Identifying & Selecting Problem PSP 1 Analyzing Problem PSP 2 Generating Potential Solutions PSP 3 Selecting & Planning Solution PSP 4 Implementing Solution PSP 5 Evaluating Solution PSP 6 R1 R2 R3 Y4 Y5 G6 1 Flow through the Bearing housing is not what was calculated / Could be obstructed See "Problem 1: Documentation" Test plan 4 in place to deduce actual flow while rig under full operation. Subject matter expert guidance will be sought out to generate correct oil flow requirements under dynamic loading In Progress Anthony 2 Material costs for mounting designs are too high [tool steel] See BOM, details material costs Run analysis with other steels to see if deflection and stress can remain low with new material Looking at material properties, 1045 steel is a reduce in cost with out compromising strength Run analysis with 1045 cold drawn steel, further check material selection with experimental testing before mounting on rig Since experimetation is not yet possible we were only able to evaluate the analysis which was approved by SME and will be further explored with machine shop In Progess Christina 3 Delfection of mounts with 1045 steel is unrealistic See mounting document Rerun analysis, and have another person check analysis Discuss issues with SME (Dr. Debartolo) Run analysis with various initial conditions, the error was a flaw in the math model from such small deflections Various initial conditions provided a better picture of displacement of mounts In Progess Christina 4 Pressure transducer doesn't produce a useable signal Checked transducer with multimeter to see if it produced any signal. Checked connection to ensure no blockage. Used a PCB and Omega transducer to see if they worked Old transducer was broken. We looked into purchasing a new one. See Pressure Transducer Document Chose to purchase PX319- 200GV, Documentation has been completed. Awaiting Purchase 2/9 Part received 2/16/15. Worked through SOP-0006 to verify calibration of the Omega calibration sheet Calibration proved to be within 3%. We will use the Omega calibration numbers due to sources of error in our process (see SOP-0006). Results from test can be seen in tab titled "Problem 4: PT Cal Results" Completed Michael 5 Load Cells don't produce a useable signal Checked load cell with multi meter, looked over manual of meters, contacted transducer techniques, Meters are AC only unlike what manual states, Contact transducer techniques to fix output of meters, or purchase new meters Contacted transducer techniques Adjusted values inside the meters setup that allows it to properly interperate the load cells signals Both of the 2000 lb load cells are working with a corresponding meters. Notes were taken to help problem solve potential calibration issues. Learned that the meters are only capable of 60 samples a second which could effect the accuracy of our load profile. Completed Michael 6 No DAQ program from Alpha prototype Looked on edge, contacted Steven Lucchesi, contacted Luke with no luck Create Labview program, ask SME to create a DAQ, Renegotiate customer needs Create our own Labview Program See Labview folder for process. Using the DAQ Assistant node to set up each device has problems. The problem seems to be caused by the different methods of data collection, for example; on demand, continuous etc. The DAQ Assistant doesn't allow each device to prioritize. This causes a bus error. Dr. K and Dr. Kempski advised to use the DAQmx nodes and rewite the code in this fundementalist way. Week 7 had no access to a working LabVIEW to code. In Progress Michael 7 Belt is slipping Belt seems to be slipping because of an issue with the journal. System was taken apart and inspected. Visual evidence of damage to the pillow bearings was discovered. When comparing the two pillow bearings one requires much more force than the other. Wear on the pillow bearins outer diameter suggest it was spinning in place. See Problem 7: Images Damage could be caused by the removal of the pillow bearings insert. This process was done with the help of Rob from the tool room. Difficulty was caused by defects in the journal caused by the set screws that secure the journal to the insert. Flats were milled into the journal to prevent this from happening in the future. New bearing inserts were priced through applied technologies at $249.17 a peice. The insert with new blocks would be $447.00 a peice. When talking with the associate it was confirmed that P14453 purchesed one fixed and one free. This explains why there is only one split clip present. Typically a free bearing would be used in applications where the journal "swells" due to heat and or high rates of rotation. Our system experiances neither. Selected solution is to purchase a new bearing insert and compared with the old ones to ensure that its the cause of the problem. Made order and picked up the bearing insert from Applied Technologies in Rochester on 3/12/15. Compared it to the two bearing inserts in question. When comparing the new insert to bearing insert A, see Problem 7: Images tab, the new bearing was more difficult to rotate. However, the bearings side to side movement was the same. When comparing the new bearing insert to bearing insert B, the new bearing was easy to rotate and had much more side to side movement. This side to side movment or off axis play allows for the insert to adapt to mis-alignments under 2 degress. We reassembled the test rig using bearing insert A and the new bearing insert. Upon completion we rotated the journal by hand, which felt less restricted than before. After running the pump for 5 minutes we started the belt drive system. The motor was able to turn the journal without restriction. Completed Michael P15453: Dresser Rand Journal Bearing Similarity Test Rig MSD II Problem Tracking Problem Number Status Team Member Responsible