PRP: P15452 - Reciprocating Compressor: Universal Wired Data Recording Device
Rev 7-21-14
ADMINISTRATIVE INFORMATION:

Project Name (tentative):

Project Number, if known:

Preferred Start/End Semester in Senior Design:
Fall/Spring
Spring/Fall

Faculty Champion: (technical mentor: supports proposal development, anticipated technical mentor during project
Reciprocating Compressor: Universal Wired Data Recording
Device
P15452
execution; may also be Sponsor)
Name
Jason Kolodziej
Dept.
ME
Email
[email protected]
Phone
585-475-4313
For assistance identifying a Champion: B. Debartolo (ME), G. Slack (EE), J. Kaemmerlen (ISE), A. Becker-Gomez (CE)

Other Support, if known: (faculty or others willing to provide expertise in areas outside the domain of the Faculty
Champion)
Name

Dept.
Email
Phone
Project “Guide” if known: (project mentor: guides team through Senior Design process and grades students; may
also be Faculty Champion)
o Bill Nowak & Jason Kolodziej

Primary Customer, if known (name, phone, email): (actual or representative user of project output; articulates
needs/requirements)
o Jason Kolodziej

Sponsor(s): (provider(s) of financial support)
Name/Organization
Dresser-Rand (OLN)
Dresser-Rand (PPT)
Contact Info.
James Sorokes,
[email protected]
Scott Delmotte
[email protected]
Type & Amount of Support
Committed
$2,000
PROJECT OVERVIEW: 2-3 paragraphs that provide a general description of the project – background, motivation,
customers, problem you’re trying to solve, project objectives.
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PRP: P15452 - Reciprocating Compressor: Universal Wired Data Recording Device
Rev 7-21-14
The objective of this project is to design a universal wired data acquisition device
capable of operation within a harsh environment. The intent is to be able to mount the
device, possibly on a moving component (e.g. connecting rod), and have it continuously
record a wired sensor to a memory storage. The data needs to be accessed via
removable storage (e.g. SD card) or wirelessly (e.g. bluetooth). The device will be
capable of recording analog measurement voltages from a variety of sensors and be
pre-programmed to accommodate a sampling rate between 0.1 Hz and 10 kHz
depending on the application. To accomplish the
goal of use on moving hardware the device must
consider ease of mounting, significantly reduced
size and mass, and an expected harsh
environment.
The goal of this project is to be able to
collect measurement data from hard to access
areas for short-term, targeted investigations
where traditional permanent wired solutions are
unnecessary or impossible. Two years ago a
MSD team successfully focused on a continuous,
wireless
transmission of shaft vibration data.
Figure 2 – Wired-DAQ on
However, there is a potential for significant size
Compressor Flywheel.
and weight reduction from the device while
improving functionality if post-processing of the data is acceptable. Last year a team
attempted a universal wired data recorded with mixed success. While the software
goals were met the physical aspects were not. This project should be reviewed in great
detail to learn and build upon their work.
Figure 1 – Dresser- Rand Reciprocating
A strong component to this recording device is its universal flexibility of
Compressor Test Cell @ RIT
adjusting the sample rate to meet a wide variety of sensors and still function in a
harsh environment. PCB design and fabrication along with the integration of userfriendly sensor I/O, a source of sensor reference voltage, and data storage is critical. The intended use of this device is to continue the
theme of health monitoring research by enabling sensors to be placed in challenging locations throughout the whole compressor for
specific testing using a wide range of measurement technologies.
DETAILED PROJECT DESCRIPTION:
The goal of this section is provide enough detail for faculty to assess whether the proposed project scope and required skills
are appropriate for 5th year engineering students working over two semesters. The sequence of the steps listed below may
depend on your project, and the process is usually iterative, so feel free to customize. Emphasis is on the “whats” (qualitative
and quantitative), not the “hows” (solutions), except for the section on “potential concepts,” which is necessary to assess the
appropriateness of required skills and project scope. Not all of the information in this section may be shared with students.
(Attach extra documentation as needed).

