pickle upgrade final
TRANSCRIPT
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 1/33
Team Members: Nolan Cmerek
David Haverlah
Jeffrey Bell
ASE 463Q 12/06/2006
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 2/33
2/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 3/33
3/33
Team Schedule
Nolan CmerekTeam Org. Outline Prev. Work Tunnel Specs Goals Remote
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 4/33
4/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 5/33
5/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 6/33
6/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 7/337/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 8/338/33
Wind Tunnel Specifications (2)
Nolan CmerekTeam Org. Outline Prev. Work Tunnel Specs Goals Remote
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 9/339/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 10/33
10/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 11/33
11/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 12/33
12/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 13/33
13/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 14/33
14/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 15/33
15/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 16/33
16/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 17/33
17/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 18/33
18/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 19/33
19/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 20/33
20/33
Average Lift Coefficient Plot Example
Need for Tunnels Pickle History User Manual Other Wind Tunnels
Jeffrey Bell
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 21/33
21/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 22/33
22/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 23/33
23/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 24/33
24/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 25/33
25/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 26/33
26/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 27/33
27/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 28/33
28/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 29/33
29/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 30/33
30/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 31/33
31/33
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
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 32/33
32/33
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?
8/22/2019 Pickle Upgrade Final
http://slidepdf.com/reader/full/pickle-upgrade-final 33/33
33/33
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