pickle upgrade final

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Team Mem bers:  Nolan Cmerek  David Haverlah  Jeffrey Bell  A SE 463Q  12/06/2006  

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Page 1: Pickle Upgrade Final

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Team Members: Nolan Cmerek 

David Haverlah 

Jeffrey Bell 

ASE 463Q 12/06/2006 

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Team Organization

Dr. Ronald StearmanProject Sponsor 

Nolan CmerekTeam Manager 

Website Designer Software/Remote Access

David HaverlahPersonal RelationsCost and Analysis

Jeffery BellWind Tunnel Specialist

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Team Schedule

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Outline

Previous Q Project Work

Wind Tunnel Specifications Project Goals

Remote Control

Need for Wind Tunnels

Pickle Wind Tunnel History

User Manual

Other Wind Tunnels

AC Variable Frequency Drives (VFD)

Anti-Turbulence Screen

Interview with Eddie Zihlman Cost Proposal

Work Completed

Recommended Future Work

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Previous Q-Project Work 

BAA Research (2003) Included background on the wind tunnel Purpose of this project was to improve the condition of the continuous-

flow type subsonic 5’ x 7’ wind tunnel at Pickle Research Center (PRC)

Researched a semi-circular inlet screen which would be added to the

mouth of the wind tunnel to dissipate turbulent eddies and ensurelaminar flow

Sting control system code is currently in the process of being convertedfrom Rocky Mountain Basic to LabView

Recommended the purchase and installation of the inlet screens todissipate turbulent eddies throughout the tunnel

Nolan CmerekTeam Org. Outline Prev. Work Tunnel Specs Goals Remote

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Previous Q-Project Work 

Joshua Foxworth ThesisCompleted BAA Research sting control systemChapter 4General Test Procedure –Cessna 208B Start Procedures

Chapter 7Sting Operations

LabView Controls

Math Behind Control 

Nolan CmerekTeam Org. Outline Prev. Work Tunnel Specs Goals Remote

Foxworth Thesis Report

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Wind Tunnel Specifications (1)

5’x7’ by 50’ long test section  Powered by four 200 hp fans Designed for a maximum speed of 200 mph

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Wind Tunnel Specifications (2)

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Project Goals

Main ObjectivesDevelop a comprehensive user’s manual for the tunnel and

data acquisition systemDevelop a cost proposal for a feasible upgrade to the wind

tunnelTurbulent Screens AC ControllersRe-shell and Structure Patches

Develop outline for possible remote access

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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 Aeolus-Remote Control 

ME Wind Tunnel Simplistic Approach Robust to handle multiple users

while maintaining real-timeinteractivity

Integrated real-time video Axis 2100 ActiveX control 

Security Token server application ran as anembedded application on theFieldPoint unit 

User interface Compiled application-Aeolus 

Nolan CmerekTeam Org.  Outline Prev. Work Tunnel Specs Goals Remote

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Dr. Phillip Schmidt Interview 

Lent us old ME Tunnel Reports Had to set up controls for sting in LabView Speed control working in FieldPoint FieldPoint is commercial hardware for remote data

acquisition and controlCreates a node on the internet

Worked on a scheduling algorithm Aeolus system is not operational in the production

sense. Never used it with a large class onlydemonstrated it.

Nolan CmerekTeam Org.  Outline Prev Work Tunnel Specs Goals Remote

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FieldPoint(1)

A small rugged, easy to use, highly expandable,measurement and control deviceSolid metal backplaneRemovable compact flash drive

Ethernet and serial ports I/O Boxes

Expandable modular architecture

Nolan CmerekTeam Org.  Outline Prev Work Tunnel Specs Goals Remote

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FieldPoint(2)

Real-Time LabView embedded control

Develop—compose application using graphical blocks Download—target FieldPoint controller  Deploy—reliable long-term execution

