FINAL YEAR PROJECT

DESIGN, FABRICATION AND TESTING OF A PRESSURE TRANSDUCER FOR THE CONDITION MONITORING OF THE OIL LUBRICATION SYSTEM FOR GENERATOR SET
NAME OF THE COMPANY: SAM Integration Pvt. Ltd.
Internal Guide: Prof. M. M. Nadkarni (B8310830) (B8310865) (B8310874)

Compiled By: Sumeet Ghodke Kedar Lele Ravish Nagarkar

OBJECTIVE OF THE PROJECT

TECHNICAL SPECIFICATIONS:
PARAMETER Pressure Range Output Deflection Required Accuracy expected Temperature VALUE 0-5 bar 15mm (for 5 bar) +/- 5% 70C max

DIFFERENT MECHANISMS FOR PRESSURE MEASUREMENT

BOURDON BELLOW U-TUBE MANOMETER

DIAPHRAGM

SINGLE ACTING CYLINDER

DESIGN OF CYLINDER
FAILURE THEORIES USED FOR DESIGN: For calculation of cylinder thickness (t) Maximum principle strain theory Clavarinos theory Birnies theory Maximum shear stress theory Distortion energy theory
Material
For Cyl. ID=8mm Steel Brass 0.01677 0.04061 0.02096 0.05076 0.77 0.7867 0.8106 1.1009 1.1307 2 2 2 2

ta

T1=t+ta

For Cyl. ID=10mm

Steel Brass 1.08

(Continued-)

FEM Approach: (Structural Analysis)

Parameters- Burst Pressure (Pb)= 20 bar , per = 50 MPa

Equivalent Stress(max)=1.62MPa

Max Principle Stress(max)= 0.2825 MPa

Max Shear Stress(max) =0.8871MPa

Total Deformation(max)=30.36 nm

Hence cylinder is safe

DESIGN OF PISTON

DESIGN OF O-RINGS
IMPORTANT PARAMETERS FOR O-RING SELECTION:
SEAL TYPE STRETCH VALUE COMPRESSION VALUE GROOVE WIDTH MATERIAL

O-RINGS WORKED ON
SILICON- ACCEPTED WITH BEST RESULTS NITRILE- FRICTION OBSERVED WHITON- FRICTION OBSERVED TEFLON- NO DEFORMABILITY

Failure of O-rings:

DESIGN OF SPRING
Material used: Spring steel (Unalloyed, oil hardened and tempered) Type of ends: Square & ground Given parameters: Pressure= 7.5 bar Max working displacement= 22.5 bar Calculation Results:
Wire Dia. Spring 1 Spring 2 Mean coil Dia. No. of turns Free length

5.8mm 8mm

0.8mm 1mm

15 10

42 40.5

Spring-1 for Cylinder having ID=8mm Spring-2 for Cylinder having ID=10mm

JOINTS USED
FEM Approach: (Structural Analysis) Parameters- Burst Pressure (Pb)= 20 bar , per = 50 MPa
Head hex nutEnd hex nut-

Hence joints are safe

PREDICTING SEAL FRICTION

Theoretical Approach: Prediction of Coulomb friction (F) involves Friction due to seal squeeze (Fc) Friction due to pressure (FH) i.e F = FC + FH where, FC = fc x Lf & FH = fh x Ar Lf = Piston circumference Ar = Seal projected area

Friction due to O-ring compression

Friction due to fluid pressure

(Continued-)

Parameters - Seal shore A hardness=70

Variation of Pressure force (Fp) & Friction force (Fc) with Cylinder ID

Results: (For 0.5 Bar pressure) For Cyl. ID

Total Frictional force (F) Pressure force (Fp) Avail. Force (Fp - F)

8mm
1.641 N 2.513 N 0.872 N

10mm
2.1884 N 3.927 N 1.7386 N

TYPES OF LINEAR MEASUREMENT SYSTEMS

A . Linear Potentiometer

B . Strain Gauge

C. L.V.D.T.

D . Capacitive Transducers

TESTING OF THE PRESSURE TRANSDUCER

TEST RIG
PRESSURE TRANSDUCER TESTS:
CALIBRATION TEST OVER LOAD TEST ENDURANCE TEST OF FLUCTUATING PR. TEST FLICK TEST

TEST RESULTS
FOR 8mm CYLINDER
Pressure Vs Displacement curve 20 UPPER LIMIT LOWER LIMIT IDEAL LOADING UNLOADING
20 UPPER LIMIT LOWER LIMIT IDEAL LOADING UNLOADING

FOR 10mm CYLINDER

Pressure Vs Displacement curve

15

15

Displacement in mm

Displacement in mm

10

10

-5

-5

3 Pressure in Bar

3 Pressure in Bar

ERROR OBSERVED: Zero error Hysteresis error

SWOT Analysis of Pressure Sensor

Strengths
1] Use of brass enhances the aesthetic appeal 2] Reliable testing methods adopted 3] Due to elimination of diaphragm, life of the product increases significantly

Weaknesses
1] Advanced manufacturing processes are not used 2] Required accuracy (+/-5%) is not obtained 3] Vibration testing has not been carried out due to lack of the necessary testing apparatus

Opportunities
1] If manufacturing capabilities are improved and accuracy will improve significantly 2] Could be used for other low pressure range applications 3] If the same product is manufactured in plastics would prove to be economical

Threats
1] If the oil used is having SAE rating greater than SAE 30 then leakage failure is possible

Qustions???

Thank you!!!