Transcript Presentation 3 - Senior Design

Connecticut Corsair Senior Design
Simulator Refurbishment
EE Design Team 194
Connecticut Corsair Senior Design
Problem Statement Summary
In interdisciplinary team of mechanical, computer and electrical
engineering students are reengineering the base of an outdated flight
simulator to have movements characteristics akin to that of a Corsair
F4U-4 aircraft.
2
Connecticut Corsair Senior Design
Previous Work
Pros/Cons of Induction vs. Servo Motors
SERVO MOTORS
INDUCTION MOTORS
Small
Large
Integrated Encoder
Encoder Separate
Low Run Temperature
High Run Temperature
Easier to Prototype
Hard to Develop Prototype
Efficient
Less Efficient
Expensive
Cheaper
Servo drives are expensive
VFDs are less expensive
Arduino compatible
Arduino compatible
3/15
Connecticut Corsair Senior Design
Previous Work
Ideal Motor Specifications
OLD SPECIFICATIONS
NEW SPECIFCATIONS
RPM: 26
RPM: 65
Torque Out: 1212 in-lbs
Torque Out: 3484.1 in-lbs
Gear Ratio: 63:1
Gear Ratio: 21:1
𝑀𝑜𝑡𝑜𝑟 𝑠𝑝𝑒𝑒𝑑 = 120 ∗
𝑓𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦
60
= 120 ∗
= 1800 𝑅𝑃𝑀
𝑝𝑜𝑙𝑒𝑠
4
𝐼𝑛𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑
1800
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =
=
= 21.1
𝑂𝑢𝑡𝑝𝑢𝑡 𝑆𝑝𝑒𝑒𝑑
85
𝐼𝑛𝑝𝑢𝑡 𝑇𝑜𝑟𝑞𝑢𝑒 =
𝑇𝑜𝑟𝑞𝑢𝑒 𝑂𝑢𝑡
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜
=
3484
21.1
= 164.5 in-lb =13.7 ft-lb
𝑅𝑃𝑀
1800
𝐻𝑜𝑟𝑠𝑒𝑝𝑜𝑤𝑒𝑟 = 𝐼𝑛𝑝𝑢𝑡 𝑇𝑜𝑟𝑞𝑢𝑒 ∗ 5252 = 13.7 ∗ 5252 = 4.7 𝐻𝑃**
**4.7hp non-standard. 5hp required.**
4/15
Connecticut Corsair Senior Design
Current Work:
Second Design Semester
Motor Purchase and Installation
- Induction motors mounted, relays built
- Existing VFDs wired to motors
- Servo purchased and being shipped
Electronics Interfacing
Components include...
- Motor,
- Arduino
- VFDs
- Protective circuitry, i.e: relays
- Computer
- Joystick inputs
Arduino Sketch development
- Function documentation and specifications
5/15
Connecticut Corsair Senior Design
Current Work:
Existing Motor Rebuild and Servo Integration
- Initial Design: three servo motors
- Redesign: single servo, two
induction!
- More compliant with budget
- Small simulator load makes this
possible
- Induction motor damage update
- Motor stator housings replaced
Connecticut Corsair Senior Design
Current Work:
Second Design Semester
7/15
Connecticut Corsair Senior Design
Current Work:
Rewire VFDs
Given the previous design team’s
wiring…
• Wiring modifications were made
•
Parts of existing setup cut out
•
New wiring allows for variable frequency input
• Old schematics didn’t provide Arduino
pin numbers
Connecticut Corsair Senior Design
Current Work:
Wire Schematics
Connecticut Corsair Senior Design
Current Work:
Arduino Sketch Development Thus Far
• Reads Joystick(Pots) inputs to move motors
at variable speeds using PWM.
• Easy to write analog output with simple
math.
• Only at half capacity, will be solved with
circuit elements.
• Encoder code is being developed for the
AS25 Gurley Absolute Encoder.
Connecticut Corsair Senior Design
Current Work
What’s Next?
• Interfacing with Servo drive
• shipment estimated between 3/14 and 3/22
• Actual position controlled induction motors.
Connecticut Corsair Senior Design
Current Work
Absolute Encoder
• Provides absolute position information to Arduino controller
• 16 bit resolution - very accurate
• Synchronous serial data communication between encoders and Arduino
• High speed: ~1 microsecond response time
Connecticut Corsair Senior Design
Current Work
Simulation Software: Prepar3D
• Lockheed Martin’s Prepar3D Academic v 1.4.4747.0
•
Used for both entertainment and training
•
Immersive cockpit with real-life airports and environments
•
Mission Design, capable of entertainment and training purposes
• SimConnect Developer SDK
•
Add-ons can be written in C, C++, C#.net or VB.net
•
Add gauge processing, replace events processing, record/monitor flights, create custom missions,
weather manipulation, enable hardware with Prepar3D, control additional views and/or AI
aircraft
• F4U-4 Corsair Plane Model Import via A2A
•
A2A is a software add-on company
•
“Aircraft Factory” Line
• Fine distinction: use software to control machine
• Future application: 3D immersive LCD screen
Connecticut Corsair Senior Design
Timeline
2/24/2014
3/3/2014
3/10/2014
3/17/2014
3/24/2014
3/31/2014
Zach Mosch
Run VFD's
Absolute
and Induction
encoder
motors with
feedback
Joystick
Position
controlled
Induction
Motors
David
Tartaglino
Complete
VFD and
Induction
motor wiring
Finalize
wirings and
mount to
simulator.
Unpack and
Make new
start working Complete
wiring
See previous on servo
servo and
diagrams and
motor
drive wiring
schematics
installation
Amanda
Sweat
Contact
Lockheed
customer
support for
installation
issues
Corsair model Outline how
Create
imported
encoder
Purchase A2A
logfiles of
using client feedback
simulation
positions
server. Model inputs are
Corsair model
from
joystick
imported into
Prepar3D
control
software
Randy
Bertrand
Find usable
code for
Prepar3d
outputs
Absolute
encoder
feedback
Link motors
to Prepar3d
position
outputs
See previous
Servo's
hopefully?
See previous Servo motors
4/7/2014
4/14/2014
Transfer
Arduino code See previous Testing
to servo drive
4/21/2014
Testing
Make servo
wiring
Testing
diagrams and
schematics
Testing
Integrate
logfiles with
existing
Arduino code
Answer: Can
environment
outputs be
processed to
affect flight
simulator?
Manipulate
machine and
software for
simulation
Help with
servo setup
Incorporate
servo position
info with
encoder
Testing
feedback
from other
motors
Write up on
machine +
Prepar3d
integration.
Computer
wired.
Testing
Connecticut Corsair Senior Design
High Level Joystick Motor Diagram
=
Arduino
Sketch
Connecticut Corsair Senior Design
ME Contributions
• Drive motor Analysis and Replacement
• Free body Diagrams
• Torque Requirements and Comparison
• Nonlinear Linkages Analysis
• Scissor Arm Analysis and Redesign
• Determined failure scenarios
• ANSYS analysis
• CAD models
• Motor Mount Redesign
• Gearbox designs
• ANSYS analysis
• CAD models
Connecticut Corsair Senior Design
Questions?
17