Issue: 12
November 2015
Simulation-based Design and Thermal Analysis Ready Prototype for Pilot Installation

Simulation-based design offers the opportunity to evaluate a large number of product design configurations much more quickly and cost effectively than can be done through traditional "build and test" development approaches. A variety of simulation capabilities are available in computer aided design (CAD) and computer aided engineering (CAE) software tools and suites. Finite element analysis (FEA) based heat transfer and thermal analysis simulation is one of these capabilities. Thermal simulation can look at steady state and transient heat transfer in electrical circuits, within air-conditioning system components, and in manufacturing processes such as machining or injection molding.

Council Rock, a telecommunications engineering company that designs, deploys, and maintains private wireless networks, turned to the Center of Excellence in Sustainable Manufacturing to aid them in the design and analysis of an enclosure for radio communications equipment used in electrical grid and wellhead automation markets as shown in the pictures above. These systems have critical electronic components and must operate in very cold dry environments and also on very hot, humid and sunny days. There are many different design choices that need to be made considering both thermal performance of the overall system and the function of the communications equipment. Simulation can be used to understand the impact and interactions of different design decisions.

A simulation model was developed and the model performance verified by collecting an array of temperature data during functional testing of a prototype in a temperature controlled chamber. The validated thermal analysis model was then used to evaluate the design under extreme conditions (e.g., Phoenix, AZ, on a hot sunny day and Minneapolis, MN, on a cold winter evening).

The simulation results allowed COE-SM and Council Rock engineers to understand how design factors such as component placement, enclosure size, material, and color affected the conduction, convection, and radiation of heat between the electronic components and the environment. Feedback from the model, coupled with functional testing of the electronics in the thermal chamber ensured that even in the most extreme conditions, the equipment will be protected and operational.

David Rodriguez, President of Council Rock, said, "We turned to RIT to assist us with this new product and I can say we are very pleased with the results. The COE was able to provide us with extremely valuable feedback that will be used to improve the reliability of our product in deployments throughout the USA. Working with the COE proved to be a good business move and facilitated sales of our product."  Council Rock is now making their first shipments of the new product for a pilot installation.
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Applications of Thermal Imaging in Manufacturing

Excess heat radiation can be a sign of energy wasting inefficiencies, or a sign of a problem developing in mechanical or electrical components that may lead to dangerous or expensive failures. Analysis of building or process systems with an Infrared Thermographic Imaging camera is a relatively easy method to identify opportunities to identify leaks (such as in steam systems and HVAC ducts), improve insulation and prevent heat loss, yielding reduced energy consumption and associated cost savings. Preventive maintenance audits can also identify damaged or degraded components that result in heat loss, such as insulation that needs repair. More important in a manufacturing setting is the potential to identify equipment that may need repair prior to the event of unscheduled failure.  Overheating of machine tools, motor faults, bearing failures, and problems in electrical panels and breakers can all be detected through thermal analysis. Proactive response to conditions that result in energy loss or equipment failure have significant opportunity to save money in the short and long term.

As suggested in ' 3 Reasons You Need a Thermal Imager ,' Buildings Smarter Facility Management, March 2013, thermal images allow maintenance staff or energy auditors to clearly see thermal issues that would otherwise be invisible upon visual inspection. Thermal cameras detect infrared radiation allowing for identification of potential areas of concern that other inspection or energy audit equipment may not be able to readily distinguish. FacilitiesNet describes how thermal imaging can be used to detect failing electrical components and motor bearings allowing maintenance teams to intervene before failures and downtime affect production efficiency. 

Capital investment in a thermal imaging camera is an important consideration in a cost-benefit analysis of this technology. Grainger is a major distributor of FLIR Instruments that supplies cameras in almost any range of equipment budget and technical capability. A basic still-image spot camera with relatively low resolution is available for around $400, but its thermal range is limited at -4 to 482 °F. Models with equivalent thermal ranges with two to four times the image resolution range between $1,000 and $5,000. As resolution and thermal needs continue to increase, so too does equipment cost. Devices with a wider thermal range and higher image resolution may reach upwards of $30,000. In situations where temperature ranges are large, equipment failures are difficult to isolate, or small improvements in efficiency can have a very large economic impact, the cost of a more advanced device may be warranted.


As a practical example, the New York State Pollution Prevention Institute (NYSP2I) at RIT's Golisano Institute for Sustainability conducted a study, ' Energy Reduction from Improved Pipeline Insulation ,' with NOCO Energy's Tonawanda branch. Their Intermodal Terminal is located on 80 acres, with a storage capacity of over 45 million gallons of various petroleum products. Working with NOCO engineers, NYSP2I consultants used thermographic analysis to identify immense potential for energy and emissions savings at the pipeline transport level due to insulation inefficiencies. Analysis revealed that nearly half of NOCO's pipeline had degraded insulation, evidenced by pipeline surface temperatures as high as 400ºF resulting in major energy losses. Reinsulating the degraded sections allowed the heating plant to burn less natural gas to maintain the temperature required to flow material in the pipeline. Ultimately, this saved thousands of dollars in natural gas costs and reduced the plant's greenhouse gas emissions due to natural gas combustion by 95 metric tons CO2eq per year.

COE-SM has several types of thermal imaging technology, as well as experience in using thermal imaging in building and process energy, and in preventive maintenance applications.  If you are interested to learn more about applications to your business, contact us. 
Golisano Institute for Sustainability at RIT Chosen to Lead Strategic Remanufacturing Roadmap

The Golisano Institute for Sustainability (GIS) at the Rochester Institute of Technology (RIT) was selected by the U.S. government's National Institute of Standards and Technology (NIST) to lead a strategic roadmapping process to identify remanufacturing research priorities and improve advanced manufacturing capabilities of U.S.-based firms.
 
According to the Remanufacturing Industries Council, remanufacturing is a comprehensive and rigorous industrial process by which a previously sold, worn, or non-functional product or component is returned to a "like-new" or "better-than-new" condition and warranted in performance level and quality. Some of the most commonly remanufactured product categories are aircraft components, automotive parts, electrical and electronic equipment, engines and engine components, medical equipment, office furniture, restaurant and food-service equipment, and printing equipment.

Over the 24 month project, GIS will assemble industry technical experts from priority topic areas and convey key findings and recommendations. Goals for the project include:
  • Creating an industry-led Remanufacturing Research consortium involving all sectors of the industry to build consensus around barriers to competitiveness and research priorities.
  • Diagnose major cross-cutting challenges facing the industry over the next 20 years and deliver a Technology Roadmap with prioritized Research & Development action plans for overcoming those challenges.
COE-SM is interested in engaging NY State remanufacturers to participate in the project. To learn more, go to  remanroadmap.rit.edu , or contact us.