Transcript edge.rit.edu

P12463 : Hydrodynamic Kite Model
System Design Review
Team Members:
Mark Negro
Adam Dunn
Andrew Garland
Michelle Wang
Vulf Kirman
1
P12463 SDR
Contents
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Desired Outcomes of System Design Review (SDR)
Project Background and Key Objectives
Team Member Roles Responsibilities
System Architecture and Diagrams
Customer Needs
Customer Specifications
Concept Selection Process
Feasibility Analysis
Schedule for MSD 1 + 2
Risks
2
P12463 SDR
Desired Outcomes
 Guidance
 Verify method of approach
 Reveal any unexplored areas of study from customer
and guests
 Inform guide and customer of progress
 Approval to start detailed design
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P12463 SDR
Project Background / Key Objectives
 The goals of the project:
- Design vertically mounted hydrofoil system for testing
- Will replicate a simplified model of a tethered kite system
- Data collected will be used to verify or improve an existing
model simulation.
- Calculate power output created when the hydrofoil is
attached to a freely pivoting boom
- Done by measuring angular velocity of moving boom arm
- Interface with tow rig platform designed by P12462.
4
P12463 SDR
Member Responsibilities
5
P12463 SDR
Functional Decomposition
6
P12463 SDR
System Overview
Output
Input
Tethered Hydrofoil
Model
Power generated
Current boom angle
Current hydrofoil angle
Digital video of surface interaction
Boom length
Output
Input
Aspect ratio
Hydrofoil flip
locations
Resistive torque
Resistive torque
“Flow” velocity
Tow Rig
Output
Hydrofoil flip locations
Controls / Data
Acquisition
Input
Hydrofoil flip
angles
Real-time visual representation
of model motion
Current hydrofoil angle
Hydrofoil flip angles
“Flow” velocity
Current boom angle
Net power
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P12463 SDR
Control System Architecture
Symbol
Device
Function
1
Strain Gage
2
Potentiometer
Measure ϴ
3
Video Camera
Capture high-speed
_video of foil
4
Actuator
Measure torque, τ
1
3
Control Ф
4
2
Φ
8
Hydrofoil
Tow Rig
Actuator
Angular
Position
Monitor
Power
Source/
Regulator
Control flip orientation of hydrofoil
Output angular position of hydrofoil
Linkage
Data
Acquisition
Computer
Boom
Output angular position
of boom
Angular
Position
Monitor
Support/
Linkage
User input
(if desired)
Generator
Station
Key:
Digital
Video
Camera
P12463 SDR
User
Interface
Dump
Load
Input resistive torque
delivered by dump
load
-
Physical connection
-
Data connection
-
Power connection
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P12463 SDR
Functional Diagram
Physical interface with
tow rig platform (bolted
flange connection
Hydrofoil actuation
(pneumatic or electric
servo motor?)
Hydrofoil angle (hollow
shaft potentiometer)
Digital video
camera
Dump load
(constant torque;
power generation)
Coupled shafts
Boom support / free
rotation (roller bearing)
Boom angle (hollow shaft
potentiometer)
Controls / Data
collection
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P12463 SDR
Construction Assumptions for SDR
 Boom length and hydrofoil aspect ratio will be changed manually
 Hydrofoil flip location, hydrofoil flip angle, platform velocity and
dump load torque will be controlled via Labview
 Rather than directly measuring torque, we will be calculating it as a
function of angular acceleration and moment of inertia
 Potentiometers will be used to measure angular position of both
the boom and the hydrofoil relative to the boom
 The linkage between the dump load and the boom will consist of
coupled shafts and a bearing (roller or ball) that is capable of
supporting axial loading
 We will be using a laptop for controlling our system and collecting
data
 Hydrofoil actuation has not been determined; choice is between
pneumatic/hydraulic actuation and an electric servo motor
 Digital video camera will neither receive nor transmit data or power
to the rest of the system
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P12463 SDR
Customer Needs
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P12463 SDR
Engineering Specifications
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P12463 SDR
Decision Criteria
Functions:
 Attach Tow Rig
 Multiple Boom Lengths
 Hold Hydrofoil Position
Constant Relative to Boom
 Flip Hydrofoil
 Measure Angular Position
of Boom
 Connect Hydrofoil to
Boom
 Allow Rotation of
Boom/Types of Dump
Loads
 Measure Torque of Boom
 Change when Hydrofoil
Flips in Cycle
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P12463 SDR
Feasibility Analysis:
Boom Arm & Hydrofoil (Maximum)
Milestones Reached
 Created an excel spreadsheet which would take a set of inputs on dimensions of boom
and other factors to determine the bending stress on the boom at different boom
angles and angles of attack based on the data retrieved from the MATLAB simulation.
