Blog 6

For the week of February 4th-February 17th, the tasks allocated for that period can be found below. 

• Task 1: Re-do engineering drawings to add machining tolerances and datum 
• Task 2: Provide a Purchase document to Sulzer for review and approval for bearings and seals
• Task 3: Provide a calculation document to the Sulzer engineer to verify our research and findings 
• Task 4: Start machining the shaft diameter down to fit the deep grove ball bearing bore diameter concerning the tolerances 

In Task 1, the team made unexpected changes to the engineering drawing initially submitted to Sulzer engineers. Following feedback on the bearing housing and shaft engineering drawing, it was noted that machining tolerances needed inclusion. The edited drawings, as illustrated in Figure 1-3, were subsequently submitted for Sulzer engineers' approval. Additionally, modifications were made to the bearing housing geometry to simplify the machining process. Once the revised drawings were submitted for approval, Sulzer engineers requested a comprehensive document outlining the calculations to elucidate the team's decision-making process. Subsequently, all necessary documents, including a filled-out purchase order, were submitted. Task 4 focused on machining down the shaft diameter to align with the bearing bore diameter.

Figure 1: Engineering drawing of bearing housing 

Figure 2: Engineering drawing of shaft 

Figure 3: Bottom view of split block-bearing housing 

Milestone 5: Testing and Validation (2/17/2024-03/09/2024) 

● Complete shaft machining 

● Complete bearing housing machining 

● Assemble bearing housing onto concrete foundation 

● Secure deep groove ball bearing onto the shaft 

● Secure shaft into bearing housing along

During Milestone 5, scheduled from February 17, 2024, to March 9, 2024, the team aims to accomplish several tasks related to testing and validation. Firstly, the shaft machining process will be finalized to ensure its precise dimensions and alignment. Simultaneously, the machining of the bearing housing will be completed, focusing on the geometry adjustments made in the engineering phase. Following this, the assembly of the bearing housing onto the concrete foundation will take place, ensuring a secure and stable foundation for the entire system. Concrete bolts along with split housing bolts will be secured on that shaft to ensure housing security.  Subsequently, the team will meticulously secure the deep groove ball bearing onto the machined shaft, ensuring a robust connection. Finally, the shaft will be secured into the bearing housing, aligning it based on the specified parameters. 

During this process, the team is encountering obstacles primarily related to lead time and collaboration with Sulzer engineers. As a project sponsored by the company, the validation and verification steps require thorough checks by Sulzer engineers before progressing with the actual work. This involves obtaining additional calculations requested by Sulzer, providing extra documentation to support the team's proposed plans, and incorporating any information not initially provided in the problem statement. The team has emphasized the urgency of completing the project by the end of Capstone 2. To address these challenges, a meeting with the Vice President of the company is scheduled for February 21st to explore possibilities for expediting the process. It is crucial for clear communication to be established between Sulzer and the team to effectively address these issues. The meeting will also serve as a platform to discuss potential strategies for reducing the lead time required for machining the components essential to the project.