Post on 12-Jan-2016
Detailed Design ReviewMultidisciplinary Senior Design 1Friday, February 15th, 2013
P13051
P13051 – PIV Experiment for Flow Mapping in Lungs
• Customers: ▫Dr. Risa Robinson▫Dr. Steven Day
• Team Guide:▫Michael Antoniades – Chemical Engineering
• Team:▫Kristin Roberts – Project Manager, ME▫Morgan DeLuca – ME▫Brad Demarest – EE▫Ryan Mark – ME▫ Jimmy Moore – CE▫ Jake Snider – ISE
Agenda•Project Background•Customer Needs & Engineering
Specifications•Component Design & Feasibility
▫Pressure Measurement & Control System▫Pump System▫Lung Tank & Reservoir▫Camera/Laser Positioning System
•Preliminary Test Plans•Risk Assessment
Project Background
•The Army Medical Research Lab needs to validate their CFD models for healthy and diseased lungs
•RIT will perform particle image velocimetry (PIV) on lung models to validate the CFD.
•The senior design team will design and develop the lung models and testing apparatus.
What is PIV?•Used for flow visualization and velocity
measurements•Fluid is seeded with tiny tracer particles•The particles are illuminated using a laser
sheet, and a camera takes pictures of the particles.
•Fluid velocity profiles can be obtained by analyzing particle movement from frame to frame.
Key Customer Needs1. Accommodate various image locations2. Simulate inhalation and exhalation3. Monitor flow rate and pressure4. Control flow at outlets to mimic
boundary conditions of CFD model5. Accommodate imaging with no
distortion6. Create LabVIEW Program and
procedure to run experiment7. Can easily switch between models
Pressure Control Subsystem
Comprised of:
• T-hose splitter
• Dual flow needle valve
• Amplified voltage
pressure transducer
• Powered breadboard
Needle Valve
• High resolution, therefore
minor adjustments to flow
can be made (5 turns)
• Dual flow capability
(allows inhale and exhale
simulation)
• Low profile for
organization purposes
• Low cost (20$)
T-Hose Splitter
Reasons for using a T-hose splitter:
• Separate static pressure
from dynamic flow
• Allow pressure readings to
be taken parallel to flow
increasing accuracy
• Organize flow path from
model to valve system
Amplified Pressure Sensor
• Accuracy (can measure static
pressures +/- 1% with proper
calibration)
• Cost (65$ per sensor)
• Compact design (no extensive
cables or adaptation, plug into
breadboard)
• Easy to calibrate and
characterize to increase
accuracy
Breadboard Implementation
• Keeps voltage sensors organized and setup compact
• Allows user to adjust voltage getting applied to sensors easily
• Flow from pressure control to DAQ device will be smooth
Pressure Control Path
Fluid will leave outlet
With steady state conditions fluid will separate due to splitter and apply static pressure on sensor
Flow will be adjusted with needle valve based on logger pro readout compared to desired conditionsBack to
pump
Calibration Technique
Fluke 718 series
• Can use to apply very accurate known pressure
• Output voltage can then be read and adjusted to create new curves accurately matching sensor performance
• Device is on loan from ME Department
Flow Characteristics
•Viscosity determined through index matching, (550 SSU, 109 cP, 0.109 Pa-s)▫Much higher than water (1 cP)
•Flow tested by Army is from 2-10 L/min▫Using Reynolds number matching, 6-32
GPM•Pressure loss through system ranges from
20 psi to 50 psi▫Calculated using Poiseuille flow
Positive Displacement vs. Centrifugal
Conclusion: PD pumps provided better flow control, regardless of pressure and handle high viscosities.
Graph Credit: pumpschool.com
PD Pump SelectionPump Flow Rates Pressures Comments Cost (3 highest)
Gear pump Acceptable,Up to 30 gpm
Acceptable,Up to 50 psi
Common, can be self-priming
2
Rotary Vane Acceptable Acceptable Not really used in our application, better for thin fluids and high pressure differentials
1
Diaphragm Acceptable Acceptable Create pulsing flow, need air supply, cheaper
1
Lobe Pump Acceptable Acceptable Used in Sanitary applications where fragile solids are used, bi-rotational, may be overly complex
3
Image Credit: Wikipedia; Info Credit: pumpscout.com
3 GPM 35 GPM
6 GPM 33 GPM19 GPM
Siewert, 1.6-16 GPM, $2,079
Siewert, 3.2-32 GPM, $2,319
Siewert, 2.3-23 GPM, $2,189
Emerick, 3.3-33 GPM, $2,754
• Max flow rate: 33 GPM• Min flow rate: 3.3 GPM• Max Pressure: 200 psi• Speed Ratio: N/A• Price: $2,745• Shipping not included• Lead time: 3-4 weeks
• Max flow rate: 32 GPM• Min flow rate: 3.2 GPM• Max Pressure: 100 psi• Speed Ratio: 10:1• Price: $2,319• Shipping included• Installation Assistance• Lead time: 5-6 weeks
Emerick Siewert
Inhalation Pipe Schematic
Lung Tank Design• The project team has
decided to go with acrylic siding for the tank, as it is easy to machine and is readily available in the needed sizes.
