiment Derived from Fouriers Law Estimated
Temperature Ranges Use k-values for plausible samples Stay within a
reasonable range Heat into the system (using potential materials)
Heat loss (for safety and efficency)
Slide 53
Rod Length vs. Steady State Time
Slide 54
Approximations
Slide 55
Fouriers Law q=Heat Flux (W/m^2) Ti=Initial Temperature (K)
Tf=Initial Temperature (K) R= Thermal Resistivity (K*m^2/W)
A=Surface Area (m^2) Q=Heat (Watts) r=Radius of Rod (m) x=location
(m) k=Thermal Conductivity (W/m*K)
Slide 56
Estimated Temperature Ranges x=10 r=1Q=110 W T(Al)=82.5K
T(Cu)=35.5K T(Br)=119.9K k(Al)=167 W/m*K k(Cu)=388 W/m*K
k(Brass)=115 W/m*K 10
Slide 57
Lab View HMI Example
Slide 58
Temperature Data Example 140.321 123.128 98.789 75.451
56.266
Slide 59
Heat Source I=Current (amps) R=Resistance of heater ( ) V=Volts
(Volt) P=Power (Watts) Q=Heat (Watts) For Potential Power Source
and Heater V=23Volts (variable) I=5amps (constant) *Assuming all
electrical power is transfer to heat
Slide 60
Heat Loss l=length (m) w=width (m) t=thickness (m) k=Thermal
Conductivity (W/(mK)) Tin= Temperature on the inside surface of the
insulation (K) Tsur=Temperature of the outside surface of the
insulation (K) *Assuming whole inner surface is at one temperature,
and the entire outer surface is at room temperature (293 K)
Slide 61
Inner surface temperature of 400K Outer surface temperature of
293K Dimensions (19x6x2.5) Material: Calcium Silicate k=.073W/(m*K)
Heat Lost (Q)= 9.04 W This calculation is
