mech486 project summary – 2010/2011€¦ · small hybrid propulsion system demonstrator (4)...

MECH486 Project Summary – 2010/2011• SAE Formula Hybrid Competition (1) P. Fitzhorn• SAE Aero Design Competition (2) H. Sakurai• ASME Human Powered Vehicle Competition (3) S. Schaeffer • Small Hybrid Propulsion System Demonstrator (4) T. Bradley/

K. Stanton• SAE Formula Hybrid “Clean Sheet” (5) P. Fitzhorn• Large Bore Natural Gas Engine (6) C. Hagen• Smart Engineering II Building (7) G. Johnson• Compressed Air Energy Storage Pilot (8) R. Malhotra• Emissions Control for Tier 4 NOx Emissions D. Olsen

on a 4.5L John Deere Engine (9)• Safety-Critical Turbine Shutdown Device (10) J. Gessaman/

K. Greeb• Force-Sensing Power Remote Manipulator (PRM) (11) P. Linnebur• Production of Biofuels from Oilseed Crop Harvests (12) S. Schaeffer/

S. Nettles-Anderson

ME Senior PracticumProjects Overview 2010/2011

MECH486 Project Summary – 2010/2011• Plug-in Electric Vehicle Demonstrator (13) G. Johnson• Biological Soft Tissue Testing Apparatus (14) C. Puttlitz• Passive Solar Water Purification Systems for Remote

Areas & Disaster Relief (15) W. Duff• 3D Printing of Cells on Scaffolds (16) K. Popat• Zero Gravity Fuel Gauge for Spacecraft (17) A. Yalin/

B. Lee• Organic Rankine Cycle (ORC) Waste Heat Recovery (18) D. Zimmerle• Tunable Left Heart Simulator for Cardiac Work

Load Analysis (19) L. P. Dasi• Homogeneous Charge Compression Ignition (HCCI)

Engine Conversion for Bio-Butanol Engine Research (20) A. Marchese• Plasma Contractor System for an Electrodynamic Tether (21) J. Williams• Lodge and Shipley Lathe (22) P. Fitzhorn/

S. Schaeffer• Small Wind Turbine Instrumentation, Monitoring and

Performance Verification (23) M. Kostrzewa


SAE Formula Hybrid Competition (1)

Objectiveso Show a running vehicle at E-days

Project Details• Finite Element Analysis performed on

redesigned components to ensure their structural integrity

• Electric power system designed to complete the electric only run as well as the endurance race at the 2011 SAE Formula Hybrid competition

CPC-II• Redesign and manufacture components for a more robust drivetrain layout

• Rebuild internal combustion engine• Redesign and manufacture front and rear

uprights• Install new electric motor, motor

controller and accumulators


SAE AERO Design Competition (2)

CPC-II

Project Details•Predicted to lift 30 lbs of payload•Airfoil selected for high lift, low velocity flight•Stable in flight with and without payload•Fly multiple flight rounds•Completed Aircraft Weight: 8.6 pounds

•Balsa Wood Structure•Take-off in 200 feet•360˚ flight path•Land in 400 feet•Competition in Marietta, GA on April 29- May 1

ObjectiveDesign an aircraft that can lift as much weight as possible while observing the available power and aircraft’s length, width, and height requirements. Accurately predicting the lifting capacity of the aircraft isan important part of the exercise.

.


ASME Human Powered Vehicle Competition (3)

CPC-II

OBJECTIVEThe Human Powered Vehicle Challenge is an opportunity for engineering students to design, fabricate, present, and race their vehicles against as many as 40 other collegiate teams from across North and South America.

PROJECT DETAILSDesign A Light Weight Aluminum Frame

Must with stand a 600lb top, and 300lb side impact loadNo more than ½” deflectionWeigh less than 15lbs

Analysis and Testing of Stress on Components and FramePerform FEA to analyze componentsDesign real world test to validate design and FEA

Fully Integrated Storage and Drag Reducing FairingMust hold at least a volume of 1560 cubic inches of cargoMust significantly reduce drag

Easy adjustability for heights of 5’4” to 6’ 3”Ergonomic design for riders of all agesAdjust between heights by only adjusting one component

Meet Performance RequirementsBrake in 20ft from 15MPHTurn in less than a 25ft radius


Small Hybrid Propulsion System Demonstrator (4)