Nolan CmerekTeam Org.  Outline Prev Work Tunnel Specs Goals Remote

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Remote Access to Pickle

Use FieldPoint system fromNational Instruments

Allow only restricted access No need for password

changing system Axis 2100 for easy video

integration

Nolan CmerekTeam Org.  Outline Prev Work Tunnel Specs Goals Remote

Total Device Access Rate (fps) Required Hardware Ease of Integration Quality of Video Maintainability Security

0 Axis 2100 0 0 0 0 0 0

-4 USB Web-Cam 1 -2 -1 0 -1 -1

-4 IEEE 1394 Webcam 1 -3 -1 1 -1 -1

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Need for Wind Tunnels

Airflow simulation over aircraft and structures is a complex and involved process. A few common methodsof flow analysis used today; scaled wind tunnel testing, full size wind tunnel testing, and computational

fluid dynamics (CFD)

Basic Needs; Safety, Economics and Education Proof of design prior to test flight which puts life and prototype at risk Education, ―hands on‖ learning and observation of fluids (modeling can only be as accurate as one’s

perception and understanding of nature) Flows around complex structures are presently difficult to model with CFD. Scaled model wind tunnel

testing is comparatively easy to setup and research Scaled testing is more economic than full size testing simply because a full size capable wind tunnel is a

few orders of magnitude more expensive than a scaled wind tunnel (simultaneity with Reynoldsnumbers)

CFD was used entirely for the design of Scaled Composites’ SpaceShipOne prior to test flights. However,during one of the initial test flights, flight threads were attached to the surface of the wings in order toaugment the computational model

http://en.wikipedia.org/wiki/Wind_tunnels

Jeffrey BellNeed for Tunnels Pickle History User Manual Other Wind Tunnels

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History of the Pickle Research Center Wind Tunnel 

1970, design was started on an open circuit 5 x 7 foot 200 mph tunnel to accommodateaeronautical, meteorological and architectural needs

1971, construction initiated using State funds available to the College of Engineering Used to purchase and erect four main drive fans and construct the test building

1980, tunnel construction completedand testing started

1995, Joshua Foxworth performed lift, drag and moment coefficient testing on the Cessna208B

Other testing includes a cable mounted Cessna Caravan aerodynamic testing, skeleton sleddrag coefficient optimization, and this semesters aerodynamic damage team

Future testing includes the Design Build Fly and UAV projects

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

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User’s Manual Summary  General Test Procedure: Force and 

Moment Measurement 

The following steps must be performed in order to safely and properly perform ageneral force and moment measurement test on a model in the windtunnel.These sections were summarized, condensed and/or directly copied fromFoxworth’s Chapter 4 thesis, and the Wind Tunnel Startup Procedures manualauthored by Eddie Zihlman’s work study students. 

Call 1-3600 on the day of a run to inform grounds keepers, etc. and page Bobby(grounds crew supervisor) at 625-8145 and leave a call back number. 

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

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Summarized Steps(1)

Step 1: Perform Safety Checks Sting Force Balance Safety Check  Fan Motors and Wind Tunnel Preparation and Safety Checks

Step 2: Prepare the Sting for Use Check hydraulic system for proper fluid levels Turn on water cooling system Sting is controlled with “Main_controller_code.vi” in Labview

Step 3: Move Sting to Zero Degrees Angle of Attack  Measure and input sting rest angle into sting control window to zero the AoA of the sting

Step 4: Take Initial Force Balance Readings  Zero the force load on the sting to eliminate DC bias errors

Step 5: Mount the Model

Mount model when sting is at 0 degrees AoA Check for clearance during range of AoA

Step 6: Run Tare Test Using Automated Testing Function Measures and records forces for each angle of attack with no wind load

Need for Tunnels Pickle History User Manual Other Wind Tunnels

Jeffrey Bell

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Summarized Steps (2)

Step 7: Turn on Fans and Achieve Proper Tunnel Speed

Measure airspeed via airspeed indicator box or digitally with the scanivalve interface

