04013 Micro Turbine Senior Design Micro Turbine Senior Design PDR – May 20 th, 2004 Project 04013

Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013

Micro Turbine Senior Micro Turbine Senior DesignDesign

PDR – May 20PDR – May 20thth, 2004, 2004

Project Project 0401304013

0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign

Meet The TeamMeet The Team

Donald Slate (ISE) Lucas Lessa (ISE) Ream Kidane (EE)

Simien Lin (ME) – Project ManagerSimien Lin (ME) – Project Manager

Chuck Daze (ME) – Lead EngineerChuck Daze (ME) – Lead Engineer

Matthew Davis (ME) Meg LaRochelle (ME) Thomas Cague (ME)

Dr. Kozak – Faculty AdvisorDr. Kozak – Faculty Advisor

Dr. Hensel – Faculty CoordinatorDr. Hensel – Faculty Coordinator


Presentation Presentation LayoutLayout

Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary


OVERVIEWOVERVIEW


PurposePurpose Micro Air Vehicle

Surveillance purpose Approx. 90 grams.

Use of batteries for electrical power.

Search for lighter power source.

Courtesy of Dan Holt


BackgroundBackground Micro Turbine Project Overall Scope

Replace BatteriesMount onto MAV

Last year’s design – Proof of concept was successful18 watts of power100 grams


Design ObjectivesDesign Objectives

Refine Micro Turbine More feasible for

MAV applications 18 watts down to 5 100 grams down to 40

Courtesy of www.symetrics.com


Turbine Turbine DesignDesign


Concept Concept DevelopmentDevelopment

Pel

ton

Impu

lse

Axi

al I

mp

ulse

Rad

ial O

ut-

Flo

w

Rad

ial I

n-F

low


Turbine FeasibilityTurbine Feasibility


Final Turbine Final Turbine DesignDesign

8 Blades

Overall Dia. – 5/16”

Pitch Dia. – 0.27”

Blade Height – 0.05”


Turbine Design Turbine Design ValidationValidation


Housing Housing DesignDesign


Housing Design Housing Design ConceptsConcepts

Con

cep

t 2

Con

cep

t 3

Con

cep

t 1

Con

cep

t 4


Housing – Pugh’s Housing – Pugh’s WeightedWeighted


Final Housing Final Housing DesignDesign

1.75”1.75”


Housing Design Housing Design DetailsDetails Attributes

LightweightEqually Split Flow ChannelMinimized Flow Restriction Two inlets, Two ExitsImproved Alignment


Lightweight Lightweight MaterialMaterial Objective: To create housing from the

lightest material that will meet specifications.

Solution: MDS-Filled Cast NylonProperties

Tensile Strength 11,000 psi Good Manufacturability (ductility) Enhanced Pressure/Velocity Capabilities

Resulting Weight Total System weight < 44 grams


Flow ChannelsFlow Channels Objective: To direct airflow to turbine with

minimum pressure loss.

Solution: Curved channel, cylindrical shellProperties

Reduced sharp turns/losses Equivalent flow channels/velocities

Calculated Head Loss Total Head Loss = 9.1%


ComponentsComponents


Housing Assembly Housing Assembly


Housing Housing ComponentsComponents Screw Selection

Resulting force calculatedScrew selected provides a F.O.S over 4

SealsStepped design provides for gasket

compression. Alignment

Cap/Shell design provides accurate alignment


Shaft to Shaft Shaft to Shaft CouplingCoupling

Previous CouplingDuct Tape

Belgian Group CouplingShrink Tubing~1% Power Loss

Original ConceptSingle Piece CouplingPurchased Coupling


Coupling Coupling CompaniesCompanies Manufactured Micro Couplings

NBKRelianceBellows


Coupling SelectedCoupling Selected Final Concept

Rigid Shrink Tubing InexpensiveLightweightSimple Assembly, Disassembly


Turbine ShaftTurbine Shaft Original Concept

Stainless Steel Micro Shaft0.059 in diameter, .8064” in length

14200

14400

14600

14800

12000 13000 14000 15000

Rad/Sec

Str

ess

(psi

)


BearingsBearings Previous Design Problems Possible Solutions

Air BearingsMagnetic BearingsSealed Bearings

Selected Bearings

Courtesy of NMB Minebea Co.


