Transcript MSR

MEDUSA
Methane Engine Design for Unmanned Small Aircraft
Manufacturing Status Review
University of Colorado at Boulder
02/03/2015
Customer: Dr. Ryan Starkey
Daniel Frazier
Christopher Jirucha
Alexander Truskowski
Team
Nathan Genrich
Crawford Leeds
Carlos Torres
Advisor: Dr. Jelliffe Jackson
Abram Jorgenson
Huikang Ma
Corey Wilson
1
Outline
2
• Overview
• Schedule
• Manufacturing
• Mechanical
• Electrical
• Software
• Budget
Project
Overview
Project Overview
and Schedule
Christopher Jirucha
Mechanical
Alexander Truskowski
Electronics
Nathan Genrich
Software
Crawford Leeds
Budget
Crawford Leeds
Mechanical
Electrical
Software
Budget
Project Statement
3
Project Description: Modify a JetCat P90-RXi mini turbo jet engine to
run on gaseous methane fuel to address the USAF’s interest in the
possible use of the methane gas as fuel.
Functional Requirements
Engine Control Unit
(ECU)
Fuel Delivery System
(FDS)
Project
Overview
Start, run, and shut down engine
Maintain JetCat recommended safe operation conditions
Log data
Deliver up to 4.2g/s of methane to combustion can
Deliver kerosene/oil mix to bearings at stock rates
Mechanical
Electrical
Software
Budget
Project CONOPS and Objective
RC Signal
RC Receiver
4
Current Stock Engine: JetCat P90-RXI
JetCat
ECU
RPM and Temperature
from Engine Sensor
Board
Commands to
pump/solenoids
Injection point
RPM < 130,000
Shaft
Lubrication Line
Kerosene
Fuel/Lubricant
Exhaust
Temp < 700oC
Project CONOPS and Objective
Mass Flow Safety
Controller Valves
Commands to Controller
Student
ECU
Fuel
Commands
to
RPM and Temperature
Manifold
pump/solenoids
from Engine Sensor
Board
5
Pressure
Regulator
Methane Tank
RPM < 130,000
Student
Engine
Board
Six Student
injectors
Exhaust
Temp < 700oC
Fuel System
RC Controller
Methane
Tank
(175 ft3)
Startup
Command
Thrust
Command
Shut down
Command
Kerosene
Tank
Fuel Pump
Lubrication
Solenoid
Engine
0-12V
Data Logging
9.9V, PWM
Input Receivers
Command
Outputs
Provided
Purchased
Designed
Lubrication System
ECU
Logic
Algorithms
Physical Contact
Electrical Signal
Data
0.9 - 4.2 g/s
Mass Flow
Controller
Throttle
Start
Stop
PWM
Key
Starter
Motor
Injectors
Combustion
Compressor Bearings
Can
Turbine
Nozzle
Injectors
T5 < 700oC
0-2500 Hz
Square Wave
Differential
Amplifier
3.6V, 14.4 W
0-3.3V
Amplification
Cold Junction
Compensation
6
7
SCHEDULE
8
MEDUSA Original Work Plan (CDR)
Week 1
Where We Are
Week 10
Week 15
Original
phase I plan:
CurrentECU
Plan:
Electronics: Prototype finished during break
Move two weeks from “Modified Engine
Integration and Testing” to ECU phase I
Software: Coding finished during break
Electronic and software testing begins right
after break
ECU phase I
ECU
MSR
FDS
Engine Integration
Engine Repair
Milestone
Uncertainty
TRR
SFR
MEDUSA Current Work Plan
Where We Are
Week 6
9
Week 10
Week 12
Week 14
I:III:
ECUPhase
Phase
II:Test:
FDS
II:
Final
System
ECU
components
ordered
andcompleted
received
ESB component
manufacturing
completed
FDS
tests
completed
and
ECU
manufacturing
complete
Modified
engine
integration
ECU
&
ESB:
Prototype
manufactured
Electronic
Software integration
requirements
verified
and
testedand
individually
FDS
components
manufactured
completed
ECU
and ESB
verified
and
ready
Modified
engine
test
completed
and
Software:
All board
code
completed
and
ECU
Prototype
passed
engine
Lubrication
experimental
test simulator
to
integrate
with
the modified
engine
requirements
verified
tested
individually
test, requirements
verified
completed
and lubrication
data
LabVIEW:
LabVIEW
code completed
collection
and
testedcompleted
individually
ECU phase I
Spring Break
ECU phase II
Electrical
Software
MSR
Labview
ECU Integration
Fuel Delivery
Lubrication
