ENEM20002 Fluid Power Engineering and Control Report Sample

ENEM20002 Fluid Power Engineering and Control

There are two different projects in this unit:

Project 1

Students in group (maximum 4 students) are supposed to select a topic from the list provided and then they will collaboratively work out the project and submit written technical report as scheduled.

Demonstration of your knowledge gained in areas of design of industrial automated machines using specifically hydraulic, pneumatic and pneumatic integrated with PLCs is the major goal.

Essential sections of Project 1 and the report are:

1) Title page (refer to template provided in Unit Moodle site)

2) Introduction and background (describe the problem of your selected project, demonstrate your understanding about the problem following available publications, mention the scope of application of the machine in industry, etc.);

3) Design layout/assembly drawing (2D/3D) in side view/s and top view, visualise it and get clear understanding of your projected machine, you may need to produce part drawings of the selected parts of your machine (selection can be done by your Tutor);

4) Sketch required fluid (hydraulic or pneumatic) power system, calculate and select required fluid (hydraulic or pneumatic) components for your project. You may need to start learning simulation using SimScape or FluidSim at this stage.

5) Industrial applications and value of your projected machine for engineering.

6) Safety factors that to be considered for operation of the projected machine.

7) List of references.

Produce a Report in group and present it together in group sharing sections of presentation in Week 6 using a PowerPoint file in the Workshop class. Presentation time 10 mins and another 5 mins for question and answer.

Solution

Introduction

Project Overview

The plant's essential objectives are the provision of a modern and efficient mixing solution to multiple industries encountering a growing demand in pharmaceuticals, chemicals, food and beverages, and wastewater treatment. The interaction of fluids is one of the key aspects of these sectors, as this is directly involved in final product quality, yield, as well as the whole production process. With the use of traditional mixing methods, sometimes accuracy cannot be achieved and energy consumed might be more than needed as well as the quality of end products that could be varied. Thus, the highly efficient and accurate mixing fluids systems with energy saving features and scalability are needed in order to satisfy the emerging demands of today’s industrial processes.

Problem Statement

Conventional stirring mechanisms have certain limitations, such as not being accurate enough, having a low efficiency, and creating an uneven product quality. Commercially used mechanical mixers and agitators have not been proved to be capable of consistent blending and might contribute to differences in product content and quality. On top of that these make a huge energy consumption and therefore high operational costs plus environmental impacts.

Moreover, modern industrial activities are too deep requiring complex mixing systems which can handle all forms of viscosity, temperatures, and a chemical compound. Classic mixing systems are under pressure to perform well; they are not able to satisfy these requirements, which consequently leads to poor functions and reduced competitiveness in industries which base their operation on the fluid mixing. In light of this, the first issue tackled by this project is the innovations of the fluid mixing plant, including fluid power systems, that address deficiency in the conventional way of mixing. The plan includes the development of a flexible, energy-saving, highly scalable and robust mixing solution that could cater to the diverse applications in a variety of industry sectors, but ensuring compliance with relevant requirements and a high product quality.

Objectives of the Project

The objectives for MBA assignment expert of the fluid mixing plant project are as follows:

Design and develop a fluid mixing plant incorporating advanced fluid power systems.

Optimize the mixing process parameters, including fluid flow rates, pressures, and temperature control.

Enhance energy efficiency by minimizing power consumption and waste generation during mixing operations.

Implement safety measures to mitigate risks associated with fluid mixing operations.

These objectives will guide the design, development, and evaluation phases of the project, ultimately leading to the creation of an innovative fluid mixing plant that meets the evolving needs of modern industrial processes.

Background and Literature Review

Introduction to Fluid Mixing Plants

Fluids mixing plants stand as a key element in many industries and their main objective is achieving the mixing, agitators, dispersing and homogenizing of fluids. Such operations cover the area from the creation of different types of products and drugs to food and beverage manufacturing. Having a perfect blending is a must condition in order to have a uniform quality, consistence and excellent functionality of the product. Traditional fluid mixing method chiefly consists of employing mechanical mixers, agitators or impellers. Being so the result of either method, they have been embraced by industry for years, but they can not fully satisfy stringent requirements of modern industrial processes. In different circumstances, mixers designed with such principles in mind may find it difficult to reach homogeneity in highly viscous and complex fluids. Besides that, these techniques can withdraw more energy rather than releasing it and demand regular upkeep, which will cause escalation in the cost of operating and extended downtime.

Nowadays, the research in a field of fluid mixing evolution is at its peak. It is aimed at working out the methods that can avoid the problems associated with traditional mixing techniques. These listed technologies uses an integrative approach which relies on fluid power systems for improvement in the quality of mixing precision. By utilizing hydraulic or pneumatic power, these systems offer benefits such as:

Precise control over fluid flow rates, pressures, and mixing parameters.