 Brainstormed the possible worst case scenarios for the system as far as bending stress
and stall were concerned.
 Some of the assumptions that were made during the brainstorming session are as
follows:
 Static Equilibrium
 Angular velocity of the boom arm is 0 rad/s
 Hydrofoil chord length is perpendicular to the direction of the flow velocity
 The brainstorming session was verified by altering some of the values in the MATLAB
simulation to mimic our setup.
Milestone that have yet to be reached
 Must get the MATLAB code to output lift forces in order to change the moment
equation in the excel spreadsheet to account for bending based on both drag and lift.
 Need to test out a set of worst case scenarios for both the hydrofoil and boom arm
(for bending stress) to be able to see which set of boom and hydrofoil dimensions fit
best for both the tank team and our team.
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P12463 SDR
Feasibility Analysis:
Hydrofoil (Minimum)
 Minimum hydrofoil size is limited by manufacturing
methods and precision of instrumentation.
The team will be contacting a manufacturer of hollow
shaft potentiometers to, hopefully, determine the
accuracy of this device when monitoring angular
position
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P12463 SDR
Feasibility Analysis:
Tank Width and Boom Arm
 Option 1: Boom is in middle of tank
 Assumptions:
-assume 90 degrees total rotation. Rotation is
equal on both sides of platform (45 degrees)
Option 1
Chord Length [inches]:
 Option 2: Boom is at side of tank. Boundary layer is less
than Wph
 Assumptions:
-platform against tank wall
-90 degrees maximum rotation
-rotation starts parallel to length of tank wall
4
Tank size [inches]
Boundary Layer thickness (1 side) [inches]
Usable Tank Width [inches]
Length of Boom [inches]
Option 2
Chord Length [inches]
Tank Size [inches]
Boundary Layer [inches]
Wph [inches]
Usable Tank Width [inches]
Length of Boom [inches]
60
16
28
19.8
4
30
8
10
12
12
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P12463 SDR
Feasibility Analysis:
Tank Width (cont.)
 Option 3: Boom is at side of tank. Boundary layer is greater than Wph
 Assumptions:
-platform against tank wall
-start of cycle outside of boundary layer
Option 3
Chord Length
Tank Size [inches]
Boundary Layer [inches]
Wph [inches]
Length of Boom
4
30
8
4
18
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P12463 SDR
Feasibility Analysis:
Tank Size and Cycle Time
Control
Symbol Unit Value
Parameter
Mass of kite
Mass of boom
Length of boom
Angle of foil to boom
Value of braking torque
Span of foil in water
Chord Length
River velocity
Initial angle of boom
Initial angular velocity of boom
Angular position limits
Angular velocity limits
Return Angle
Cycle Time
mk
mb
l
beta
K
r_dep
chord
vinf
Y0(1)
Y0(2)
theta
thetadot
beta
kg
kg
m
rad
Nms
in
in
m/s
rad
rad/s
rad
rad/s
rad
s/cyc
0.05
0.25
0.45
70
0.5
14
1.4
1
5
60
>90,<5
<2
-70
1.78
Parameter Variation
0.05
0.25
0.45
70
0.1
14
1.4
1
5
60
>90,<5
<2
-70
1.26
0.05
0.25
0.45
70
0.3
14
1.4
1
5
60
>90,<5
<2
-70
1.58
0.05
0.25
0.45
70
0.7
14
1.4
1
5
60
>90,<5
<2
-70
2.02
0.05
0.25
0.45
70
0.9
14
1.4
1
5
60
>90,<5
<2
-70
2.29
Cycle Time (s/cyc)
Dump Load Torque Coefficient
vs. Cycle Time
2.5
2
1.5
1
0.5
0
y = 1.25x + 1.161
R² = 0.9953
Series1
Linear (Series1)
0
0.5
Dump Load coefficient
1
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P12463 SDR
Feasibility Analysis:
Tank Size and Cycle Time (cont.)