Objective•Implement a fuel cell hybrid electric power system into an Unmanned Aerial Vehicle (UAV) ground based demonstrator: motorcycle• Focused on important UAV performance metrics:

Increase range and endurance Limit weight Maintain top speed and acceleration

.Project Details

•Developed and ran computer simulations of complete power system performance for making major design decisions• Testing completed for UAV performance metrics• Built fuel cell battery hybrid power system and modified off-the-shelf electric motorcycle

CPC-II


SAE Formula Hybrid “Clean Sheet” (5)

ObjectiveAnalyze the formula hybrid competition, and develop a series drivetrain design that sets a foundation for future teams.

Project Details• Full engineering analysis of the

endurance competition• Series hybrid component analysis

and selection• Thermal analysis of the selected

a123 lithium iron phosphate battery

CPC-II


Large Bore Natural Gas Engine (6)

Objective.

Project Details

CPC-II

• Develop a dynamic simulation model of a large bore engine

• Automate the peak pressure balancing process via a control algorithm within 5% pressure deviation

• Design and fabricate a fuel jumper system

A simulation of a two stroke large bore natural gas engine has been constructed for testing and analysis of a low pressure fuel injection cylinder balancing algorithm. The algorithm will remain versatile enough to be applicable to a wide range of engines. Control of the balancing process will be achieved by means of a user friendly GUI constructed in LabVIEW.


Smart Engineering II Building (7)

Goal: Make a significant contribution to the LEED Gold certification of the Engineering 2 building by doing baseline energy use measurements in laboratories that will be moving to the new building.How this was accomplished:• A wireless sensor array system was used to

monitor environmental and energy usage data in a high energy usage laboratory (Unit Operations 1 and 2) and a low energy usage laboratory (Stardust).

• In addition to existing temperature and humidity capability, the hardware and software were modified to incorporate:

• Anemometers to monitor air flow• Photoresistor circuit networks to

monitor lighting loads• Kill-A-Watt meters to monitor plug loads

• The data flows from each sensor to its attached node, which then wirelessly transmits the information to a gateway attached to a netbook computer running software to manage the wireless network.

• Live data recorded to the netbook is streamed to a webpage, which graphically shows the energy usage for both laboratories by each sensor type.

Stardust Unit Ops 1 Unit Ops 2

Kill-A-Watt

Netbook

Node

Anemometer

Photoresistor Circuit

Gateway


CPC-II

AccomplishmentsSuccessful assembled system with off the shelf parts. Tested system under multiple settings and conditions to obtain a maximum efficiency of 2.875%Produced 320W of power sustained for over 15 minutes. Production of 0.185 kWh electricity during single test.Analysis of larger scale systems using model.Large Scale programmable model was compared to tested data with a 6% calculated error.Payoff analysis including maintenance estimates where calculated.

Project Objectiveo To design and manufacture a system which stores

energy in the form of compressed air then produces electricity at a desired time.

o To test and analyze the system and determine ideal running environment.

o Monetary feasibility analysis of system.o Analysis of larger capacity system.

Compressed Air Energy Storage Pilot (8)


Emissions Control for Tier 4 NOx Emissions on a 4.5L John Deere Engine (9)

Accomplishments:

CPC-II

Goal Investigate feasibility of meeting Tier 4 emissions with high levels of

EGR

Stock Tier 3 Setup

Experimental Tier 4 Setup

Install 4.5L Tier 3 engine into test bed Run a baseline test of stock configuration Create integrated design of new EGR system; retrofit 13.5L

engine EGR cooler to Tier 3 engine and perform test Performed test mapping of boost, EGR%, and injection pressure

for ISO 8178 test modes 1, 3, and 5 Analyze data for report to Senior Design Management Team and

John Deere Assess ability for new system to meet Tier 4 NOx levels and

evaluate CO, PM, and BSFC trade-offs

Objectives: Ensure Stock 4.5L John Deere engine meets Tier 3

requirements for particulate matter and NOx emissions Baseline testing of Modes 1, 3, and 5 of John Deere 4.5L

Diesel engine Evaluate possible changes to engine performance such as

• Timing • Injection profile • Common rail fuel pressure


Safety-Critical Turbine Shutdown Device (10)

CPC-II

OBJECTIVES

• Design, fabricate, and test a safety certified triple redundant trip-block for an industrial steam turbine

