510: IGV Testing Fixture

Compressors are mechanical machines that capture the surrounding air and store it in a tank. The compressor’s inlet guide vane contains seven blades that open and close. These blades regulate the inlet airflow. Occasionally, these blades may fail to open or close.

We aimed to develop a tool to check the proper work of two out of seven inlet guide vane blades for Danfoss Tallahassee campus. Our 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, we created an acrylic cover to store them safely. 

We 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. We selected steel and aluminum for their strength and resistance in a manufacturing environment. Our testing fixture created for Danfoss a method to confirm each inlet guide vane assembled. During the assembly line, the inlet guide vane could prevent problems having faulty parts. This tool 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.