Step 8: Run Force Test Using Automated Test Sequence Press the “Run Automated Test Sequence” button

Step 9: Take Timeline Data Measures and recorded force data for 6 axes Dynamic force measurements allow frequency content to be analyzed

Step 10: Reduce Tare and Force Files to Proper Coefficients Press the “Calculate Coefficients / Plot Data” button  Calculates lift, drag and moment coefficients

Step 11: Calculate Frequency Content of Timeline To view the frequency content of a recorded timeline, the “Plot Frequency Spectrum of 

Timeline” button

Step 12: Remove Model, Lower Sting, Power off all Equipment Make sure floor inserts do not obstruct the sting when it powers off 

Need for Tunnels Pickle History User Manual Other Wind Tunnels

Jeffrey Bell

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 Average Lift Coefficient Plot Example

Need for Tunnels Pickle History User Manual Other Wind Tunnels

Jeffrey Bell

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Other Wind Tunnels

9’ x 15’ Low Speed Wind Tunnel at NASA GlennResearch Center 

Pininfarina Aerodynamic and Aeroacoustic

Research Center Automotive Wind Tunnel (Italy)

University of Washington Kirsten Wind Tunnel

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

9’ 15’ L S d Wi d T l t NASA

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9’ x 15’ Low Speed Wind Tunnel at NASAGlenn Research Center 

Characteristics and Performance

Test Section Size: 9 ft high by 15 ft wide by 28 ft long Mach Number Range: 0 to 0.2 Fan Drive Rigs: 1000, 2000, and 5000 shp 1024 channel pressure measurement system

Flow Visualization Pressure sensitive paint Both conventional and focused Schlerien systems Sheet laser  Oil flow visualization High speed video - up to 1000 full screen frames/s

Remote Access Control Room Real-time remote access to all data Online calibration Video conferencing in real time Workstations supplied for remote site Secure network connections provided

http://facilities.grc.nasa.gov/9x15/9x15_desc.html

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

Pi i f i A d i d A ti

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Pininfarina Aerodynamic and Aeroacoustic Research Center Automotive Wind Tunnel (Italy)

Characteristics and Performance Test Section Size: 4.20 m high by 9.60 m wide by 8.00 m long

Max Flow Speed = 56 m/s DC Motor Power = 1.1 MW

Flow Visualization, Acoustics, and Other Instrumentation Hot wire,14 pressure tab probe, smoke, laser light sheet 3 component Laser Doppler Velocimeter  Acoustic field measurement inside and outside of the vehicle Brake Disk and Radiator Cooling flow measurement

http://arc.pininfarina.it/english/index_en.html

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

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University of Washington Kirsten Wind Tunnel 

Characteristics and Performance Test Section Size: 8 feet high by 12 feet wide by 10 feet long with 1.5 feet high (45º)fillets in all four corners Max Flow Speed = 250 mph Two 500-hp dc motors 30 data channels with 2 additional for model positioning at 100 samples per second

Flow Visualization Smoke, tufts, china clay, oil, sublimation Digital and analog video capture with normal and ultraviolet lighting, … 

China Clay Flow Visualizationhttp://www.uwal.org/uwalinfo/techguide.htm

Jeffrey Bell

Need for Tunnels Pickle History User Manual Other Wind Tunnels

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 AC VFD Control 

VFD-Variable Frequency Drive

Changes the output frequency to control motor RPM

Current control is On/Off only,with shutter vane options

VFD allows total control of fan speed-needed for UAV

Remote computer controlsupported

David Haverlah

AC Control  Turbulent Screen Eddie Cost Work Completed Future 

http://www.clrwtr.com/Yaskawa-Drives.htm

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 Anti-Turbulence Screen

Currently there is only one anti-turbulence screen

 Approximate cost is $15,000-$25,000 each + installation per screen. Aerolab technician cost~$1,000 man/day + travel. Needed installation~2 men minimum for assembly and installation. Total cost for 2 screens~$30-$60K.

