Author: Matt Desautel

ME Design Group 8

Danfoss Turbocor Stator Insertion

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The fundamental task of the project is to redesign the current method for heating compressor housings. The housings are heated in order to press a stator inside. Once the housing cools the stator is locked in place through an interference fit. Currently a large convection oven is used to heat four housings at a time. Heating time is roughly 45 minutes at an oven temperature of 300 °F. Before the housing can continue through production it must cool for approximately one hour. The primary goals are as follows:
•Minimize the overall size of the heating/insertion mechanism to maximize floor space
•Reduce overall heating time
•Lower overall part temperature
•Decrease total cooling time
•Eliminate batch processing to allow just in time order processing

ME Design Group 8

Danfoss Turbocor Stator Insertion

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1/14/2011
Today we met with Rob Parsons of Turbocor to discuss the upcoming semester. It sounds like we are on schedule and making good progress. We are essentially done fabricating the heating unit. The last big hurdle will be testing to verify that our design can heat the housing in the required time. Hopefully by the end of next week we will be able to complete the wiring of the heater and blower and complete this test.

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1/21/2011
This afternoon we learned that it will not be possible to vary the speed of our blower. This may prove to be a challenge, but we are moving forward with testing as planned. We picked up the heater and returned to the College machine shop to continue working. We finished wiring the blower and insulated the housing. We have a couple more things to complete. If all goes well we will test the heater this week.

4/4/2011
Since the last update the team has been working hard to complete the final prototype build. New pictures of the prototype are posted in the pictures section. A Solid Works animation demonstrating how the stator and housing are located was created by Matt and is posted in the videos section. We have all learned a great deal about time management this semester.

4/19/2011
The design team finished the final design successfully. A video showing stator insertion can be found in the video section. We presented our final project to our faculty and advising committee. Our project received an award for best presentation. Special thanks to Rob Parsons of Danfoss TurboCor for all of his useful insight and advice. All of our document and presentations for the year are posted in the presentations section. All documents for the project are located in the deliverables section.

ME Design Group 8

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Fall Semester:

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1. Preliminary thermal expansion calculations to determine temperature change needed in housing to reach the desired clearance
2. Experimental measurements of housing to verify calculations
3. Calculation of heat input needed to achieve desired temperature using hot air convective heat transfer analysis
4. Design concept and component selection based on analysis
5. Proof of Concept

Fall Semester Pictures

Using a precision bore gauge to measure a heated housing in order to verify initial thermal expansion calculations.

Checking the temperature of the housing while collecting data on the internal diameter of the housing.

Removing unnecessary parts of the heater.

Building the top portion of the heater unit that will support the housing.

Assembling the top mount.

Another late night…...

Finished heating unit with housing in place.

Finished heating unit with hood in place.

Spring Semester:

1. Finish Proof of Concept (Mount blower , duct, and wire heater and blower)
2. Final design and prototype of heating unit
3. Experimental testing and design adjustment
4. Final product evaluation

Spring Semester Pictures

Blower that will be used to re-circulate hot air through system

Looking down into the heating element. The system is designed so that several nozzles can be attached to the heater. The idea is to create a nozzle that promotes turbulence thus enhancing heat transfer

All that is left to do is attach the return hose to the blower and wire the heater and the blower.

Ready for wiring and testing.

Wiring the blower for testing.

Applying insulation to the hood.

Routing the duct work for the blower return

Testing the housing to ensure it mates properly to the heating unit.

Partially assembled unit. Still need to wire the heater and seal up newly discovered leaks.

Prototype Pictures

This is the main base plate used to align the stator and the housing

This shows the main structure of the unit

This picture shows the stator in the alignment . The ring is used to align the stator to the housing.

This picture shows the total size of the unit. Kevin is assembling the top sliding lid.

ME Design Group 8

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Gregory Boler Jr.

Gregory is a senior Mechanical Engineering student originally from Philadelphia Pennsylvania. Gregory is a member of the FAMU Football team and the Omega Psi Phi Fraternity Inc. He loves breakfast, watching football, working on engines, and long walks on the beach.

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Matthew Desautel

Matthew is a senior Mechanical Engineering student. Matthew is enrolled in the BS/MS program and is a member of Tau Beta Pi Engineering honor society and Pi Tau Sigma Mechanical Engineering honor society. He enjoys racing shifter karts, riding motorcycles, working on cars, and camping.

Ivan is a senior Mechanical Engineering student originally from Ukraine. Ivan enjoys Computer design and getting dirty with engine parts. His hobbies are rock-climbing, go-karts and being Sofa-King cool.

Ivan Dudyak

Kevin Lohman

Kevin is a senior Mechanical Engineering student from Miami. Kevin enjoys fabrication and hunting.

ME Design Group 8

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Code of Conduct
Product Specification
Needs Assessment
Final Fall Report
Final Spring Report
Design Fair Poster

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Danfoss Turbocor

In a new world of deregulating energy markets, environmental focus, and converging technologies, Danfoss Turbocor's mission is to redefine lifetime operating costs for commercial HVACR applications. The enterprise is dedicated to the design, manufacture, marketing and support of the world's most efficient commercial refrigerant compressors. The result is the world's first totally oil-free compressor specifically designed for HVACR. With its breakthrough convergence of industrially proven component technologies largely sourced from the aerospace industry, Turbocor's compressors promise new horizons in energy efficiency and lifetime operating costs for mid-range chiller and rooftop HVACR applications

FAMU/FSU College of Engineering

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Stator alignment and insertion animation

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A Solidworks animation demonstrating stator alignment procedures for our design

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Stator insertion using final design

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A short video demonstrating stator insertion using our final design

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