P07441 Detailed Design Review - EDGE

P07441 Detailed Design Review Meeting Design Specifications 1. Capable of testing variable module length and width Design test stand mounting system to accommodate modules specified in the Engineering specifications. The optimal cooling area is large enough to accommodate the largest commercially available thermoelectric module, and will accommodate subsequent thermoelectric modules.

2. Capable of testing variable module thickness Design test stand mounting system to accommodate modules specified in the Engineering specifications. The clamping mechanism for the TEG is flexible enough to accommodate the height of any single-stage module. 3. Single Phase 120V Power Choose parts during design stage based on power demand to ensure power does not exceed breaker limit. Verify that the power consumption of primary and auxiliary components is well below the breaker limit. 4. Robustness: test stand can withstand max temperature Apply intense thermal load (hot side temperature 600 Celsius) via ANSYS, confirm with prolonged test at that temperature with a dummy thermal load (ceramic) 5. Record current Design LabVIEW system to accept current input, confirm with simulation data and test series on a dummy current load (ceramic). 6. Record voltage Design LabVIEW system to accept voltage input, confirm with simulation data and test series on a dummy current load (ceramic). 7. Modules can be compared to each other DAQ system outputs data in a format which allows the creation of IV curves for each module. 8. Modifiable ∆T, Thot, I, V Confirm that the temperature controller can change the power output of each heating element in addition to controlling the flow rate of the pump. 9. ∆T, Thot may be measured with a reasonable uncertainty Compare the FEA simulation of load with predicted temperature from the measured temperature gradient in heater block or dummy thermal load equipped with a surface thermocouple. Repeat experiment to determine the variation in measurement. 10. Provide heat flux for current modules Mount three thermocouples in parallel on the heating block and capture temperature information. Estimate the heat flux at the surface based on this information. 11. Provide heat flux for future modules Mount three thermocouples in parallel on the heating block and capture temperature information. Estimate the heat flux at the surface based on this information. Check against number indicated in engineering specification.

P07441 Detailed Design Review 12. Electrical power curves at different operating conditions Design LabVIEW to create power curves for each steady-state temperature achieved. Compare the measurements to published curves (where available) to confirm their accuracy. 13. System can test a reasonable number of thermal cycles Run twenty thermal cycles on a dummy thermal load within error tolerance. 14. Robustness: Electrical power components Choose components with appropriate lifetimes. Check for wear after tests are completed. 15. Robustness: structural Complete structural analysis on components at risk of failing from mechanical or thermal stresses. Inspect structural components between testing suites to ensure soundness. 16. Minimal time required to complete experiment FEA thermal simulation. Create system able to quickly heat and cool. Confirm with testing on cycle time. 17. Minimal setup Measure the time required to prepare for a particular test suite, and compare the recorded figure to the engineering specification. Confirm with testing on setup time. 18. Operators are shielded from electrical components All bear wires are isolated from human interaction while system is attached to power source. Design routing of wires carrying unsafe amount of electrical power such that the exposure is minimized. 19. Thermal isolation between hot surfaces and operator Design shielding for test stand. Test exterior temperature during entire thermal cycle. Design the system so that DAQ and test stand are separate entities. 20. Warning and hazard messages are mounted at appropriate locations Place warning signs at appropriate locations on test stand. Have a third party confirm the placement of safety messages. 21. DAQ system automatically conducts test once the system is setup. Design LabVIEW program to conduct tests automatically. Perform simulations to determine if the program works in the expected way. 22. Kill switches implemented in software and hardware Implement failure routines in LabVIEW which are automatically triggered when certain conditions are met. Have an easily accessible button on or near the test stand which terminates power to the heating side. The cooling side system should be powered from a different source to ensure operation while the heating side cools down.

P07441 Detailed Design Review 23. Test stand experiments are repeatable Conduct several experiments under the same operating conditions with different TEG’s of the same model number at different points in time. Compare the results from these experiments to confirm consistency. Contingency Plan: 4. Robustness: test stand can withstand max temperature Apply intense thermal load (hot side temperature 600 Celsius) via ANSYS, confirm with prolonged test at that temperature with a dummy thermal load (ceramic) Contingency: In case of failure, first examine analytical models that decrease the thickness of the plate in order to reduce maximum temperature around the heaters. If shortening the plate does not look viable, then look to a higher-temperature copper alloy, or metal (i.e. steel) to machine block out of. 8. Modifiable ∆T, Thot, I, V Confirm that the temperature controller can change the power output of each heating element in addition to the pump flow rate. Contingency: In case of failure, check to make sure that signal amplification is adequate. Otherwise, increment the flow rate manually. 9. ∆T, Thot may be measured with a reasonable uncertainty Compare the FEA simulation of load with predicted temperature from the measured temperature gradient in heater block or dummy thermal load equipped with a surface thermocouple. Repeat experiment to determine the variation in measurement. Contingency: In case of inaccurate measurements, embed a fine thermocouple in the heater block at the interface surface. 13. System can test a reasonable number of thermal cycles Run twenty thermal cycles on a dummy thermal load within error tolerance. Contingency: In case of failure examine replacing failed part with more robust part. 15. Robustness: structural Complete structural analysis on components at risk of failing from mechanical or thermal stresses Contingency: Re-design modular parts to be more robust. 16. Minimal time required to complete experiment FEA thermal simulation. Create system able to quickly heat and cool. Confirm with testing on cycle time. Contingency: Examine improving the thermal interface material or shortening the heater block.