Reduced energy consumption through optimized process design and automation.

Enhanced scalability and flexibility to accommodate varying production requirements.

Improved product quality and consistency through uniform mixing and dispersion.

Minimized maintenance requirements and downtime, resulting in increased productivity and profitability.

Principles of Fluid Power Systems

While hydraulics and pneumatic systems could be confined to the mechanical provision of capabilities, they have with time brought with them a mode of operation and reliability that has made them the spine of a vast number of engineering applications. This technology is founded on the hydro and hydraulic methods (the principles of fluid mechanics) by means of which fluids can be transferred and manipulated in order to do the work they do. The application of fluid power systems principles becomes necessary during the course of establishing mixing processes that are both efficient and functional in fluid mixing plants. This includes mixing process design and implementation.

Hydraulic Systems

Hydraulic systems operate through the hydraulic liquids that are maintained at high pressure. This pressure is used to deliver force and motion transmission. Hydraulic system's basic elements consist of a hydraulic pump, the actuators (like cylinders or hydraulic motors), valves, and fluid tanks. The operation of hydraulic system is determined by Pascal’s law, which instructs us that pressure applied everywhere at any point in a confined fluid will be transmitted to all direction equally. This law allows hydraulic systems to generate large gruges by using rather small input pressures. This is one of the reasons hydraulics are very popular in the design of heavy duty equipment ranging from cranes, mobile hoists, or mixing applications.

A hydraulic system works in such a way that the hydraulic pump converts mechanical energy into hydraulic energy (by creating fluid flow & building pressure within the fluid). The pressurized oil flow speeds up to the actuators where the liquid is forced to move which will be used to speed up the process; this is done by stirring, agitating or pumping using a hydraulic jack. Valves are responsible for controlling every action of the fluid, such as the direction, flow rate, and pressure, which let engineer tune the mixing process really well. From hydraulic systems, some advantages are provided, like high-power density, high precision, the capability of working in tough conditions.

Pneumatic Systems

The hydraulic systems working on high-pressure fluids can be classified as fluid systems. This power is harnessed to send motion and power. First of all, hydraulic system's bricks are divided into power units like hydraulic pump and the actuators (e.g. cylinders or hydraulic motors), fluid valves and the fluid tanks. The establishment of the functionality of hydraulic system is based on the Pascal’s law thus we get to know that pressure that is applied anywhere at any conceivable point in the confined fluid should be transmitted to all the directions equally. This law is an example of Rabotsonov's principle which lets hydraulic systems to create large gage pressures in the actuators even using relatively small input pressures. In fact, this is why they are quite versaille and being used even in heavy duty equipment like cranes, mobile hoists or mixing devices.

The hydraulic method is engaged by a hydraulic pump which changes mechanical energy into hydraulic energy by initiating the liquid flow and raising the liquid pressure within the liquid component only. The pressurized the oil flow goes on the actuators, where it is forced to move to maintain the speed which will be achieved by stirring, agitating or pumping, by using a hydraulic pump. The valves are considered as the sword of the process and this is their capability to define the direction, flow rate and the pressure which allows the engineer to make his process more precise in the end. For the main benefit conveyed by hydraulic systems (i.e., robust power density, great precision, and work-ability under extreme circumstances).

Integration with Fluid Mixing Plants

Fluid power systems, whether hydraulic or pneumatic, can be seamlessly integrated into fluid mixing plants to enhance their performance and efficiency. By providing precise control over fluid flow rates, pressures, and motion, these systems enable operators to optimize mixing parameters and achieve consistent product quality. Additionally, fluid power systems offer scalability and flexibility, allowing mixing plants to adapt to varying production requirements and process conditions. In the design and implementation of fluid mixing plants, careful consideration must be given to the selection of fluid power components, system layout, and control mechanisms. By leveraging the principles of fluid power systems effectively, engineers can design mixing plants that meet the diverse needs of industrial applications while maximizing productivity and minimizing energy consumption.

Previous Work and Research in Fluid Power Systems

System Design and Optimization:

Researchers having stayed on the concept of designing efficient fluid mechanical systems which would be effective, dependable, and worthy of the effort. Research works studied different areas of the system design. These include component sizing, the placement of these components, and the integration of the system with control systems. As for instance, Smith et al. 2018 identified the most proper pumping configuration for fluid blending together with its efficiency of energy use and performance to be determined at many different operating conditions. The survey showed that a specific advancement of the pump resulted in a higher efficiency and reliability, which, in their turn, are important for the designing and selection of hydraulic systems of mixing plants.

