ME, ECE, BE Capstone Design Programs

To Predict To Design To Perform

Budget• Materials: $749.96

• Instrumentation: $1353.45

• Others: $381.84

• Total: $2485.25

Team 25: Rotary Kiln Training ToolJohn Darbonne, Jacob Lee, Jaron Thurnau, Gregory Vied

Adviser: Dr. Shengmin Guo

Objectives• To create a scaled model of the existing kiln for a better

method of training employees

• Show shell manipulations and adjustments

• Include a scaling document to estimate resulting

movements from supporting roller adjustments

Background• Phillips 66 Westlake facility uses a rotary kiln to process

petroleum byproducts

• Adjustment methods are used to correct misalignment to

prevent mechanical damage

• Current training methods are ineffective and/or costly

Customer Requirements• Visually train maintenance personnel on alignment

discrepancies

• Hands-on interaction with representation of roller

adjustment

Educational Points

Testing Objectives• Handle and Latch Mounting Points: strength of mounts

• Fiberglass Tensile Test: robustness of case

• Shell Deformation

• Document Rubrics: usefulness and understanding

• Temperature: overheating of electronics

Electronics

Measuring ToolsCasing

Aluminum

ShellFasteners Others

Safety Considerations• Pinch points

• Rotating Machinery

• Heavy lifting

• Laser brightness

• Electrical shock

Timeline (Major Milestones)

Photo above (left) shows the side

view deflection on the fiberglass.

Pictured right is the front view.

Left photo shows the tensile

machine used. Right photo is

the sample specimen after

failure.

Sponsor: Kelly Goudeau Phillips 66

April24:EndTes ng,Opera onManual,andScalingDocument

February15:BeginOpera onManualandScalingDocument

March5:BeginAssembly

January20:BeginManufacturing

January31:EndPurchasing

December15:BeginPurchasingParts

April17:EndAssembly

April1:EndManufacturing

September11:BeginEngineeringSpecifica ons

December1:BeginTes ng

November23:EndEngineeringAnalysis

AugustSeptember

MarchAprilMay

NovemberDecember

January-February

October

October30:BeginCADDrawings

October15:BeginMaterialsSelec on

November13:EndEngineeringSpecifica ons

November7:EndMaterialsSelec on

October5:BeginEngineeringAnalysis

May6:FinalReportDue

March31:EndCADDrawings

1.995

1.997

1.999

2.001

2.003

2.005

2.007

2.009

0deg

45deg

90deg

135deg

180

225

270

315

ShellDeforma on

3

13

17

28

Engineering SpecificationsConstraint Goal Actual Value

Weight ≤ 50 lbs 57 lbs

Cost ≤$2500 $2485.25

Accuracy 5% of Travel .1% of Travel

Set Up Time

5 min 2.5 min

Size 8ft^2 4.5ft^2

Pictured above is the actual kiln at Phillips 66.

Testing Results

Desired Values Experimental Values

Mounting Weight >40 lbf At least 46.3 lbf

Document Rubrics 95% satisfactory 98% satisfactory

Temperature <122° F 82.4° F

Distance From

Top End (in.)

Radial

Distance

(in.)

Pictured above is the side view of the

model. The photo on the far right shows

the front view displaying the roller and

carriage assemblies. Near right is a

picture of the prototype 3D drawing.