Abstract

Compressors are mechanical machines that capture the surrounding air and store it in a tank. The inlet guide vane is a part of the compressor which contains seven blades that open and close. The blades regulate the inlet airflow of a compressor.  The Danfoss Tallahassee campus produces compressors that contain an inlet guide vane. Occasionally, inlet guide vane’s blades may fail to open or close. Team 510 aims to develop a tool to check the proper work of two out of seven inlet guide vane blades. The test apparatus employs two lasers and two receivers, assigned evenly across two blades. Placement of lasers and receivers precisely show whether a blade opened or closed. The laser aims at the edge of the blade to ensure proper coverage. To prevent damage to the sensors, the team created an acrylic cover to store them safely. Team 510 devised a method to test steel ball motion, showing compressor blade status. A magnet causes the ball to move. Magnetic sensors measure the magnet's strength for moving the ball. For testing, sensors at the housing ends assess if the inlet guide vane running status as the tool works. Finally, the fixture records and tracks each tested inlet guide vane’s color. Steel and aluminum were the primary materials selected because of their strength and resistance for a manufacturing environment. The testing fixture helped Danfoss by creating a method to confirm each inlet guide vane assembled. During the assembly line, the inlet guide vane could prevent problems having faulty parts. The tool created could test those parts to make sure it is working properly, that prevents future problems down-the-line when the complete compressor undergoes testing. A piece of acrylic will cover the top of the receivers to withstand scratches and impacts.