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Mass of boom vs. Cycle Time
1.86
Series1
Linear (Series1)
Cycle Time (s/cyc)
y = 1.362x + 1.0849
R² = 0.9944
y = -0.1482x2 + 0.2638x + 1.7245
R² = 0.9995
1.84
1.82
1.8
Series1
1.78
Poly. (Series1)
1.76
1.74
0
0.5
1
1.5
2
2.5
0
0.5
Length of boom (m)
1
1.5
Mass of boom (kg)
Mass of kite vs. Cycle Time
2.5
Cycle Time (s/cyc)
Cycle Time (s/cyc)
Length of boom vs. Cycle Time
y = 1.7533e0.2135x
R² = 0.9988
2
1.5
Series1
1
Expon. (Series1)
0.5
0
0.01
0.1
Mass of kite (kg)
1
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P12463 SDR
Feasibility Analysis:
Flipping Mechanism
Timing
Input
Comments
Desired Cycles, n
3
Usable tank length (meters)
Minimum cycle time (m/cycle)
4.3
1.43 Eqn = desired cycle time/n
Flow velocity, v (m/s)
0.5
Attainable cycle time (m/cycle)
1.2
Output
Number of flips
5 Eqn = (n*2)-1
Allowable time to flip (s/flip)
0.28 Eqn = (((Minimum-attainable)*n)/v)/# of flips
Comparison
Weight
Speed
Torque
Cost
Servo
>50 g
0.08 s/60°*
12 kg-cm
to $70
Hydraulic
Heavy
Lots
Hundreds
* At 6V
Available in high resolution
^ Not practical for our use.
sampling ranges. Don't know if Will consult with Wellin about
torque is sufficient to keep foil his thoughts on hydraulics.
from slipping. High-torque
Let's move forward with
models available
Servo.
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P12463 SDR
Budget: Estimations
P12463 Budget:
Expense Description
$2,000
Qty
Unit Cost
Cost
Hydrofoil Materials
Dump Loads
Hollow-shaft Potentiometer
Flipping Mechanism
Boom Materials
Camera
Bearing for Boom
Shaft Coupling
Attachment Rig Material
Laptop
Environmental Protection
5
1
2
1
3
1
1
1
1
1
?
$8
$600
$10
$100
$50
$0
$100
$50
$50
$300
$100
$40
$600
$20
$100
$150
$0
$100
$50
$50
$300
$100
Cables and Wires
1
$50
$50
Remainder:
$440
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P12463 SDR
Schedule for MSD 1
Task Name
Brainstorming
Risk Assessment
Duration
2 days
3 days
Start
Finish
Mon 10/3/11 Thu 10/6/11
Sun 10/2/11 Tue 10/4/11
Predecessors
Send Preview of System Design Review
0 days
Mon 10/3/11 Mon 10/3/11
System Design Review Calculations
5 days
Sun 10/2/11
Thu 10/6/11
Design Review "Check"
0 days
Tue 10/4/11
Tue 10/4/11
Make Changes from Design Review "Check"
2 days
Tue 10/4/11
Wed 10/5/11 5
Send SDR Presentation to Attendees
0 days
Wed 10/5/11 Wed 10/5/11 6
Decide methods to fulfill functions
16 days
Tue 10/4/11
Tue 10/25/11
System Design Review
0 days
Fri 10/7/11
Fri 10/7/11
Detailed Calculations on Hydrofoil Loads
6 days
Fri 10/7/11
Fri 10/14/11
Design Boom Arm
6 days
Mon 10/10/11 Mon 10/17/11
Detailed Calculations for Boom Connections
10 days
Mon 10/10/11 Fri 10/21/11
Identify Parts Needed to Acquire
16 days
Wed 10/12/11 Wed 11/2/11
Prepare for Detailed Design Review
Detailed Design Review
4 days
0 days
Mon 10/31/11 Thu 11/3/11
Thu 11/3/11 Thu 11/3/11
Additional Detailed Design Based on Review
8 days
Tue 11/8/11
Order Long Lead Time Parts
14 days
Mon 10/31/11 Thu 11/17/11
Prepare for MSD I Review
MSD I-Final Design Review
Thanksgiving Break
4 days
0 days
6 days
Mon 11/14/11 Thu 11/17/11
Thu 11/17/11 Thu 11/17/11 18
Sat 11/19/11 Sun 11/27/11
14,10,11,12,13
Thu 11/17/11 15
23
P12463 SDR
Schedule for MSD 2
Task Name
Order/Acquire Short Lead time Parts
Manufacture Hydrofoils
Manufacture Boom
Assemble Boom Connections
Test Boom Connections
