learning outcomes ( electrical and fluid drive systems )

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ENEM13011 – Fluid and Electrical Drive Systems (Spring 2018)

Dr. Ahmad Sedaghat, Dr. Raouf Mbarki, and Mr. Bader Alansari

Project Brief: Design and Built of an Automated Moody Chart Machine

As a team of engineers, you are requested to develop the best idea, design, and product. At the end

of semester, all products will be evaluated based on the product evaluation criteria and the

students who have created the best product will be awarded with an Official Certificate of

“ACK best automated Moody Chart Machine award” and allowed to attend the graduation

exhibition.

The objective of this project is to size, design, manufacture, test, and calibrate a stand-alone very

small Moody Chart machine to simulate different fluid flow regimes from laminar, transitional,

and turbulent in pipe flows and continuously create f-Re curves point by point using a control

system for changing fluid velocity automatically, sensors to measure needed fluid parameters,

electrical drives, and Arduino micro-processor for processing inputs and outputs.

The goal is to produce curves of friction factor, f, versus the Reynolds number (f-Re curves)

automatically to be validated with the standard Moody Diagram curves. A typical Moody diagram

is shown in Figure 1. The machine should automatically change flow velocity and automatically

create 10 points or more of (f, Re) points to create the full range of f-Re curve (in one run) for a

particular pipe roughness and display on a laptop.

Figure 1: The Moody diagram, the friction factor versus Reynolds number at flow regimes of

laminar, transition, and turbulence for different relative roughness values.

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In this project, the following limitation will be applied:

1. The volume of fluid in the Moody Chart machine must be limited between minimum

ONE to maximum TWO litters. The preferred fluid is water.

2. The Moody Chart machine must be designed in minimum possible size and all Mechanical frames and holders are preferred to be easily assembled and dismantle.

3. The machine should be capable of working continuously for long time (hours or days) so that generated heats should be carefully evaluated and removed from the system.

4. An automated control system must be designed to change flow speeds at 10 fluid flow speeds or more to simulate different flow regimes and create all points of (f, Re) in one

run.

5. All flow regimes from laminar, transition and turbulent should be covered in your design. 6. An Arduino microprocessor must be used to control the system, record the measurements

from sensors, and apply formulas to obtain the friction factor, f, the Reynolds number,

Re, and display that in a diagram in a laptop screen.

7. All necessary parameters in the Reynolds number, Re, and the definition of friction factor, f, should be calculated using appropriate tables or measured using suitable sensors

in the Moody Chart machine and processed by Arduino. No analytical formula such as

Colebrook or similar should be used for calculating the friction factor. The friction factor

f must be measured experimentally using appropriate pressure or other sensors.

8. In all measurements, you must make sure that the fluid flow is steady and measurement sensors are located away from entrance region of the pipe.

9. The curve produced by your machine should be compared with similar curve from Moody diagram for validation.

10. The total budget available for the project is 50 KD. 11. Detailed performance curves of any Electrical Drives should be presented by week 7. 12. Detailed design for any mechanical, pump and piping system are required by week 7

using appropriate CAD/CAM (or SolidWorks) drawings.

13. Detailed programming in Arduino is required by week 10. 14. Performance curves of the pump system should be presented and the system curve (for

any piping system) is expected to be created by measurements (see Figure 2).

15. Moody Chart machine calibration should be explained.

16. Figure 2: The typical characteristic curves of a pump and piping system.

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In this PBL course, you should consider:

 You are working as mechanical engineers for an industrial company.

 Your boss (represented by your Instructor) requires you to design and build an automatic Moody Chart machine operating safely.

 Your workplace is your classroom in the design stage and ACK Workshop and Fluid Mechanics Labs are those for the build (manufacturing) stage.

 Your late arrival or absent from your workplace (classroom or workshop) will be deducted from your salary (your marks here). You must reflect on any missing meetings when you

were late or absent.

 Your tools in classroom is ONE bonded book for hand writing (reflective workbook) which should be with you in all classes in all times. Three times forgetting this will receive an

official warning and FIVE TIMES will mean that you are not a professional engineer for

this job!

The design and implementation phases require the following: 1. Consideration of relevant codes and standards, safety, as well as industry practices.

2. Required material should be available in Kuwait.

3. Assumption of all missing information

4. Available budget: maximum 50 KD; teams should buy only materials not available at

ACK.

5. Detailed design (planning) should be completed (with all given sizes of the system in

proper software drawings) and presented on the beginning of week 7 by student teams (team

of 4 to 6 students).

6. All implementation and build works must be safely conducted in ACK under supervision

of course Instructor and Lab or Workshop technicians.

7. Managing the Design/production processes (including submission of design, quality

control, time monitoring, budget control, organizing meetings, project management,…etc.).

Product evaluation criteria:

 Satisfying the seven requirements listed above

 Demonstration of creativity, innovation, and novelty

 Demonstration of actual operation of the automated Moody Chart machine

 Demonstration of laminar, transitional, and turbulent flow regimes

 Creation of f-Re curve verified with standard Moody Diagram curves

 Stability and uniformity of precise operation at real work condition

 Quality and refinement of the manufactured product.

Note: The best project award will be given to the smaller, lighter, and perfectly operating

Automated Moody Chart machine. The machine must be repeatable and create the same f-Re

curves in two repeated cycle of operation. Higher score goes to the Moody Chart machine which

provide the higher “Overall Machine Efficiency”. There is extra points for teams that present

detailed evaluation of costs including “Man Power Costs” and “Process Costs”.