Transcript CDR October 9, 2008 Mike Oertli Jonathan Karnuth Jason Rancier Division of Labor  Mike O.  Program MCU  Matlab interface  Jonathan K.  Construct rails  Assist.

CDR
October 9, 2008
Mike Oertli
Jonathan Karnuth
Jason Rancier
Division of Labor
 Mike O.
 Program MCU
 Matlab interface
 Jonathan K.
 Construct rails
 Assist in control system design and coding
 Jason R.
 Construct capacitor array
 Design voltage sensors
Block Diagram
Pneumatic
Starter System
Keypad
Inductor
Railgun
Voltage
Sensor
Encoder
Capacitor
Array
Power
Supply
Voltage
Sensor
Kill
Switch
MSP430F169
LEDs
LCD
Budget
Item
Qty. Needed Cost Per Total for item
Brass Rails (36")
2
58.68
117.36
Garolite G-10 (39")
1
92.16
92.16
Teflon (12")
6
9.21
55.26
Aluminum (12")
2
17.41
34.82
50 Donated
0.00
Capacitors
PCB
2
33.00
66.00
Microcontroller
2
0.00
0.00
Air compressor
1
56.10
56.10
Air tank
1
62.00
62.00
Solenoid Valve
1
170.00
170.00
Pressure Regulator
1
35.00
35.00
Transformer
1
100.00
100.00
Plastic housing
1
50.00
50.00
Sensors/Miscellaneous
Grand Total
200.00
1,038.70
Safety Features
 Voltage sensors on rails, cap bank, & source
 Kill power if out of expected range
 Plexiglas casing
o Keep user isolated from high voltages and short
circuited rails
 Pressure Regulator
o Added ability to safely release tank pressure
Power System Diagram
Capacitor Battery
 50x 450V 3.7mF Capacitor
 Donated by CDE
 Array of 3 banks of 16 in parallel
 Overall: 1350V ~ 20mF
Capacitor Battery
Basic Charger
Power Parts
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2x 200KOmh @ 3W
1x 800Omh @ .25 W
50x 100kOmh @ 3 W
3x 22KOmh @ 50 W
1x 120V 15 Amp AC switch
1x Fuse Holder 120VAC
1x 1600v Power Diode
2x High Voltage Switch(1000V)
1x Microwave Transformer
1x Variac Variable Transformer
Copper Plate
Plexiglass Box
Cylindrical Rail Design
Design Difficulties
• Material Tolerances
• Material Loss
• Toxic materials
• Difficult to machine at
desired barrel length
Efficient Design method
• Maintain physical contact
despite material disintegration
Machined & Fabricated Parts
Compressed Air Injector Adapter
Injector Adapter Drawing
Brass Rails
 Composite: ~70% Copper, ~.07% Lead, ~.05% Iron,
Remainder Zinc
 Electrical Conductivity: 28% IACS
 Electrical Resistance: 6.2µΩ/cm
 Friction: Very low with Most metals
 Melting Point: 910oC
 Inner/Outer Diameter: 0.87”/1”
Projectile
 Metal: Aluminum
 Composite: 2011
 Temper: T3
 Part #: 88615K411
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Melting point: 540oC
Electrical Conductivity: 45% IACS
Electrical Resistivity: 3.8µΩ/cm
Diameter: 7/8”
Length: ~1”
Pneumatic Kick-start
 Avoids spot welding projectile
 Added kinetic energy
 Eliminates static friction coefficients
 Compressed Air system
 Activated by Microcontroller post safety checks
 Additional safety with inclusion of Pressure Regulator
Injection System
Complete System
 Compressed Air Tank
 Compressor
 Solenoid Valve
 Ball Valve
 Pressure Regulator
 Manufactured Parts
 Railgun Adapter
 Tank Adapter
 Compressor Adapter
Electromagnetic Solenoid Valve
Pressure Regulator
Features
 High Pressure capabilities
 Very Low Flow
 1/150 Flow of the Solenoid (.06 Cv)
 Adjustable Pressure Range
 Low leakage Value
 3600 Psi Capabilities
Chassis Specs
Inner Support Outer Sheath
Composite
Teflon PTFE
Grade G-10/FR4
Crosswise Tensile
Strength
3,900 PSI
35,000 PSI
Melting Point
335oC
~384oC Max Temp
Dielectric Strength
19.7MV/m
15.7MV/m
Inner/Outer
Diameter
.875”/1”
1”/1.375”
Cost
$9.21 per 12”
$92.16 for 39”
Part #
8547K29
8668K49
Parts List- Control System
 Voltage Sensor
 MM74C922 16 key encoder
 Keypad, 3-line LCD
 Master kill switch
 “Hot” switch
Parts List- MCU
 MSP430F169
 2 ADC
 1 RS232
 Voltage regulator
 LEDs
Interfaces
MSP430F169
MSP430F169
MSP430F169
RS232
Matlab
Wire-wrap/Solder
Wire-wrap/Solder
Key Encoder
3-Line LCD
P6 I/O (ADC)
MSP430F169
Voltage Sensor
Wire-wrap/Solder
Keypad
Keypad Pin Layout
1
2
3
4
5
6
7
13
12
11
10
9
8
Truth Table
Pins 2
1
3
14
5
4
12
13
1
2
3
ST
4
5
6
PT
7
8
9
TI
CL
0
FX
PI
14
Key Encoder
 MM74C922
 16 Key
 Debounce
 Continuous row scan
Keypad & Encoder Schematic
Keypad Demo
Software- MCU
 Language: C++
 Inputs: Keypad (via encoder chip on P1), voltage
sensors (1 on ADC on P6, 2nd via off board ADC),
power (6V)
 Outputs: 3-line LCD (P2), Matlab (RS232), capacitor
charging control (switch based on sensors), safety/kill
switch
MCU Logic
Software- Matlab
 Plot time domain analysis of sensor readings
 Keep test-run information
 Inputs: Data from MSP
 Outputs: GUI showing data
 Interface: RS232
Questions?