• The tank will be 24” x 16’’ x 16’’, which will hold slightly less than 27 gallons worth of liquid.
Lung Tank Design• The case will be made
watertight using silicone gel, and then made more structurally sound using L-brackets along the side.
• 8 holes will be drilled along the bottom of the side panels for the multi-tube connectors
• A single hole on the top of the case will allow liquid to be pumped in to the model.
Tank Wall Deformation Analysis• ANSYS Workbench was
used to analyze wall deflection due to hydrostatic pressure (P=ρgh).
• Original choice of 1/8” thick acrylic resulted in 1.868” outward deflection.
• Needed to find appropriate wall thickness that would not affect PIV results
1/8”
5/16”
Tank Wall Deformation Analysis•Treated tank wall as a
simply supported beam•Able to calculate
deflection and slope of deflection
•Calculate angle between laser and perpendicular𝜃1=tan
− 1(𝜃𝑠𝑙𝑜𝑝𝑒)
(𝑠𝑙𝑜𝑝𝑒)
Tank Wall Deformation Analysis•Used Snell’s Law to
calculate the angle of the laser after it enters the tank (θ2).
•We can then calculate the error associated with refraction using the distance the lung is from the wall.
θ2
Error
Distance to model
)(distance)
Tank Wall Deformation Analysis
Panel Thickness
(in)I (in4) Max P (psi)
(q)Max
Deflection (approx)
Max Slope (Magnitude) θ1 (deg) θ2 (deg)
Distance to Model
(in)
Error due to
refraction (in)
Error due to refraction
(mm)
0.25 0.0208 1.0595 0.2441 0.0347 1.9885 1.3344 8 0.1863 4.7333
0.3125 0.0407 1.0595 0.1250 0.0178 1.0184 0.6835 8 0.0954 2.4240
0.4375 0.1117 1.0595 0.0455 0.0065 0.3712 0.2491 8 0.0348 0.8835
0.5 0.1667 1.0595 0.0305 0.0043 0.2487 0.1669 8 0.0233 0.5919
0.6875 0.4333 1.0595 0.0117 0.0017 0.0957 0.0642 8 0.0090 0.2277
0.9375 1.0986 1.0595 0.0046 0.0007 0.0377 0.0253 8 0.0035 0.0898
1 1.3333 1.0595 0.0038 0.0005 0.0311 0.0209 8 0.0029 0.0740
Tank Wall Deformation Analysis
For a 16”x24” acrylic panel, 7/16” thick
Reservoir Design•Similar design to
Lung Tank•1/8” thick acrylic
will be fine since tank is not used for PIV – only 0.17” deflection.
•12”x12”x12” box•Holes cut for
connection to pump system
Omega Multi-tube Connectors
•Can handle 10 tubes per connector. Will allow easy connection/disconnect when we switch out models.
•Allows for thru-wall connection to simplify the tank and tube interface.
Lung Holder
•Used to hold lung in tank
•Put rubber between holder and lung model to ensure a tight and secure fit
•Can rapid prototype in clear Watershed XC 11122 for ~$300
Lung Holder Drawing
Labview – Data Acquisition•NI-USB-6225, Screw
Terminated▫80 Analog Input Ports▫Compatible with
Labview▫$1749
•This will output to the Labview program which will collect the pressure data and display it to the user.
Labview Code
•Not fully completed ▫Need all
components before testing and construction can occur.
Positioning System
•Need: Ability to take PIV pictures of all branches and bifurcations
•XYZ Stages alone are not the answer ▫Used for low travel, high resolution▫Very expensive for more than one
•Optics rods and clamps also too expensive & precise
•Make it ourselves – 80/20
Design•Essentially a square arch
that translates•L-Handle brakes to keep it
in position•Strong frame – no vibration•Drop-in T-studs allow for
camera movement •When combined with a
rotation allows for all angles
Result
•Contacted Bob Proscher at Ralph W. Earl Co.
•Developed a kit including all requested machining▫Quote: $243.75
•Mount an optical stage (5 – 10 mm) ▫$600 - $1,000
•Refractive index (RI) of fluid must match that of the model.▫Model will be made using RedEye
Veroclear n = 1.47
•Fluid used will be made from glycerin.▫85% Glycerin, 15% Water
n = 1.45 While RI may not be matched exactly, the
difference is negligible.
