P19605 Customer Handoff & Final Documentation

Team Vision for Final Demo and Handoff

Mechanical Adjustments

• New Pumps Wound and Manufactured to avoid leaking around pins. See Winding Manual for reference to this procedure. 
• Small shims utilized in fixed-end/test stand interface to ensure constant tooth engagement and pump chamber contraction/expansion. 
• Software tool utilized for all testing plans. 
• Electrical Clean Up and waterproofing.

Figure 1: Finalized pump assembly

Electrical Subsystem Update

The below schematic is a comprehensive representation of the electrical system as it was / is implemented. The wire colors in the image below match the colors of the actual wires.

Figure 2: Finalized Electrical Schematic

Budget Update

Test Results Summary

Final Test Plan Editing

• After a testing meeting with the customer, unnecessary tests were eliminated.
• P4 (Pump Pressure vs. Volumetric Displacement), P5 (Optimal Frequency), and P7 (Life Cycle) were eliminated.
  • P7 was eliminated because it was deemed unnecessary information by the customer.
  • P5 was eliminated because it had been previously calculated analytically multiple times by the customer so the answer is already known.
  • P4 was eliminated upon further inspection and knowledge of the system. The plot created was deemed unnecessary as a pump performance metric.
• The final test plan document can be found here.

Master Test Matrix

Performance vs. Requirements

Below is the original ER list paired with the results of testing. The document can be found here.

Positives

• System integration worked as expected.
  • Motors were able to expand and contract both chambers easily.
  • Water from leaking pumps and dropped tubes were unable to reach the electronics.
  • Easy to control pumps using the pump.rit.edu website interface.
• Did not need to bolt down pump system as originally planned. The weight of the four motors keeps it from moving during operation.
• P3 was tested using the torsion tester rather than the test fixture (approved via discussion with customer). Both chambers were tested without water due to complications with existing tooling and valve locations.

Negatives

• Pumps were more prone to significant leaking around the pins than expected.

Test Results

• The composite body pump and test fixture passed all four test methods.
• P1: The average pumping potential for 20 trials was 8.12, more than double the minimum pumping potential of 4.
• P2: The average pump power efficiency was 20.79%. The raw and processed oscilloscope data for P2 is located here.
• P3: Using the torsion tester, a plot showing pump angle of twist versus input torque was generate fro both chambers
• P6: The composite body pump consists of two separate chambers which are both actuated by a central torsional coupling between both chambers.

Risk and Problem Tracking

• All risks identified have been addressed and mitigated. 
• Problem tracking template not useful for team purposes. 
  • Only problem throughout phase was pump leakage. Mitigated through sealing procedures and re-manufacture of pump chambers. 

Final Project Documentation

Links to Final Design Documents

• Final Paper
• Poster
• Winding Manual
• Lightning Talk Video
• CAD/Drawings (Due to file size, please email Dr. Ghoneim hngeme@rit.edu or Elijah Eaton ene3048@rit.edu for access to the full CAD library)
• Bill of Materials
• General Operation Manual 
• Electrical/Software Manual

Future Recommendations

• Create tooling for the winding of several chambers and have several (4+) wound chambers ready to be utilized for testing. 
  • Pump chambers wear and can become leaky after several repeated cycles. Multiple chambers would reduce testing time, not having to rely on 24+ hours for remanufacture of an additional chamber for testing. 
• Integration of torque measurement sensor/method on the designed test facility. 
  • Generate "wet" data for pump torsional stiffness.
  • Could test at various operational frequencies.
• Shim protocol to reduce excess vertical translation of PIG. 

Plans for Wrap-up

Team Level Plans for Wrap Up

• Additional detailed process review with customer: focused specifically on project hand-off and accessibility to User Manuals. 10 déc. 2019 
• Clean up of work space. 

Design Review Documentation