P07441 Detailed Design Review 23. Test stand experiments are repeatable Conduct several experiments under the same operating conditions with different TEG’s of the same model number at different points in time. Compare the results from these experiments to confirm consistency. Contingency: If the repeatability is outside of thermoelectric specification errors, examine variability in the pressure mounting, or thermal interface material. If the variability is large due to either of the mounting issues, develop a more rigorous, fool-proof method of module mounting. The next facet to examine is the flatness of the heating block and cold plate. Additionally, the quality of the coolant, and the accuracy of the pump and fan can be examined to ensure steady, repeatable performance. This can be done by running the cooling system with a small thermal load and no thermoelectric. If the problem persists then the mounting issues can be ruled out as a source of variability and individual system components should be evaluated. The heater can be tested at low loads, stand alone with no cooling. Any individual component that appears to be the source of a large amount of variability should be re-designed. The modular nature of the system allows for relatively easy replacement. Enough copper and insulation has been purchased to make a second heating plate if necessary. Other components, like the cooling end can be purchased mostly “off-the-shelf”. Ambient conditions also may need to be checked (humidity especially for thermoelectrics) and possibly controlled.

DAQ BoardWater Tank

Pump

Cooling Plate

Heat Exchanger

T

TC4P-5

Computer/Lab View

P-19

P-20

P-30

Temperature Controller 2Power Controller 2

P-34

S-1S-2S-3

S-4

T

TC5

T

TC6

CV2CV2

S-5

S-6

P-35P-36S-7

S-8

Necessary?

CV3

Heating Block w/Heating

Elements

Cold Plate

TEG

Servo

Rheostat 1

TC1

TC4

CV1

DAQ & Control System Diagram

Temperature

Controller 1

Temperature

Controller 2

TC2

TC3

TC1

TC4

CV1

TC2

TC3

CV2

CV3

CV4

CV4

CV5

CV2

Inputs

Outputs

PCI Card Connector Block

CV5

Thermocouple Leads:

TC1 Thermocouple embedded in heating block



TC4 Thermocouple embedded in cold plate

TC5 Thermocouple mounted at inlet to cold plate

TC6 Thermocouple mounted at outlet of cold plate

Control Inputs:

CV1 Lead from current transducer

CV2 Control signal into Temperature Controller 2, which controls pump flow rate

CV3 Output signal from pump to DAQ

CV4 Input voltage into Servo controlling the rheostat

CV5 Control signal into Temperature Controller 1, which controls the hot side temperature

Selected Blocks:

Rheostat 1 Constant resistance; used as a safety mechanism

Rheostat 2 Variable resistance; used to produce IV curves at steady temperatures

Servo Control

Board

LabVIEW PCI Card

Voltage/Current

Transducer

Power

Controller 2

Power

Controller 1

Pump

Rheostat 2

TC5 TC6TC6

TC5

CV3

Week 6 Week 7 Week 8 Week 9 Week 10Week 5Week 4Week 3Week 2Week 1 Week 11

Engineering

Drawings

Final

Analysis

Final

Formal Eng. Specs.

Test Plan

Stage 2

Bill of Materials

Final

Detailed Design Review

LabVIEW

Backend

Stage 1

LabVIEW

Program

Stage 2

Contingency Plans

Stage 1

Contingency Plans

Final

Formal Eng. Specs.