Index Matching Fluid
Complete Test Setup
Positioning System
Lung TankPump System
Reservoir
Subsystem Cost
Tanks and Containment $1207.46
Camera Positioning $191.45
Pumping System $2,597.91
Common Header $266.62
Pressure Control and Measurement $11,703.00
Total: $15,966.44
Budgetary Overview
Part Price/Unit
Quantity Cost
Acrylic Sheet, 48"x24", 7/16" thick $132.39 2 $264.78 Multitube Quick Coupling Set $64.00 8 $512.00 Perforated framing, zinc-plated steel, 4ft each, pkg qty 12 $8.78 1 $8.78 Plain Steel Square Head Low Strength Bolt 5/16"-18 Thread, 1" Length, pkg. 25 $5.59 2 $11.18 18-8 SS Type A USS Flat Washer 5/16" Screw Size, 7/8" OD, .06"-.11" Thick, pkg. 25 $5.60 2 $11.20 Plain Grade 8 Steel Hex Nut 5/16"-18 Thread Size, 1/2" Width, 17/64" Height, pkg. 100 $4.28 1 $4.28 Steel Perforated Flat and Angle Framing Hardware: Zinc-Plated Steel Bolts W/Nuts & Washers $7.42 1 $7.42 Zinc-Plated Steel Machine Screw Hex Nut 2-56 Thread Size, 3/16" Width, 1/16" Height, pkg. 100 $1.21 1 $1.21 316 SS Pan Head Phillips Machine Screw 2-56 Thread, 1/2" Length, pkg. 50 $6.18 1 $6.18 Acrylic Sheet, 12"x12", 1/8" thick $8.63 6 $51.78 All-Seal Sealant for Wet and Oily Surfaces, Clear, 10.2 oz $18.27 1 $18.27 Standard Pipe Thread Sealant 1-1/4-Ounce Stick $3.46 3 $10.38 Lung holder – rapid prototype in Watershed XC 11122 $300 1 $300
Total: $1207.46
Tanks and Containment
Part Price/Unit
Quantity
Cost
1515 Profile $13.99 5 $69.95Drop-in T-studs $2.14 5 $10.70 Single Flange Linear Bearing $38.60 2 $77.20Hidden Corner Connectors $7.25 2 $14.50 L-handle Brake $9.55 2 $19.10
Total: $191.45
Camera Positioning
Pump SystemPart Price/
UnitQuantity
Cost
H75M Gear Pump$2,319.00 1 $2,319.00Variable Frequency Drive
MotorTubing, 1'' ID $2.45 5 $12.25Tubing, 1/4'' ID, 3/8'' OD $0.71 25 $17.75Tubing, 1.5'' ID $4.22 10 $42.20Tube clamps, 1.5'' 10 $7.22Tube clamps, 1'' 10 $7.07Tube clamps, 3/8'' 20 $5.67Tube to pipe, adapter, 1'', 1'' $8.32 1 $8.32Pipe to tube, adapter, 1.5 , 1.5 5 $8.73Tube to pipe, adapter, 1/4'', 1/2'' 10 $4.97Pipe to tube, adapter, 1/2, 1'' 10 $8.48Valve, ball, 1.5'' $44.56 1 $44.56Valve, ball, 1/2'' $9.84 1 $9.84Valve, ball, 1'' $22.31 1 $22.31Pipe, 1-1/2'', 4'', Male-Male $3.18 2 $6.36Reducer, 1'', 1 /2'' $32.46 1 $32.46Coupling, 1 1/2'' $6.37 2 $12.74Bulkhead, 1'' $6.05 2 $12.10Cap, rigid plastic, tubing, 1/2'' $0.06 100 $5.50Stopper, rubber, 1-1/2'' $0.87 12 $10.38
Total: $2,597.91
Common HeaderPart Price/
UnitQuantity
Cost
Manifold, 10 outlets, 1 inlet 23.1 8 $184.80Fitting, wye, t-t-t, 1/4,1/4,1/4 4.91 1 $4.91Plug, tube, 1/4 0.97 1 $0.97Tubing, polyurethane, 1/4'', 1/8'', 100' 24.7 1 $24.70
Total: $266.62
Pressure Control and MeasurementPart Price/
UnitQuantity
Cost
Minature Voltage Sensor $65.00 81 $5,265.00 Needle Valve $15.00 81 $1,215.00 Urethane Hose 50 ft $15.00 10 $150.00 Hose Connectors $188.00 6 $1,128.00 Polycarbonate sheet $50.00 6 $300.00 Data Acquisition Device $3,000.00 1 $3,000.00 Powered Breadboard $90.00 3 $270.00 T splitter $5.00 75 $375.00
Total: $11,703.00
Risk Assessment
Questions?