Engine Integration
ECU phase III
FDS phase I
TRR
Final system Test
FDS phase II
SFR
10
MECHANICAL SYSTEMS
Mechanical: Design Overview
11
• Piping system with control valves
• Deliver methane to injectors
• Wood test stand will be rebuilt
• New rear mounted fuel injectors
• Deliver methane to combustion
chamber
Project
Overview
Mechanical
Electrical
Software
Budget
12
Mechanical- FDS Test Stand Status
Item
Status
Pressure Regulator
Purchased
Pressure Relief Valve
Received
Mass Flow Controller
Received
Fuel Manifold
Received
Check Valve
Received
Shutoff Solenoid
Received
Wood Test Stand
Parts Purchased
Pipes and fittings
Received
Methane
Local and in stock
Deadline Feb 12
5 Hours Remaining
Project
Overview
Mechanical
Electrical
Software
Budget
13
Mechanical- Fuel Injectors Status
Mounted Injector
Item
Status
1mm Tubing
Purchased
Internal Nut
CAM Designed for
manufacture
Washer
Manufactured
Prototype
Nozzle
Manufactured
Prototype
Stainless Steel
Elbow/Adaptor
Purchased
Deadline Feb 22
30 Hours Remaining
Project
Overview
Mechanical
Electrical
Software
Budget
Mechanical: Work Overview
14
Component Action Item
Start
Fuel
Delivery
1/1
Complete
2/2
Purchase materials for wood test stand 1/1
Complete
2/2
Purchase pipes and valves
Fuel
Injectors
Status
Deadline
Build wood test stand
1/20
Assemble test stand and mount
controllers and piping
2/1
Full FDS and fuel inject integration
2/1
2 Hours Remaining
2/7
Internal nut prototype
1/20
10 Hours Remaining
3/1
Washer prototype
1/20
3 Hours Remaining
2/20
Nozzle prototype
1/1
8 Hours Remaining
2/20
Braze 1mm tubing to nozzle
2/2
4 Hours Remaining
2/20
Where we are 2/20
1/1
Purchasing
Assembly & Manufacture
Project
Overview
Mechanical
2/7
3 Hours Remaining
10 Hours Remaining
3/1
3/22
All Manufacturing Complete
Electrical
2/7
4/19
All Testing Complete
Software
Budget
15
ELECTRICAL SYSTEMS
Project
Overview
Mechanical
Electrical
Software
Budget
Electrical: Design Requirement
16
Engine
Control
• ECU Board
Unit
• Receives signals from sensor board
• Commands Mass Flow Controller
• Sends signals to pump and solenoid
Project
Overview
Mechanical
Electrical
Software
Budget
Electrical: ECU Board Status
• ECU Board:
LED’s
Component
Assembly
Isolated
Testing
Full Load
Testing
LED Drivers
Complete
Complete
Not Started
RS232 Drivers
Complete
Complete
Not Started
RS232 Receivers
Compete
Complete
Not Started
RS232 Connector
Compete
Complete
Not Started
RS422 Drivers
Complete
Complete
Not Started
RS422 Receivers
Complete
Complete
Not Started
Dual Comparator
Complete
Complete
Not Started
Jan 1
17
5 Hours Remaining
Dual Comparator
RS422 Drivers
LED Drivers
RS-232 Driver/
Receiver
RS422 Receivers
Feb 22
Microcontroller
Project
Overview
Mechanical
Electrical
Software
Budget
Electrical: Design Requirement
18
• Engine Sensor Board
• Reads thermocouple and RPM
Sensors
• Sends signals to ECU
Engine
Sensor
Board
Project
Overview
Mechanical
Electrical
Software
Budget
Electrical: ESB Board Status
• Engine Sensor Board:
19
LDO Regulators
Component
Assembly
Isolated
Testing
Full Load
Testing
Thermocouple IC
Complete
Complete
Not Started
LDO Regulators
Complete
Complete
Not Started
RS 422 Drivers
Compete
Complete
Not Started
RS 422 Receivers
Complete
Complete
Duel Comparator
Complete
Complete
Not Started Thermocouple IC
Not Started
RS422 Drivers
High Side Drivers
Complete
Complete
Not Started
Jan 1
5 Hours Remaining
Project
Overview
Differential
Amplifier
RS422 Receivers
RS422 Receiver
Feb 22
Mechanical
High Side Drivers
Electrical
Software
Comparator
High Side
Drivers
Budget
Electrical: Work Overview
20
Action Item
Start
Breadboard Assembly
1/1
Complete
2/1
Individual Component Tests
2/1
Complete
2/5
Isolated Full Load Test
2/6
