CONDUCTIVE HEAT TRANSFER APPARATUS P13624. John Durfee, Ryan Murphy, Fielding Confer Dan Unger, Katie Higgins, Robin Basalla Group Members

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  • CONDUCTIVE HEAT TRANSFER APPARATUS P13624
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  • John Durfee, Ryan Murphy, Fielding Confer Dan Unger, Katie Higgins, Robin Basalla Group Members
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  • 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?
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  • General Review
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  • Purpose To design a heat conduction apparatus that can illustrate fundamental concepts of heat transfer to students new to hands-on engineering
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  • 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
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  • Top Level Function Uninformed Student Partial Assembly Energy Unknown k Informed Student Hands-on Experience Thermal Energy Known k Demonstrate Principle of Thermal Conductivity
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  • 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
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  • Specifications
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  • Concept Generation Review
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  • 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
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  • Refined Subsystems Subsystems HotColdSpecimen Temp Trans. Insulation Liquid flow jacket Rectangular prism (bar) Thermocouples Form-fitted Solid Steam flow jacket Cold air gun (vortex tube) Cylinder (rod) Resistance Thermometer Form-fitting malleable Steam flow jacket Liquid N2 Thermistors WrappedElectric heater Thermoelectric Device Coloring Material Packed
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  • 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
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  • Concept Comparison Subsystems HotColdSpecimen Temp. Trans. InsulationOrientationAssembly Previous Design DATUM Box- Blocks 000+0/+0+ Box Clamp 00+++++ Hinged 000++++ Vertical Hinged Pipe 000/++++0 N2 Bath 0-0+++0/-
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  • 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
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  • Box-Blocks Concept
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  • 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
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  • Box Clamp Concept
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  • 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
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  • Hinged Concept
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  • Collaboration of Ideas
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  • 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
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  • 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
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  • 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
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  • 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
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  • Moving Forward New subsystems needed to be identified Heating Connection Cooling Connection Transmitter Connection
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  • 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
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  • Summarizing Previous subsystems can be used to help categorize new elements A new list of subsystems has to be generated
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  • 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
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  • Refining the Concept
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  • Current Benefits Modular design Simple assembly Rugged, easily replaceable components Minimal stress on transmitter connections Well insulated energy exchange
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  • 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
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  • Thermocouple Connections Options High Temp Solder Adhesive Patches Thermal Epoxy Drilled Holes
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  • 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
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  • Upper Insulation Options Rigid Formed (like middle) Soft Fiberglass or alternative Combined Structure
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  • 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
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  • 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
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  • Housing Connection Options Hand screws Buckles Structural Offset
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  • 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
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  • Selections Thermocouple Connections Drilled Holes Upper Insulation Rigid and Formed Housing Box Enclosure Housing Connection Structural Offset
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  • Finalizing the Design
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  • 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
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  • 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
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  • 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
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  • Bill of Materials Handout
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  • Final Drawings
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  • Full Draft
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  • 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
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  • Cross Sections Hot SideCold Side
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  • Calculations
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  • 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)
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  • Rod Length vs. Steady State Time
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  • Approximations
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  • 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)
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  • 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
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  • Lab View HMI Example
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  • Temperature Data Example 140.321 123.128 98.789 75.451 56.266
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  • 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
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  • 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)
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  • 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