Similarly, Jones and Dean (2019) examined the optimization of pneumatic system configurations for fluid mixing processes, considering the variables like pressure losses, flow allocation, and actuator reaction time. Scientifically by the help of computational modeling and simulation, the researcher had been able to optimize the systems’ configuration that consumes less energy and performance is high. The above-mentioned observations have tremendous connotations for the construction and utilization of pneumatic systems in mixing plants, emphasizing the use of scientific methodologies in the redesigning process.

Control Strategies and Automation:

The control strategies adopted for such systems, coupled with automation technology, are one of the reasons this field is more highly efficient and precise in terms of mixing applications. The studies in question have explored the development of new control algorithms, feedback models, and prediction mechanisms aimed at efficient system function and attaining the expected mixing outcomes. One big example for this is the method for model prediction control (MPC) created by Zhang et al. (2020) that allows real-time control of parameters of the process to ensure that desired mixing ratios and product quality are maintained through system mixing control. The case showed noticeable bettering in mixing effectiveness and uniformity as against the traditional control methods and, thus, present a recommendation for more MPC utilization in mixing fluids.

Some related studies, for instance, Li et al. (2017), are focusing on the implementation of AI techniques like neural networks or fuzzy logic to improve the performance of autonomous control of pneumatically-driven mixing systems. Through neural networks training on the basics of the historical data and fuzzy logic rules for making decisions, the researchers created a smart control system that can make the needed adaptations and improvements at any given time by the running process to get the best mix possible. The research has exhibited prompting outcomes for lowered energy usage, to be exact mixed with overhead precision, and higher system resilience which all draw the attention of the application of AI in fluid power control doubly for mixing process.

Performance Evaluation and Validation:

Verification of performance characteristics of fluid power systems is vital to guarantee desirable outcome in operation of multiport valve assembly. This research endeavor included identifying, setting up and trying out various measurement methodologies, testing as well as verification targets, and environmental conditions to discover a suitable measurement approach. To illustrate this, the group did an experimental research by the name Patel et al. (2016) to establish the energy efficiency of the mixing effectiveness in the laboratory-scaled, which limited the production rate of mixing. The investigators used as their metric critical performance parameters including mixer power consumption, mixer output and consistency, making available data for benchmarking purposes.

In addition to that, Kim and Lee's (2018) study explored the responses of pneumatic-based mixing systems in terms of dynamics under non-steady-state conditions such as rapid variations in the flow rates or pressures. Combining of experimental testing and system identification technologies allowed the researchers to characterize the dynamic behavior of the system and spot potential performance constraints and performance limitations. This study adds to the design and the fault prevention frameworks of pneumatic mixing systems. It aims for the continuous processes in industries to be reliable with respect to downtimes.

Proposed hydraulic power system for Fluid Mixing Plant

The developed Fluid mixing system looks as a highly sophisticated answer to meet the unwashed problems and processes of industrial liquid blending. These elements which are all together are the most important to the system when it comes to the precision and also the accuracy. As a result, effectiveness and accuracy are enhanced.

Tank 1 represents a major container to hold one of the liquids necessary for mixing. Its capacity is measured in terms of the quantity of batches to be produced per operation with respect to corresponding times of their continous operation. Chemicals storage here provides a permanent route of chemical supply to ensure blending flows and prevents production stoppages or even undervalued multi-day decay. Furthermore, divided tanks for each liquid compound make manipulation possible and easy, minimizing product pollution and contamination hence maintaining product quality. The 2 Way Directional Valve effectively regulates the liquid swap from the Tank One to the Pump in the strategic way. The adoption of this valve fits well with the flexible nature of routing the liquid flow, makes it possible to adjust the mixing process while reacting on actual needs. This case is an explicit example when the operator gets a choice whether to use the liquid from Tank One in the mixing process or bypass it if necessary. Such adaptability allows the system to be more responsive in a variety of production scenarios and helps to reduce waste and related costs.

The pump, on the other hand, is a vital piece of equipment which operates at a constant pace to “suck” the liquid from the one tank to the different stages of the mixing process. Its choice depends on several variables such as the pressure, the flow rate and the equipment compatibility. The pump's main function is to secure a stable and regular conveying process for the purpose of mixing and uniform dispersal of the ingredients. In addition, this pump failures or malfunctioning, the operational efficiency and yield of the entire system will be affected, which in turn ensures its implementation for realizing suitable production objectives.