LabView Programming
Duration
6 days
10 days
7 days
7 days
2 days
36 days
Start
Mon 11/28/11
Mon 11/28/11
Mon 11/28/11
Wed 12/7/11
Fri 12/16/11
Mon 11/28/11
Finish
Predecessors
Mon 12/5/11
Fri 12/9/11
Tue 12/6/11
Thu 12/15/11 23
Sat 12/17/11 24
Fri 1/13/12
Incorporate Actuation Devices
19 days
Wed 12/14/11 Mon 1/9/12
Test Actuation Devices
Incorporate Dump Load
Test Dump Load
3 days
4 days
3 days
Mon 1/9/12 Thu 1/12/12 27
Tue 1/10/12 Fri 1/13/12
Mon 1/16/12 Wed 1/18/12 29
Incorporate Instrumentation
6 days
Mon 1/16/12 Mon 1/23/12 23,25,26
Test Instrumentation
Protect Components
Test Protection of Components
Winter-Holiday Break
Preliminary Integrate System With Team P14262
Debug After Preliminary Integration
Preliminary Customer Demo
Debug per Customer Needs
Reintegrate System with Team P14262
Final Customer Demo
3 days
10 days
5 days
16 days
3 days
4 days
0 days
7 days
3 days
0 days
Tue 1/24/12
Mon 1/9/12
Mon 1/23/12
Sat 12/17/11
Mon 1/30/12
Thu 2/2/12
Tue 2/7/12
Thu 2/9/12
Mon 2/20/12
Wed 2/22/12
Thu 1/26/12
Fri 1/20/12
Fri 1/27/12
Sun 1/8/12
Wed 2/1/12
Tue 2/7/12
Tue 2/7/12
Fri 2/17/12
Wed 2/22/12
Wed 2/22/12
Prepare for MSDII-Final Review
13 days
Tue 2/21/12
Thu 3/8/12
MSD II-Final Review
0 days
Thu 3/8/12
Thu 3/8/12
31
33
22,23,25,28,30,32,34
36
37
38
39
39,40
41
24
Risk Item
Effect
Cause
Incorrect
Component or total system
Incorrect assumptions,
1
engineering
failure, unsatisfied customer
miscommunication
analysis
Inability to hold
Failure of mechanism, poor
hydrofoil angle Unsatisfied customer, unable to
integration with other function
2
constant relative
collect data
components, higher loads on
to boom
hydrofoil than expected
3
Failure for boom
to rotate
Inability to get correct data,
safety issues, must
redesign/manufacture
Improper calculations and
unexpected
stresses, improper construction
Importance
Risk Assessment
Likelihood
Severity
P12463 SDR
Action to Minimize
2 3 6
Double-Check Calculations,
Facility Confirmation
All of team
2 3 6
Testing, Double-check
calculations
Vulf/Andrew
Testing, proper design,
2 3 6 compare with other existing
technologies
Adam/Mark
Improper sizing of instrumentation,
Double-Check Calculations,
Improper installation of
Facility Confirmation, Check
3 2 6
instrumentation, miscalculation of
Manufacturing
loads
specifications
Vulf/Adam
Adam/Mark
4
Inaccurate
measurements
5
Inability to
connect with
P12462
Must rework or reconceptulize
connection
Miscommunication or lack of
documentation between groups
Communication of current
plan and changes, keep
2 3 6
current interface document
between groups
6
Change in
customer
needs/priority
Narrow project scope, reevaluate functional
decomposition and system
design
Customer decisions, Purpose of
collected data changes
2 3 6
Inability to get correct data,
safety issues, must
redesign/manufacture
Improper calculations and
unexpected
stresses, improper construction
2 2
Testing, proper design,
4 compare with other existing
technologies
Inability to get correct data,
safety issues, must
redesign/manufacture
Improper calculations and
unexpected
stresses, improper construction
2 2
4
Flipping
7
mechanism failure
8
Structural failure
of hydrofoil
Unsatisfied customer
Owner
-
Double-Check Calculations,
Facility Confirmation
Mark/Customer
Adam/Mark
Vulf/Mark
25
Risk Item
9
Over budget
Effect
Cannot order necessary parts
Cause
