Date of Award

5-8-2023

Degree Type

Capstone Project

First Advisor

Bahram Nassersharif

Abstract

Team 22, nicknamed "The Fantastic Four," has been tasked with developing a tribology testing device for Magseal seals with a diameter of 1.5". This project is being done in collaboration with Team 21, who is responsible for designing the seal that will be tested using Team 22's device. The first step in this project was to gain an understanding of magnetic seals and tribology testing, which was achieved through literary and patent searches, as well as reviewing the work done by last year's team, Team 18, known as "The Challengers." The team was also given the opportunity to tour the Magseal facility and meet with their sponsors to gain a better understanding of their current testing machine and how the device they were creating should differ. Armed with this information, each team member generated 30 design concepts, resulting in a total of 150 designs. Using Pugh and QFD analysis, the team selected the top designs that focused on the design specifications given to them by Magseal.

These specifications included reaching a rotational speed of 7500 rpm, being able to apply 15 psi of pressure onto the seal, having a standardized seal mount that could exchange seal mounts easily, being lightweight and portable, and being able to generate 300°F of heat. Additionally, the device was required to have live data acquisition using a data logger.

During the first semester, Team 22 designed the skeleton of the device using paper and Fusion 360 software. They repurposed most of the previous year's device, but scrapped a majority of it. The working prototype was made entirely of aluminum, with plans to partially redo it in steel to ensure a long-lasting machine. However, the device was unable to generate heat at this point, as it had not yet been integrated into the machine. While the motor could reach the required rpm, it generated a lot of vibration that would need to be addressed in the future. Despite these small issues, the prototype was deemed a success, providing a solid foundation for the team to build upon while staying within their budget.

Continuing into the second semester, Team 22 worked diligently to meet all the design specifications set by both the team and Magseal. After much deliberation and trial and error, the team was able to minimize vibration, which had been the main issue during the first semester. The device now met all the required specifications, including the desired rpm, a standardized seal mount, portability, longevity, at least 15 psi, and heat applied to the seal. The only outstanding issues were that the heating element had not been installed onto the device yet, and the weight of the device slightly exceeded the desired weight. However, given the recent changes and modifications, the weight was necessary and unavoidable.

Finally, live data acquisition was a challenge during the first semester, but the team worked tirelessly to develop adequate code for data collection and interpretation. After presenting the device in the Design Build Test Redesign Presentation to the class and showcasing it to peers, professors, and visitors, the device was deemed a success and approved by Magseal, including the company's president.

Comments

Team Name: The Fantastic Four (Team 22)

Company Sponsor: MagSeal

Sponsor Representative: Nick Daggett and Jared Desrosiers

Document Reference: URI-MCE-402-22-2022

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