MIE.38 – Air Flow Sustainability Monitor
Team Members Heading link
- Salim Aboufariss
- Humaid Al-Suwaidi
- Anthony Gulyk
- Parth Patel
- Maeve Shannon
- Kelly Witkus
Project Description Heading link
A spraying process consists of fluid being dispensed through a nozzle to achieve a desired flow rate, spray pattern, and drop size distribution. These systems are applied throughout a multitude of industries to streamline many processes. One worn nozzle moderately over consuming compressed air can cost a customer roughly an additional $300 per year in energy consumption. Monitoring changes in pressure, temperature, and flow rate of fluid within a spraying system allows the operator to identify worn nozzles. Spraying Systems Co. is a global company that supports all industrial and agricultural spray applications. Air atomizing nozzles are a significant part of their product offering. This implies a substantial opportunity to market a device that monitors changes in air flow and alerts users when it is time to replace worn nozzles. By identifying and replacing these nozzles their customers can increase the efficiency of their operations while significantly reducing wasted energy and materials. Our team was tasked with creating a device that monitors the air flow to air atomizing nozzles allowing customers to identify wear within their nozzles. This monitoring system was to be designed to be compatible with a monitoring system previously designed for liquid spray processes by Spraying Systems Co. Compatible sensors were researched and tested for implementation within our sustainability monitor. The data collected through our experiments led to the selection of a flow rate sensor that was both inexpensive and maintained accurate readings within the parameters of intended use. Using Solidworks software a housing for the sensors was designed. The design was analyzed for safety in Ansys Workbench and a model of the housing was 3D printed. The sensors were fitted to the model and circuitry was fabricated between the sensor outputs and a LED screen allowing for their readings to be viewed in real-time. The result was a successful proof of concept for Spraying Systems Co.