15 Hours Remain
2/22
Integrate ECU and ESB
2/23
10 Hours Remain
3/15
Manufacture PCB Boards
3/15
1 Week Turnaround
3/22
Integrate With Engine Controls
3/15
15 Hours Remain
3/22
PCB Boards Rev 2
3/22
1 Week Turnaround
3/29
Run with MatLab Simulator
3/22
15 Hours Remain
4/5
Software must be done
Run with actual Engine
4/5
15 Hours Remain
4/19
Difficulty just running on
kerosene
1/1
Status
Deadline Concerns
Where we are 2/22
Breadboard
Project
Overview
Full Load
Mechanical
3/15 3/22
ECU& ESB
Electrical
Most bugs will occur here
4/5
4/19
Controls Simulation Engine Testing
Software
Budget
21
SOFTWARE
ECU Software: Overall Design
22
• 5 Critical routines – same as CDR
• Engine Maintenance (CR.1)
• Check for extremes
• Engine Start Up (CR.2)
• Start the engine from user input
• Engine Shut Down (CR.3)
• Shut down the engine from user input
• Engine Running (CR.4)
• Allow throttle control
• Emergency Shut Down (CR.5)
• Shut down engine in case of extreme
Project
Overview
Mechanical
Electrical
Software
Budget
ECU Software: Status
23
Item
Start
Familiarize with IDE
1/1
Program the Chip
1/15
Complete
1/25
Basic I/O (LED Blink)
1/15
Complete
1/25
Interrupt Modules
1/25
40 Hours Remain
2/20
Logic Template
2/1
10 Hours Remain
2/20
Compartmentalized Testing
1/20
2/20
Integrate Software
2/22
20 Hours Remain
20 Hours Remain
3/7
Minimal
Simulator Testing
3/8
10 Hours Remain
3/22
Software Bugs
Test Review
3/22
4/19
Glitches during full engine test
1/1
1/25
Status
Deadline
Concerns & Notes
1/20
Longer than expected. 2 weeks
behind CDR expectation.
Complete
N/A
Where we are 2/20
Familiarization
Individual Modules
Project
Overview
Mechanical
3/7
3/22
Integration Simulation
Electrical
High Risk
4/19
Engine Testing
Software
Budget
24
BUDGET
Project
Overview
Mechanical
Electrical
Software
Budget
MEDUSA Budget
25
Testing
Expenditures Through 2/2/15
$149.27
$111.20 Shipping & Other
$350.00
Remainder FDS
$726.75
$2,697.22
Margin
$1776.75
FDS
Unspent
$700.00
Remainder ECU
$265.56 ECU
ECU
FDS
Testing
Shipping & Other
Remainder ECU
Remainder FDS
Remainder Testing
Total used = $ 3223.25
Total remainder = $ 1776.75
Project
Overview
Electrical
Mechanical
Software
Margin = $726.75
Budget
MEDUSA
Methane Engine Design for Unmanned Small Aircraft
Manufacturing Status Review
University of Colorado at Boulder
02/03/2015
Customer: Dr. Ryan Starkey
Daniel Frazier
Christopher Jirucha
Alexander Truskowski
Team
Nathan Genrich
Crawford Leeds
Carlos Torres
Advisor: Dr. Jelliffe Jackson
Abram Jorgenson
Huikang Ma
Corey Wilson
26
27
BACKUP SLIDES
Spring Work Plan (Worst Case)
28
Where We Are
MSR
TRR
SFR
29
Verification and Validation
57
FDS V&V: Fuel Delivery System
Purpose
Pressure
Relief
• CPE3: Verify FDS delivers up
to 4.2g/s of methane
•
Methane
Use
Tank full
Pressure
Relief Valve
Pressure
FDS
system
Regulator
Shutoff
Solenoid
• Inject into pressure vessel
Fuel Manifold
Pressure
Controller
Injectors
Check
Valve
• Measure mass flow
• Pressure vessel simulates
engine pressures
• Relief valve keeps constant
pressure
• Perform test across range
of safe pressures
Pressure
Transducer
2L Pressure
Vessel
FDS V&V: Lubrication System
Purpose:
• CPE 4:Verify Stock lubrication
conditions maintained
Pump fuel and lubricant into
graduated cylinders
Compare with flowmeter values
from engine tests
58
32
Lubrication Test
Purpose:
• Acquire stock lubrication rates
Flowmeter
Pump
Fuel Solenoid
Concept
• Run engine with two flowmeters
• Use difference in measurements
Flowmeter
Lube Solenoid
ECU Verification & Validation Overview
Purpose:
• Verify the student built ECU
behaves as expected based on
ECU requirements
Equipment Needed:
• Engine Simulator: Provide
simulated engine data to the
ECU.