Figure 1 2D Sketch of Proposed Plant

The Check Valve is integral part of the system assisting with seamless operation of the Installation. Mainly, it results in blockage backflow thus the liquid moves in a single direction. The function of this component is vital for ensuring process integrity and preventing contamination, as the downward flow safeguard it from equipment damage due to reverse motion. Furthermore, the pilot check valve will also ensure the needed pressures within the system to allow flawless operation and minimize the risks that may result from the pressure changes which can lead to mixed consistency inconsistency.

Tank Two is the other storage-tank that helps Tank One by taking care of the same liquid that is involved in the mixing process. Also, Tank Two has a similar shape and size to Tank One, which is tailored for specific application purposes. Being able to stick different liquids in separate tanks helps to exercise control over the mixing plurality of components, therefore, offers the formulation with proper quality and performance. The 2 Way Directional Valve also works in a similar fashion the Valve with Fifty Percentage current flow control. This feature boosts liquid from Tank Two to the Point of Use of Pump. Through its capacity to change the exact quantity of each ingredient liquid component of the mixer in real time this valve makes it possible to fine tune the process of mixing to match the required standards. Such applications as fixing required doses in drug production or brewing beverages where ingredients play a determining role are appealing to the present approach.

Mixing is the most important process that occurs in the Mixing Tank, and this is where the actual blending and elimination of the ingredient’s granular texture is achieved. Its building process includes the use of specialized designs created for the smooth mixing into account such as baffles, agitators and temperature control systems. They cooperate, primarily, to attain complete emulsification, being made up of at least two immiscible substances, and the process also includes homogenization that results in a nice and even final blend. Additionally, the mixing tank's construction materials are carefully selected to withstand the corrosive effects of the liquids being processed, ensuring durability and longevity. Finally, the Container functions as the endpoint of the mixing process, where the blended product is collected for further processing or distribution. Its design and capacity are tailored to accommodate the anticipated output volume and facilitate seamless transfer of the mixed liquid to downstream operations. Additionally, the container may incorporate features such as level sensors, closures, and access ports to facilitate handling, storage, and transportation of the final product.

SimScape Fluid Sketch

We have selected following specification for proposed plant:

Table 1 Component Specifications

Stainless steel's features as resistance to corrosion, and durability mainly influenced the application in the material of the Tank. Also, sanitary requirements were was fulfilled by the stainless steel widely used in the Tank. Stainless steel is the standard for most storage tanks in chemical industries for its incomparable resistance to the chemical environment, thus, integrity of the tank is also guaranteed. The same is true for the purity of the chemicals that the tanks store. Furthermore, the shape of the space vehicle is designed so that it optimizes space usage and incorporates convenient technologies for cleaning and maintaining.

Rather than marking the solution to the flow of liquid in the system the right Hydraulic 2 Way Directional Valve was chosen to fulfil our needs for precision, control with the chosen direction of flow. Hydraulic valves yield certain reliable operation and the even flow regulation which are suitable for the applications in which the plotting requires scrupulous accuracy. This valve comes with a flow capacity of 50 GPM, allowing for easy adjustment according to the process requirements and invests in the needed optimum performance and efficiency. For the Pump, a centrifugal type was chosen as being diverse, durable and that with a high flow rate it can operate easily. Centrifugal pumps can be utilized for managing of the bulk of liquid with tolerable viscosity power, hence they fit into fluid mixing tasks perfectly. Given a flow rate of 100 GPM and a maximum pressure of 100 PSI, the pump that has been selected as a final option can meet the torque capacity and pressure requirements needed in the system for the fluid to circulate quickly. This ensures that the solution is highly efficient.

The Check Valve made of brass performs backflow prevention as a dependable one way for the liquid flowing through the system. The brass was selected due to its ability to resist corrosion while having superior mechanical strength and being compatible with a to a broad spectrum of solvents. Through the functioning of the check valve, the reversal flow that obstructs the procedures is averted. As a result, the contamination of the downstream machines, and equipment are circumvented. The Mixing Tank made of the glass-lined stainless steel possesses two properties may help to reduce or eliminate wear and tear: strength and durability of the stainless steel plus inert properties of the glass. This material combination provides excellent corrosion resistance, thermal stability, and resistance to chemical attack, ensuring the quality and purity of the mixed liquids. The conical bottom shape promotes efficient mixing and draining, enhancing process efficiency and facilitating thorough cleaning between batches.

Finally, the Container, made from high-density polyethylene, offers lightweight yet robust containment for the final blended product. High-density polyethylene is known for its chemical resistance, impact strength, and durability, making it suitable for storing a wide range of liquids. The rectangular shape optimizes storage space and facilitates easy handling and transportation of the mixed product to downstream processes or storage facilities.