• The device must ensure quick and reliable turbine shutdown

ACCOMPLISHMENTS• Trip block fails to the trip state (valves are

normally open)

• System operates with given supply pressure between 80-500 psi

• Minimum trip block flow coefficient rating (Cv) of 12 from trip header drains with two valves in trip state


Force-Sensing Power Remote Manipulator (PRM) (11)Project Objectives

• Devise a way to add additional protection to the “Dead Link” to prevent failure from over stressing in any orientation

• Determine minimum number of sensors and their positions to protect link

• Determine the type of sensors to be used• Calibrate sensors for consistent and accurate readings from strain gages• Interpret feedback from the sensors for an easy interface that predicts

pending failure

Accomplishments• Analyze external forces and moments of arm to predict, with FEA,

internal stresses in “Dead Link”• Modified center web to direct and isolate maximum stresses to two

locations for accurate strain gage placement and detection• Use LabVIEW program to analyze outputs from sensors, environmental

conditions and system variables for accurate readings of strain gages• House all electrical components in a protected enclosure for easy

diagnostics and organization• Indication provided by stack lights and onscreen warnings of increasing

strain


Production of Biofuels from Oilseed Crop Harvests (12)Objective

.

Project Details

Develop a prototype seed crusher to outperform current market models in oil output, oil quality, and reliability.• Crush Canola seed to produce at least 5

gallons/hour oil output• Extract >50% of oil content from seed• Maintain oil temperature of less than

60ºC

• Gathered data for oil secretion pressures

• Designed screw-type press• Incorporated cooling system to screw

press • Manufactured conventional and

complex press screws


Plug-in Electric Vehicle Demonstrator (13)Goal: To create a modularized platform vehicle that can be used for testing components of electric vehicles. This is accomplished through three main goals:

•Understanding the vehicle as a whole unit•Integrating a data logger•Creating a universal battery charger

CPC-II

Accomplishments:•Successfully assembled vehicle and restored it to working condition•Tested vehicle at Bandimere Speedway, and at PFI Speed on a dynamometer•In the process of legalizing the vehicle for street use.•Installed and began testing with data loggers in the vehicle.•Assembled and began testing on a universal battery charger.•Compiled research on the vehicle itself and any subsystem operation to permit easier implementation in the future.


Biological Soft Tissue Testing Apparatus (14)

ObjectiveTo design, manufacture, and validate a mechanicalapparatus that is capable of testing soft tissue samples of various dimensions under physiologic conditions.

This apparatus will work in concert with an imagecapture system and associated algorithm that is capableof generating a global strain map (and determine localstrain values) using digital image correlation protocol.

Project Details

CPC-II

• Apparatus is capable of exerting over 3000N in tension and compression

• Digital Image Correlation algorithm allows strain mapping through finite deformation

• Advanced software package provides extensive control over the apparatus.

• Standardized mounting configuration allow for limitless modifications to accommodate different testing requirements.


Passive Solar Water Purification Systems for Remote Areas & Disaster Relief (15) Goal: Design of a passive solar powered water purification system that:• Removes bacteria and viruses from the water to 99.99% purity

by holding the water at a minimum temperature of 65 C for 2 minutes.

• Reduce toxic ions and particulates in the water to 500 parts per million.

• Must fit inside standard military shipping container (20’x8’x8’).

Accomplishments:• Designed and built TDS, odor removing, giardia,

cryptosporidium, and sediment filter• Complete SolidWorks model & analysis• Tests:

•Temperature tests using thermocouples at 11 locations throughout the system• Contaminant Level testing & E. coli• External E. coli test verification• Heat exchanger efficiency tests • Solar collector tube choke testing


3D Printing of Cells on Scaffolds (16)

CPC-II

Goal: Design automatic process that creates a three dimensional vascular graft (artificial blood vessel Create a three-dimensional vascular graft Scaffold should be synthesized by an

automated printing technique which includes a microstructure

Inner diameter of vascular graft is less than 6mm

DAPI stain of cells integrated into graft

SEM images of graft

Accomplishments: Designed and manufactured box for

electrospinning processes Simulate the 3 layers of a blood vessel using

endothelial, fibroblasts, and smooth muscle cells Various Tests: DAPI stain, SEM imaging, MTT

