P13623: Conductive Heat Transfer Lab Equipment

System Design Review

April 5th, 2013

P13623: Conductive Heat Transfer Lab Equipment

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

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

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.

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.

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

Engineering Matrix

House of Quality

Constraint Criteria

Power Source

Temperature Sensors

Heating Element

Cooling Element

Insulation Methods

Data Collection

Contact Resistance

Interchangeability

Pugh Matrix

Design 1

Design 2

Design 3

Design 4

Final Design

Customer Specifications review

Risk Assessment

Cost Assessment

Pro/Con List

Customer Needs

Engineering Specifications

Engineering Specifications

Functional Decomposition

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

Concept Generation

Criteria Generation

Pugh Matrix: Heating and Cooling

Pugh Matrix: Insulation

Pugh Matrix: Sample Container

Pugh Matrix: Data Measurement and Display

HeaterJacketedCoolerJacketedTemp SensorThermo CpInsulationAirOrientationHorizontalSet-upEasy

Design 1

Pros & Cons of Design 1

Pros

Simplicity

Cheap

Visual

Compatible with different samples

Easy to set up

Cons

Inconsistent insulation

HeaterDiskCoolerJacketedTemp SensorThermo CpInsulationAirOrientationVerticalSet-upMild

Design 2

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.

Design 3

HeaterDiskCoolerPlateTemp SensorThermo CpInsulationSolid or packedOrientationVerticalSet-upmed-hot

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

HeaterDiskCoolerPlateTemp SensorThermo CpInsulationMutiOrientationVerticalSet-upmed-hot

Design 4

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

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.

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

Critique of Designs

Data Collection - Design #1

DAQsCostInterface (to PC)Arduino~60USB/OtherNi Equipment>600USB/OtherLabjack~110USB/OtherNeedsManual Data CollectionDigital Data CollectionEffective For Students of Various Learning Styles33Utilization is complex enough to involve 3-4 students in the allotted time11Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles3-Allows for manual Data Collection9-Allows for Digital Data Collection-9

Data Collection - Design #1 (Digital Only)

NeedsManual Data CollectionDigital Data CollectionEffective For Students of Various Learning StylesN(3)3Utilization is complex enough to involve 3-4 students in the allotted timeN(1)1Utilization Requires Fundamental Understanding of Conducive Heat Transfer PrinciplesN(3)-Allows for manual Data CollectionN(9)-Allows for Digital Data Collection-9

Data Collection - Design #2 (Analog Version)

NeedsManual Data CollectionDigital Data CollectionEffective For Students of Various Learning Styles3N(3)Utilization is complex enough to involve 3-4 students in the allotted time1N(1)Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles3-Allows for manual Data Collection9-Allows for Digital Data Collection-N(9)

Data Collection Design #3

NeedsManual Data CollectionDigital Data CollectionEffective For Students of Various Learning Styles33Utilization is complex enough to involve 3-4 students in the allotted time11Utilization Requires Fundamental Understanding of Conducive Heat Transfer Principles3-Allows for manual Data Collection9-Allows for Digital Data Collection-9

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 T = 120 K

Chosen Parameters: T0 = 273 K, D = , L =

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

One Dimensional Transient Analysis

h

T1

T2

T3

T4

T5

One Dimensional Transient Analysis

h

T1

T2

T3

T4

T5

One Dimensional Finite Difference Steady State Analysis

h

T1

T2

T3

T4

T5

Simulation Parameters

Copper Rod ParametersDensity (kg/m3)8940Thermal Conductivity (W/m*K)401Specific Heat (J/kg*K)394Length (m)0.254Diameter (m)0.00635Stainless Steel ParametersDensity (kg/m3)7820Thermal Conductivity (W/m*K)43Specific Heat (J/kg*K)490Length (m)0.254Diameter (m)0.00635

Copper Rod Results

After 1 minute

After 2 minutes

Copper Rod Results

After 3 minutes

After 4 minutes

Stainless Steel Rod Results

After 5 minutes

After 10 minutes

Stainless Steel Rod Results

After 20 minutes

After 40 minutes

Stainless Steel Rod Results

After 60 minutes

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.

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

Means for Calculating Thermal Conductivity Transient

Risk Assessment

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

Project Schedule for Quarter

GoalWeek CompletedRevise System Design based on Review feedbackWeek 6Create assembly plansWeek 7/8Create test plansWeek 7/8Write BOMWeek 9Order materialsWeek 9/10Hold Detailed Design ReviewWeek 10/11

Questions?

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500

1000

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3500

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Q W/(m.K)

Temperature (K)

Aluminum

Copper

Iron