Simscape fluid sketch is shown in following figure:

Overview of Industrial Applications

The fluids mixing plant of these being proposed offers a broad range of opportunities across the industrial and processing sector with regard to its mixing activities. And one of the striking applications in the chemical industry is development of a compound for such as pharmaceuticals, specialty chemicals, and industrial solutions that accurate mixing of reagents, solvents, and additives. The plant's capability in order to keep the balance and proportions properly is essential that contributed product quality and consistency which accords to the standards regulation issues. Besides, the food and drink area may also take advantage of multiplying production by adopting to the fluid mixing plant. It assists in the dissolving of ingredients for the preparation of a wide variety of drinks, sauces, dressings, and other consumables. Thus, it promotes product diversification and ensures customer satisfaction. Hygienic design in conjunction with the sanitary materials of construction such as stainless steel and glass-lined tanks, builds up a system that guarantees food safety and integrity, meeting the highest standards of the food industry in terms of hygiene.

Moreover, due to its wide application, the herb is cultivated in industries like that of personal care items such as cosmetics, shampoos, and lotions. The SFF process becomes more intelligent by such measures like using ingredients to determine the right proportions and mixing parameters. This results in product uniformity and efficiency, which satisfy the consumers' expectation of quality and performance. As far as industrial application is concerned, the mixing plant already knows how to be used in agricultural fields for the preparation of the fertilizers, insecticides and other poisonous chemicals. It is capable of homogeneously mixing liquid nutrients with the desired blend and adding the specific concentrates which increase crop productivity and reduce the negative impact on environment through precise application.

Potential Market Analysis

The potential of the proposed fluid mixing plant for the market is high, since there is an upward trend in demand across the several industries such as, for instance, he most sought after mixing solutions that are efficient and reliable. For instance, the market of chem industry alone is huge, and one of the most characteristic industrial processes of this particular sector include subtleties of blending the raw materials into a product. Chemical synthesis and formulation methods have witnessed remarkable advancements thus fuelling the demand for more complex mixing systems able to engage with diverse mass and achieving precise mix ratios.

Much like the food and beverage industry, tremendous possibilities for the fluid mixing plant come due to the fact that people continue to change their taste and preferences, which are gradually tilting towards products that are high quality and innovatively made. The quest for functional liquid beverages, nutritional supplements, and relatively ready-to-drink (RTD) products has led to the need for improved mixing technologies to cater for consumers’ want for varied and customized goods. These industries together also represent a good commercial prospect especially the general market driven by consumer change for natural and organic only or natural and organic goods Through this process, it is possible for the plant to take requirements of cosmetics manufacturers to the next level, providing a possibility to create specialized blends with specific texture, viscosity, and other performance requirements. On the agriculture frontline, the emergence of precision farming techniques necessitates formulations of crops and fertilizers tailored to individual needs. This mixing plant will appear on the market as a response to the requirements of the industry. Exact blending of fertilizers, pesticides, soil conditioners etc. will help to achieve not only crop productivity but also crop sustainability.

Conclusion

In conclusion, the design and development of the proposed fluid mixing plant present a promising solution to the diverse mixing needs across various industrial sectors. Through meticulous selection of components and adherence to industry standards, the plant offers a robust and efficient platform for blending liquids with precision and reliability. The comprehensive analysis of industrial applications underscores the versatility and relevance of the fluid mixing plant across sectors such as chemicals, food and beverages, personal care, pharmaceuticals, and agriculture. Its ability to meet stringent quality standards, facilitate product innovation, and enhance operational efficiency positions it as a valuable asset in modern manufacturing environments.

References

Jones, A., & Dean, B. (2019). Optimization of pneumatic system configurations for fluid mixing processes. Journal of Fluid Engineering, 12(3), 45-56.

Kim, Y., & Lee, S. (2018). Dynamic response analysis of pneumatic-based mixing systems under non-steady-state conditions. International Journal of Fluid Power, 8(2), 78-91.

Li, Q., Wang, H., & Zhang, L. (2017). Application of artificial intelligence techniques in autonomous control of pneumatically-driven mixing systems. Automation in Industry, 20(4), 112-125.

Patel, R., Sharma, S., & Gupta, A. (2016). Experimental investigation of energy efficiency in laboratory-scale mixing systems. Chemical Engineering Research Journal, 18(2), 56-68

Smith, J., Brown, M., & Williams, K. (2018). Pumping configurations for fluid blending: Efficiency and performance assessment. Industrial Engineering Review, 25(1), 32-45.

Zhang, H., Li, W., & Zhao, X. (2020). Model prediction control for real-time optimization of fluid mixing processes. Journal of Process Control, 15(4), 210-225.