• LabVIEW: Monitoring the output
signals and verify the data rate
• Matlab: Provide digital data for
engine simulator and data
analysis
Engine Simulator
LabVIEW Based
59
LABVIEW
Verify Command Output
1. Starter Signal
2. Glow Plug Signal
3. Flow Controller Signal
4. Lubrication Signal
1. Exhaust Temp
2. RPM Data
Input
Student Build ECU
1. Exhaust Temp
2. RPM Data
LABVIEW
Verify Data Rate
1. ON/OFF Commands
2. Throttle Level
Spektrum DX7 Controller
Send Commands
Output
60
ECU V&V: ECU Commanding Test
Purpose:
• CPE 5, 6, 7: Verify student build ECU can
receive intended commands from RC
controller and send intended commands to
different engine components
Verify ECU sends intended commands to engine
components with LabVIEW
Starter signal: 0 - 10V
Glow plug signal: 0 - 10 V
Mass Flow Controller Signal: RS232
Pump signal: PWM
Lub. Solenoid signal: Variable Frequency Signal
LABVIEW
Verify Command Output
1. Starter Signal
2. Glow Plug Signal
3. Mass Flow Controller Signal
4. Lubrication signal
Student Build ECU
1. ON/OFF commands
2. Throttle Level
Spektrum DX7 Controller
Send Commands
61
ECU V&V: Data Collection Test
Purpose:
• CPE 8: Verify student build ECU can collect
and store the data at intended data rate
Using Engine simulator to provide simulated
engine data to the ECU
Measure data stored, Verify recording rate
RPM desired data rate = 475 Hz
Thermocouple desired data rate = 11.37 Hz
Engine Simulator
LabVIEW Based
1. Simulated Exhaust Temp
2. Simulated RPM data
Student Build ECU
USB
1. Digital Exhaust Temp
2. Digital RPM data
LABVIEW
Verify Data Rate
ECU Software: Detailed Status
Interrupt/PWM Based Modules
Digital I/O Modules
RPM Sensor Read
Lubrication Solenoid
Pump Motor Driver
Starter Motor
RC Controller Input
Glow Plug
Start/Stop Button
40 man hours total before 2/20/2015
36
Asynchronous Serial Comm
RS-232 to Mass Flow Controller
RS-232 to Computer (testing only)
Project CONOPS and Objective
RC Signal
RC Receiver
37
Current Stock Engine: JetCat P90-RXI
JetCat
ECU
RPM and Temperature
from Engine Sensor
Board
Commands to
pump/solenoids
Injection point
RPM < 130,000
Shaft
Kerosene
Fuel/Lubricant
Lubrication Line
Exhaust
Temp < 700oC
ECU Software: Required Functionalities
Digital I/O Modules
Digital Control
of the Glow
Plug
Digital Control
of the Starter
Motor
Digital control
of the
Lubrication
Solenoid
Digital control
of the Shutoff Valve
WORK IN PROGRESS
These are the usercommanded inputs.
They are required to
actively control the
engine.WORK IN PROGRESS
DONE with the
These are required to
ability to control
run the engine safely.
the digital output
RPM sensor read test
of
pins
User Control ModulesDONE.
PWM input:
RC
Controller
RS-232
Control of
Mass Flow
Controller
Interrupt Driven
Modules
PWM control
of the Fuel
Pump for
Lubrication
Use ADC to
read the
Thermocouple
PWM Input:
RPM Sensor