Group 8 Danfoss Turbocor

Senior Design Group 8

Danfoss Turbocor Rotor Shaft Assembly System

Executive Summary

Danfoss Turbocor is sponsoring this senior design project in order to redesign the method for heating, assembling and cooling the rotor shaft for their compressor products. The ultimate goal for this project is to eliminate the need for the assembly to cool overnight by instituting a system that can accomplish all three phases of assembly in sixteen minutes or less. Danfoss Turbocor has provided Robert Parsons as their representative in relaying their specific needs for our project. The needs are that it must be one system that can heat and expand the inconel sleeve, assemble the four parts together, and cool the entire system safely in sixteen minutes or less in order to be able to produce 30 per day. In order to accomplish this task there were multiple steps taken to start. First there were three basic principles we needed to address; heating, cooling, and assembly. For the heating, linear expansion principles were calculated and tested for the inconel sleeve in order to determine the heat necessary to achieve the desired diameter of the inconel. For cooling, heat transfer properties were analyzed using COMSOL in order to determine which method for cooling would be ideal. From here a system has to be designed to mimic the properties needed for desired cooling based on COMSOL results. For assembly the holding pressure needed was measured due to the assembly, and a system in which only one ACME power screw is needed to assemble and hold until cooled properly. The project is still in the concept stage; however there is enough data to drive a prototype and testing that will refine the prototype to be a proof of concept of what can be used on the Danfoss Turbocor production floor.