Customer Needs and Objectives: Comprehensive list of what the customer/user wants or needs to be able to do in
the “voice of the customer,” not in terms of how it might be done; desired attributes of the solution.
o Two mini-sized data recorders as small as possible, two inch cube.
o
o
o
One recorder designed for harsh environments (oil, high temperature and pressure)
One recorder designed for a lab environment.
Capable of secure mounting on a moving object
o Universal interface for sensor connection for analog voltage
o
o
o
o
o
o
o
o

User selected data sample rate between 0.1 Hz and 10,000 Hz.
Data storage with data files capable of being read by spreadsheet software.
Data storage capable of being accessed by removable flash memory or wirelessly.
Capable of manual external trigger to initiate data capture and new data file.
Capable of providing up to 5 volt source voltage for sensor needs
Accurate time stamping of voltage measurement is critical.
Testing the device versus a dedicated DAQ system is critical.
Stretch goal is to collect 3 channels of data on one device
Constraints: External factors that, in some way, limit the selection of solution alternatives. They are usually imposed on
the design and are not directly related to the functional objectives of the system but apply across the system (eg. cost and
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PRP: P15452 - Reciprocating Compressor: Universal Wired Data Recording Device
Rev 7-21-14
schedule constraints). Constraints are often included in the specifications list but they often violate the abstractness
property by specifying “how”.
o

Project Deliverables: Expected output, what will be “delivered” – be as specific and thorough as possible.
o
o
o
o
o

Design, fabrication, and test of two data recording devices
 One shall be capable of operation in a harsh environment (temperature, pressure, oil, etc.)
 One in standard laboratory conditions on a miniature scale (2-inch cube).
Both devices are required to demonstrate low (e.g. temperature) and high sample rate (e.g.
accelerometer) measurements predetermined through either software or hardware input.
Data must be easily accessible.
All analog voltage data will be time-stamped and readable using standard spreadsheet software.
A final report and poster detailing the results of the investigation with drawings / schematics of the
proposed methods is expected.
Budget Estimate: Major cost items anticipated.
o
o

Very few constraints. The lab has an industry standard shaker table to provide a known vibration to
compare the device versus a dedicated DAQ system. Harsh environment testing can be performed on
the compressor itself in a non-invasive way.
$1,500
PCB fabrication costs, demonstration sensor purchases (accelerometer, etc.)
Intellectual Property (IP) considerations: Describe any IP concerns or limitations associated with the project. Is
there patent potential? Will confidentiality of any data or information be required?
o None

Other Information: Describe potential benefits and liabilities, known project risks, etc.
o None

Continuation Project Information, if appropriate: Include prior project(s) information, and how prior project(s)
relate to the proposed project.
o
o
P13453: Reciprocating Compressor: Universal Wired Data Recording Device
 A similar project was attempted last year with mixed results. Little data collection was
performed so assessing the final design is difficult. However the user selectable sample rate
and software interface worked properly. The next team needs to embrace the testing portion
of the project to verify the capability of the device.
P13453: Reciprocating Compressor: Wireless Instrumentation For Compression Systems –
 A similar data acquisition project that focused on wireless transmission of accelerometer data
should be reviewed. This project was largely successful but the measurement data and
timestamp was not verified to be in sync. This was a crucial shortcoming of that device.
STUDENT STAFFING:

Skills Checklist: Complete the “PRP_Checklist” document and include with your submission.

Anticipated Staffing Levels by Discipline:
Discipline
How
Many?
Anticipated Skills Needed (concise descriptions)
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PRP: P15452 - Reciprocating Compressor: Universal Wired Data Recording Device
EE
2
ME
1
CE
1
Rev 7-21-14
PCB board design, electrical power needs of the device and provide sensor source
voltage.
Packaging of the device considering harsh environment. Understanding of the
measurements needed for the compressor (accel, pressure, temp, etc.) Testing.
Ability to integrate analog voltage into a SD card style data log with corresponding
timestamp. Ability to pre-select sample rate.
ISE
Other
OTHER RESOURCES ANTICIPATED:
Describe resources needed to support successful development, implementation, and utilization of the project. This could
include specific faculty expertise, laboratory space and equipment, outside services, customer facilities, etc. Indicate if
resources are available, to your knowledge.
Category
Faculty
Resource
Available?
Description
Dr. Jason Kolodziej for project guidance / interface with Dresser Rand
X
David Hathaway-ME Dept Machine Shop Manager; support to make the design
installation and facilities modifications go smoothly.
X
RIT Micro-Fabrication Lab? RIT EE department lab space?
Environment
ME machine shop & D-R compressor lab (in ME machine shop)
X
Equipment
The reciprocating compressor is currently installed and functioning in a test cell in
the ME machine shop.
Two DAQ systems are currently installed in the test cell on the compressor to
compare the results.
A professional vibration shaker and accompanying DAQ is available to provide a
benchmark test platform.
Materials
All materials will either be supplied by D-R or purchased as part of the sponsored
funding.
X
Other
Prepared by:
Date:
Jason Kolodziej
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July 21, 2014