Assay, Florescent Live/Dead Assay, Mechanical tensile test


Zero Gravity Fuel Gauge for Spacecraft (17)

Objective

Project Details

CPC-II

• Design and build a payload that uses laser interferometry to measure tank ullage in microgravity environments

• Accurately measure tank volume within 5% of the actual volume• Design the payload to specifications set forth by the RocketSat users

guide so that the payload may be launched on the June 23rd, 2011 RocketSat sounding rocket

• Design a payload capable of withstanding the vibrations of a rocket launch

• Enclosed optical fiber system designed to produce interferometer fringe data used in volume calculation

• Pressure change is induced on the system by a linear actuator piston assembly and varying measurable ullage volumes created using two tanks connected to the system through valves

• Electrical system controls the valves and actuator while reading data input from the photodetector which it stores for post launch analysis


Organic Rankine Cycle (ORC) Waste Heat Recovery (18)

CPC-II

Objectives•Finish design and construction of a waste heat recovery system that utilizes the Organic Rankine Cycle

•Increase engine efficiency by successfully recovering wasted heat from internal combustion engines to be reused as electrical energy

Project Details•Experimental organic refrigerant, R-245fa, capable of working at low pressure and low temperature conditions

•Experimental tesla turbine capable of working with steam or mixed fluid

•Our particular system has potential to increase efficiency by ~6%


Tunable Left Heart Simulator for Cardiac Work Load Analysis (19)

CPC-II

Goal:To create a validated simulator resembling a physiological heart and heart valve defects.

Objective:• Understand the fluid dynamics• Develop a heart prototype• Create a control system• Collect and analyze data from the simulator

Project Details:Translating cardiac physiology to a mechanical prototype to determine the energy losses of a beating heart in combination with certain heart valve defects.


Intake system capable of heating intake air to 150 degrees Celsius with equal pressure drops across the diesel and HCCI plenumsFuel injection system capable of delivering an equivalency ratio (Φ) between 0.2 and 0.6Variable compression ratios of 12:1, 14:1, 16:1, 18:1Convert cylinder 4 to HCCI operationEngine must run without knocking

Homogeneous Charge Compression Ignition (HCCI) Engine Conversion for Bio-Butanol Engine Research (20)

Objective.

Project Details

CPC-II

Show a measurable difference in pressures between HCCI cylinder and diesel cylindersDesign, analysis, construction, and validation of intake system and variable compression ratioEngine control with LabViewImplement LabView for data capture and analysis


Plasma Contactor System for an Electrodynamic Tether (21)

Objective• Create a functional prototype of a plasma contactor

Required Performance• Ion Production Rate: 200mA

• Gas Utilization Efficiency: 40% or better

Project Details• Versatile gas feed system designed

• Gas feed system box designed and manufactured• LabView control and Data Acquisition.

• Discharge Chamber designed• Analytical model supporting empirical results

• Magnetic Modeling of Discharge Chamber

CPC-II


Lodge and Shipley Lathe (22)

ObjectiveTo bring the Lodge and Shipley Lathe up to modern specifications by both developing a new speed control system using a Variable Frequency Drive, and restoring the lathe to a like new condition. Adding a useful piece of infrastructure to the MIL as it is expanded.

.

Project Details• Moved the lathe from the MERC building

into the senior design lab.• Checked over lathe and restored what

needed to be fixed/replaced.• Installed 220V 3 phase power into the lab.• Determined the type of VFD needed based

on power and motor requirements• Developed a wiring diagram for the

installation of the VFD between the power and motor.

• Wrote a users manual for future students to learn how to use the lathe.

CPC-II


Small Wind Turbine Instrumentation, Monitoring and Performance Verification (23)

ObjectiveDevelop a sensor package measuring wind speed, wind direction, nacelle heading, humidity, power output, battery bank voltage, temperature and pressure.Design and install an active yaw control system.Determine the effectiveness of a passive yaw control versus the effectiveness of an active yaw control for the Air-X.

. Project DetailsNo permanent modification to the turbine.Communicate wirelessly and be able to view current turbine operations through the internet.One second data sampling rate.Active yaw control to consume no more than 50 Watts.Ability to turn yaw control on and off.Added components must be weatherproof.

CPC-II


mech486 project summary – 2010/2011€¦ · small hybrid propulsion system demonstrator (4)...

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