GD&T for Reverse Engineering
|Intolerable Team in Front of a Francis Turbine|
|Duration||Fall 2016 - Spring 2017|
The team was requested by Wagstaff to create a scale model of one of their Francis Turbines to aid in the advancement of knowledge on how to decipher old drawings, implementing this knowledge in the construction of turbines components. Wagstaff Engineering company is an aluminum based company in the Spokane Area, with an advancement of knowledge on hydro power damns and equipment they can be better informed for inspections and when making parts for clients.
The current aim of this project is to 3D model a Francis style turbine system from outdated engineering drawings and if possible update them to create better understanding. This will also assist in the understanding of the students and Wagstaff on how they work and what is crucial to operation.
Tour of Little Falls Dam
The team took a trip up to the Little Falls Dam which is near Spokane in order to get an in person look of a working Francis Turbine and look at key components such as the Wicket Gates.
This is a photo of the wicket gates at the Little Falls Dam which were replaced due to erosion. The wicket gates open and close to alter flow of water to turbine in order to meet power demands of the current season.
This is a photo of a Francis Turbine which is placed horizontally. Grad student Alex who stands roughly 6'2" is standing in front of the part of the turbine where the outside of the wicket gate assembly can be seen. The outer section is the volute of the turbine which channels water into the outside of the turbine.
|3D model of a Francis Turbine on solidworks using add ons such as geomagic to assist in creation. |Prelimary research on how to reverse engineer a part |Scaled model of a Francis Turbine with a scale ratio of 1/40 which uses air as the working fluid instead of water, operating wicket gates and a way to measure power output
This software allows for the user to look at tolerances and determine which dimensions attribute the most to error. This allows for decisions to be made in order to reduce costs when machining parts.
Geomagic is a software add on that allows for parts that have been scanned using a laser or light scanner and place them into Solidworks to create a solid model out of them.
Coordinate Measuring Machine (CMM)
A tool used at the University of Idaho to obtain accurate measurements from various parts.
A tool that the team was trained on to use in order to take objects and scan them so that they can be placed into modeling programs such as Solidworks.
A tool which was used to make a lot of the components of the scaled model, this was an inexpensive and time saving method that allowed for the creating of highly detailed parts as well as parts that were too small to be made on the lathe. By using the 3D printer it was possible to work on several parts at the same time
A technique that was used to make one part that was too large for the table of the 3D printing machines. It involved having a blank placed down and placing material over the top which is then heated so that it forms to the blank. Lastly, the material is vacuumed to the blank by pulling air from understand the blank to ensure an accurate imprint on the material.
Moving these to the closed and open position inside the hydro turbine changes the flow of the water inside and allows for the change of power production from the turbine
This is the bottom ring of the hydroturbine
The wicket ring joins with the servos and also connects to the wicket gates, by moving the servos forward and back thus rotating the ring the wicket gates will open and close
The Stay ring is needed to direct the water flow into the wicket gates so that they come in at the desired angle for maximum efficiency
This is a 3D model of the runner portion of the hydroturbine, this is the part of the turbine which interacts with the water and spins to produce power
This is the fully assembled hydro turbine which, this is a full scale model of the actual turbine
|Exploded View of Full Assembly
This exploded view of the fully assembled turbine allows for parts that are hidden to be seen and the smaller parts as well
Alex is a senior in Mechanical Engineering and graduating in the Spring of 2017. He is also a member of Theta Chi
Charles is a senior in Mechanical Engineering, a local from Moscow, Idaho where he attended LOGOS High School. Outside of Engineering he likes to play basketball.
Drew is a Senior in Mechanical Engineering and will graduate in the Spring of 2017. While also being an engineer he is a part of the University Track and Field as a Decathlete.
Ken is a senior in Mechanical Engineering and will graduate in the Fall of 2017. Ken also has over 10 years in the military.