HousingHousingFinite Element Finite Element

AnalysisAnalysis


Finite Element Finite Element AnalysisAnalysis

Modeled with Worst Case Scenario Loads Used a Minimum of Stability Points Results

Sufficient Margin of Safety


Housing – Top viewHousing – Top view2.46E+2

2.21E+2

9.83E+1

7.36E+1

2.93E+1

2.47E+1

2.46E+2E-1

1.23E+2

1.47E+2

1.72E+2

1.96E+2


Housing – Housing – Side/Inlet viewSide/Inlet view

Max Stress: 286 psi

2.46E+2

2.21E+2

1.96E+2

1.72E+2

1.47E+2

1.23E+2

9.83E+1

7.36E+1

2.93E+1

2.47E+1


DeflectionDeflection2.46E+2

2.21E+2

9.83E+1

7.36E+1

2.93E+1

2.47E+1

2.46E+2E-1

1.23E+2

1.47E+2

1.72E+2

1.96E+2

Max Deflection: 1.66E-4”


System System DesignDesign


MotorMotor Motor Selection

ConsiderationsSpecs

Min/Max RPM Output Power

Direct driveThree-Phase Brushless PM DC

Motor/Generator


Motor Simulation - Motor Simulation - SimulinkSimulink

Matlab Parameters Easily modified


Measurements/Measurements/TestingTesting Initial design

Closed loop feedback controlFeasibility

Final DesignOpen loopMeasurements

LabviewData Acquisition


Data AcquisitionData Acquisition Inputs

Temperature Pressure Flow Current Voltage

Output Efficiency Power


Testing SetupTesting Setup

Servo Valve

Generator


Closing Closing RemarksRemarks


Proposed ScheduleProposed Schedule


BudgetBudgetComponent Description Price per Qty Line Price

Mini Stainless Steel Shaft 3.93$ 2m 1 3.93$

Vegetable Fiber Gasketing 9.64$ 5' 1 9.64$

Female Threaded Hex Standoff 1.27$ each 4 5.08$

Black Nylon 6/6 Nut 5.15$ 50 1 5.15$

Nylon Cheese Head Screw 5.39$ 100 1 5.39$

Polyolefin Adhesive Lined Shrink Tubing 5.03$ 4' 1 5.03$

Turbine 120.00$ 1 120.00$

Housing Fabrication 320.00$ 1 320.00$

General Purpose High Strength PVC Tubing 0.20$ 1' 25 5.00$

Male Compression Fitting 0.81$ each 2 1.62$

Female Compression Fitting 1.22$ each 2 2.44$

Turbine 120.00$ each 1 120.00$

Motor Bolt (Zinc-plated steel M1.6x6) 4.96$ 100 1 4.96$

Pressure Transducer 149.00$ each 1 149.00$

Flow Sensor 200.00$ each 1 200.00$

Servo Valve 1,000.00$ each 1 1,000.00$

Housing

Tubing

Electrical

Overall Cost = $1,957.24


SummarySummary Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary


Thank You AllThank You All QUESTIONS?QUESTIONS?


Cap – Side ViewCap – Side View


Housing CapHousing Cap1.13E+3

7.89E+2

1.01E+3

9.02E+2

6.76E+2

5.64E+2

4.51E+2

3.38E+2

2.26E+2

1.13E+2

2.83E-1

Max Deflection = 3.89E-6

Documents

04013 Micro Turbine Senior Design Micro Turbine Senior Design PDR – May 20 th, 2004 Project 04013