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INTRODUCTION
Reverse engineering (RE) is the process of discovering the technological principles of a device, object or system through analysis of its structure, function and operation. It often involves taking something apart and analyzing its working in detail to try to make a new device or program that does the same thing without copying anything from the original.
CASE STUDY:
DESIGN AND FABRICATION OF A PRESSURE TRANSDUCER FOR THE CONDITION MONITORING OF THE OIL LUBRICATION SYSTEM FOR GENERATOR SET
INTRODUCTION TO SYSTEM
The bottom line here is that any rather sudden rise or fall in oil pressure should be taken as a signal that your engines oiling system needs attention.
Filter blockage Low oil level Damaged oil pan or pick-up tube High Oil Worn Oil Pump
MARKET SURVEY
MANUFACTURER Pricol RICO Saudamini VDO
DRAWBACKS Hystersis due to torsional spring Not precisely and accurate Assembly not easy to repair Less life due to use of diaphragm
DIAPHRAGM
DESIGN SELECTION
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
(Continued-)
Equivalent Stress(max)=1.62MPa
Total Deformation(max)=30.36 nm
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 mm 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-
(Continued-)
Variation of Pressure force (Fp) & Friction force (Fc) with Cylinder ID
8mm
1.641 N 2.513 N 0.872 N
10mm
2.1884 N 3.927 N 1.7386 N
A . Linear Potentiometer
B . Strain Gauge
C. L.V.D.T.
D . Capacitive Transducers
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
15
15
Displacement in mm
Displacement in mm
10
10
-5
-5
3 Pressure in Bar
3 Pressure in Bar
CONCLUSION
Reverse engineering o Tool to understand current design solutions and technology o Save time and gain insight on current design challenges and solutions
Questions?
Thank you!!!