Bad cost management, necessary
technologies more expensive for
required performance
3
Improper understanding of
customer needs
1
3
Design to Customer
3 Needs and Customer
Specifications
Mark/All of
Team
Health, family, personal reasons
3
1
3
-
All of team
Improper construction, improper
selection of protection, unexpected 1
environmental conditions
3
3
Check test location
and conditions
Adam/Vulf
Structural Failure of
11
Boom
Inability to get correct data,
safety issues, must
redesign/manufacture
Improper calculations and
unexpected
stresses, improper construction
Unsatisfied customer, bad
grades
Other team members must
compensate for additional
workload
14
15
Unable to protect
system components
Safety issues, damaged
components,
must reorder parts
Incorrect manufacturer Must reorder, increased leadspecifications
time
Inability to complete data
16 P12462 unsuccessful collection or test functionality
of project
Importance
1
Double-Check
3 Calculations, Facility Michelle/Mark
Confirmation
Poor time management
13 Loss of team member
2
2
Bad grades, unsatisfied
customer
Customer needs not
met
2
Action to Minimize Owner
Proper utilization of
available
Andrew/Michell
4
technologies, Keep
e
track of budget
Compare progress to
4 Gantt Chart to stay
on track
May not finish project
10
on time
12
Severity
Risk Assessment (cont.)
Likelihood
P12463 SDR
2
Mark/All of
Team
?
1
3
3
Proper Testing of
product
Mark/Adam
Location/space limitations,
construction problems, lack of
proper control system, leaks
1
3
3
Assign System
Integration engineer
Adam/Mark
26
Unable to modify boom
19
length
Unsatisfied customer
Failure of boom adjustment
mechanism, poor integration with 2
other function components
3
Importance
Risk Item
Effect
Cause
Necessary technology
Concept can not be built, Inadequate concept assessment,
not
17
limited data accuracy,
limited budget, project scope to 1
available for budget
limited functional precision
large
allocated
Improper design, miscalculation,
Parts need to be sent
Unexpected costs,
18
parts require hire precision the 1
out for machining
increased lead-time
RIT capabilities
Severity
Risk Assessment (cont.)
Likelihood
P12463 SDR
Action to Minimize
Owner
Adequate brainstorm and
decision process to
3
Andrew/Adam
accomplish function,
Consult faculty
Proper design and
calculation
3
3
1
proper mechanical design,
use system diagrams,
2
compare with other
existing solutions
Vulf/Mark
Adam/Mark
21
Project parts ordered
too late
Testing, integration
delayed, miss project
deadline
Design analysis miscalculation,
improper assumptions for
calculations
1
2
2
Use Gantt Chart to
monitor progress, double Mark/Andrew
check calculations
22
Inaccurate lead-time
from manufacturer
Parts arrive late, Testing,
integration delayed, miss
project deadline
Shipping delays due to holidays,
delays in RIT receiving
1
2
2
Give extra time for parts
to arrive, Use Gantt Chart Mark/Andrew
to monitor progress
23
Team dysfunction
Inability to divide out work,
decreased communication,
incomplete project
Different ideas, strong
personalities
1
2
Abide by Norms and
Mark/Project
2 Values, Consult individuals
Guide
if problem arises
2
Work with project guide
and customer to show the
2
efforts needed for a
successful project
May not finish project on
24 Project scope too large
time
Project improperly scoped
1
Mark
27
P12463 SDR
Questions? Comments?
28