RYAN_PALMER Mechanical Design Competition

Company Sponsor Pacific States Cast Iron Pipe Company

Candidate:Ryan Palmer

CAPSTONE PROJECT

Overview Background Information Customer Needs Concept Generation Concept Selection Testing Results Design

Pacific States Cast Iron Pipe Company

Provo, Utah

• Everyday PSCIPCO produces on average 1500 pipes

• The pipes are about 18’ long and are between 6” and 36” in diameter

• The pipes are cast using the centrifugal method

Problem Statistically, 1 out of 1500 pipes produced a day experiences cracking.

Cracking occurs between casting and annealing stages.

The cracks are of various sizes and are all through cracks.

Yearly, Pacific States loses on average $130,000 in claims due to damages.

Hairline crack in pipe

Project Objective StatementResearch a suitable technology to detect cracks in cast iron pipe and design a crack-detection system for a cast iron pipe production line that will cost less than $20,000 by March 30th, 2012.

Challenges Surface temperature of the pipe (700° F)

Testing speed (4 pipes per minute)

Pipe length and varying diameter (18’ length, 6”-30” diameter)

Environment (noise, humidity, heat)

Surface roughness of the pipe

Concept Selection and ScreeningCrack Detection

Photo Diodes X-rays Pressurized Gas

with Thermal Imaging

Underwater

Submersion

Spraying with water

Pressurized Fluid

Increase Pressure

Thermal Imaging

Improving the seal

Electrical/Magnetism

Magnetic Leak

Detection

Eddie Currents

Electrical Resistanc

e

Resonance/Vibrations

Pinging the Pipe

Ultrasonic

Vibration After Shear Wave

Optical Methods

High-resolution Camera

Thermal Imaging

Visual Inspectio

n

Shining a Bright Light

Unrealistic Ideas

Probes Measurin

g Deflectio

n and Strain

Waterfall

Reduce Pipe

Length to 3"

More Ideas on Separate

Paper

Scoring Based on Testing

Thermal Imaging w/ Pres. Gas Vibration Eddy Current

RatingWeighted

Score RatingWeighted

Score RatingWeighted

Score RatingWeighted

Score RatingWeighted

ScoreSensitivity to surface roughness 20% 5 1 4 0.8 3 0.6 1 0.2 3 0.6Compatibility to op. Environment 20% 3 0.6 2 0.4 3 0.6 2 0.4 1 0.2Adapts to varying diameters 20% 4 0.8 1 0.2 3 0.6 3 0.6 4 0.8Speed of detecting 20% 4 0.8 3 0.6 3 0.6 2 0.4 4 0.8

Reliability/Accuracy - TOTAL 80% 4 3.2 2.5 2 3 2.4 2 1.6 3 2.4Cost (initial) 10% 2 0.2 3 0.3 3 0.3 2 0.2 4 0.4Cost (operating) 10% 3 0.3 3 0.3 3 0.3 3 0.3 4 0.4

Total ScoreRank

Continue?

Vision System Photo Diode

2.10 3.205 2

3.003

2.601 4

Selection Criteria Weight

3.70

Thermal Imaging w/ pressurized air

Testing ResultsGood Pipe

Before Pressurization After 10 Seconds

Testing Results

Before Pressurization After 10 Seconds

Cracked Pipe

Eddy Current

Testing Results

Photo Diode Detection System

Test Results

Oscilloscope detecting light 500 W work lamp on pipe

Failed Tests Automated Visual Detection System (Keyence)

Rough surface finish

Vibrations Detection SystemInconsistency of resonance frequencies between pipes

Failed Tests Electro Magnetic Acoustic Transducer

Too expensive and too slow

X-Ray DetectionToo expensive and too slow

Implementation of Eddy Current

Strategy• Rotate pipe• Translate probes across the surface 1/4”

distance• Adjust to pipe diameter• Use equipment familiar to PSCIPCO• Use as many ready to order parts as possible

Lifting SystemRack and Pinions

End Rollers

Suspension System

Rectangle Tube Beam

Design

Lifting System

Adjustable Mounting Bracket

Pneumatic Cylinder

End Rollers

Steel Roller

End Rollers

Igus Rail and Carriage

Suspension System

Eddy Current SensorSuspension System

Suspension SystemCopper Tubing for

cooling system

Suspension Spring

Phenolic Plate

Steel Roller

Eddy Current Sensor

Hinge

Drawings

Questions