Front View of Inlet Close up of Screen Side View of Inlet

David Haverlah

https://reader012.{domain}/reader012/html5/0821/5b7bd7c08361f/5b7bd7cf9de38.jpg

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Interview with Eddie Zihlman (1)

Discussion of tunnel operations – an involved process Safety checks and lockouts Full speed runs require shutdown of high speed tunnel

 Advanced notice required to coordinate the two facilities

Measurement issues

The sting is weak in the yaw direction Measuring balance has been damaged and repaired several times The bulk of the sting creates unwanted blockage of the tunnel at low and negative

 AOA

Initial design changes Found records where initial design was altered slightly in exhaust area which mightcontribute to tunnel fluctuations

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Interview with Eddie Zihlman (2)

Tunnel issues

Wet rot from inadequate drainage and poor initial design

Several patches have been cut into the existing tunnel to attempt to fix, but rot is spreading 

“Kink” or dog-leg in diffusion section that creates adverse flow fluctuations into fan

Sealant material used to weatherproof outdoor sections of tunnel contains asbestos

Low frequency velocity oscillations occur within test section at moderate external(atmospheric) wind speeds

This limits operations to days when winds are below 9 mph * 

Exhaust flow is not contained, and can be a hazard if the experimental model isdestroyed during operations

Highlights The tunnels does work, and was built on a shoestring budget mostly by students

Was used to measure drag on USA Olympian skeleton racer, who eventually won

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Cost Proposal 

Item  Item Cost  Number Required  Required Cost

VFD AC Motor Controller   $8,750.00 4  $35,000.00

 Anti-Turbulence

Screen 

~$15,000 -

$30,000  2 

$30,000 -

$60,000 Honeycomb Flow

Straightener  ~$15,000 -

$30,000  1 

$15,000 -$30,000 

Total Cost$80,000 -

$125,000 

Option 1 Upgrades

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Cost Proposal 

Item  Item Cost  Number Required  Required Cost 

Option 1:Total Cost

$80,000 -$125,000 

Enclosure Building 

~$25 per sq. ft+ $27,500

foundation 250 X 60 = 15,000 ft2 

~$375,000 -$403,000

Computer and DAQ  ~$1,000-$3,000  2-3 

$2,000 -$10,000 

Re-Build Tunnel ~$50,000 -

$150,000 ? 

~$50,000 -$150,000 ?

Total Cost$507,000-

$688,000 

Option 2 Upgrades

Consider New Tunnel ~ 1-2 Million

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Work Completed 

Gathered information and prices for AC motor controllers

Contacted Dr. Bragg at the University of Illinois at Urbana Generated contacts nationwide to get turbulence screens and other items

Made several trips to Pickle facility and researched tunnel history Learned of initial designs and construction period Obtained partial operation manual and documents that explain operations of the

sting Feasibility of remote access

Interview with Dr. Phillip Schmidt

Comprehensive User Manual Interview with Eddie Zihlman

Cost Proposal Option 1 –$80,000 - $125,000 Option 2 –$507,000- $688,000

Consider building new facility for 1-2 million 

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future 

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Recommended Future Work 

Film sting operations and LabView system Implement Remote Access using FieldPoint Continue search for tunnels that may be

decommissioned for possible purchase

Pending Funding:Upgrade to at least Option 1for UAV and DBF use AC Motor Controller  Anti-Turbulence Screen

Flow Straightener 

David Haverlah

 AC Control  Turbulent Screen Eddie Cost Work Completed Future

Questions?

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Questions? 

Nolan Cmerek David Haver lah Jeffrey Bel l

Thank You 

For mo re informat ion please vis i t 

http://www.ae.utexas.edu/~cmereknd/PICKLE_WIND_TUNNEL/home.htm