Test Plan

Final

Satisfying Action

Items

Stage 1

BOM – Order

long lead time

items

Satisfying Action

Items

Final

Manufacturing

Plans

Stage 1

Manufacturing

Plans

Final

LabVIEW

Program

Stage 3

LabVIEW

Simulation Testing

Stage 1

LabVIEW

Simulation Testing

Final

Function and Perform

ance Review

BOM – Order all

necessary parts

Assembly (see

Google Docs)

Stage 1

Assembly (see

Google Docs)

Stage 2

Assembly (see

Google Docs)

Stage 3

Preliminary Module

Tests

Stage 1

Test Modules

Stage 2

Test Stand

Manual

Stage 1

Test Stand

Manual

Stage 2

Testing Procedure

Stage 1

Testing Procedure

Stage 2

Testing Procedure

Final

Test Stand

Manual

Stage 2

Technical Paper, Poster, W

ebsite Due

LabVIEW

Program

Final

Project Review

Test Modules

Stage 2

Validation &

Debugging

Stage 3

Technical Paper

Stage 1

Technical Paper

Stage 2

Technical Paper

Stage 3

Technical Paper

Final

ManufacturingThis part can be hand drilled to get the proper hole.It will have a screw that will go through the acme shafta 4-40 is the designated screw size

2

DO NOT SCALE DRAWING

6473K760

345

1

UNLESS OTHERWISE SPECIFIED:

OF 1:2

REVDWG. NO.

ASIZE

TITLE:

Senior DesignNAME DATE

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MFG APPR.

ENG APPR.

CHECKED

DRAWN

FINISH

MATERIAL

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TOLERANCING PER:

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1SHEET PROHIBITED.

DIMENSIONS ARE IN INCHES

TOLERANCES:

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APPLICATION

USED ONNEXT ASSY

PROPRIETARY AND CONFIDENTIAL

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BEND ANGULAR: MACH

FRACTIONAL

THE INFORMATION CONTAINED IN THIS

DRAWING IS THE SOLE PROPERTY OF

<INSERT COMPANY NAME HERE>. ANY

REPRODUCTION IN PART OR AS A WHOLE

WITHOUT THE WRITTEN PERMISSION OF

<INSERT COMPANY NAME HERE> IS

1

0.06R

0.46

0.37

R0.25

1.99

0.58

0.28

1.69

3.03

5 X 10-32 Hole

1.97

0.13 THRU

0.21

ACME 1/2-10

ManufacturingShaft needs to be cut off utilizing the portion of the non-threaded areaIn smaller diameter will be first, essentially starting from the top going Down. (lathe)The 10-32 holes will be cut first next ( Mill)After this the ends of the shaft will be cut to size and chamfers removed(lathe)

TWO PLACE DECIMAL

acme shaft .5-10

Steel

Senior DesignC.H.


SIZE DWG. NO.

AREV.

MATERIAL

FINISH

PROHIBITED.

COMMENTS:




1

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

DATENAME

OF 1SHEET




THREE PLACE DECIMAL

NEXT ASSY USED ON

APPLICATION DO NOT SCALE DRAWING


TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

SCALE:1:2

0

8.05

9.7

5

10.5

0

0

0.75

7.30

0.7

5

1/2-20 UNF - 2B 0.75

4x 0.45 1.15

2


Base Plate

345

1

C.H.


OF 1:5

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

Al 6061

FINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

1SHEET PROHIBITED.


TOLERANCES:

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY


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BEND ANGULAR: MACH

FRACTIONAL







1

0.75

Manufacturing This part is from the aluminum 1X2 foot section cut to a 12X11 sectionTwo sides should be faced off for reference surfacesPart should be machined to length (mill)Part holes should be drilled and taped (mill)Finish process hand (removal of sharp edges)

0

1.00

5.00

6.00

0

1.500

1.50

2.00

4.00

4.50

6.00

0

1.50

3.00

4.50

6.00

Senior Design

Top Ceramic InsulationBecause the ceramic is constructed of 1 inch pieces2 will have to be machined together one slab wouldBe required for each layer, this may have to be machinedSlow first to get it to size. Once it is the correct size (mill)The hoses will be dilled slowerly followed by tapingOnce the hole part is machined it must be essential heat treated

1


Bottom spring restraint

234

1


OF 1:2

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

CeramicFINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

1SHEET

5

THREE PLACE DECIMAL


TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

C.H.

2.00

1/4-20 UNC - 2B 0.508x 0.20 1.00

x 2 THRU ALL0.20

1.254 X

10-32 UNF - 2B 0.384x 0.16 0.50

0

0.80

0.05

0.55

0.60

0.75

0.37

Flange shaft Conector


123

1

C.H.


OF 2:1

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

ERROR!:Finish

ERROR!:MaterialFINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

1SHEET

45

PROHIBITED.

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY


TWO PLACE DECIMAL

BEND ANGULAR: MACH

FRACTIONAL

TOLERANCES:








2

10-32 Hole0.16

0.25

ManufacturingConstructed from the excess material of the main supports (2in)The part will be faced off to the correct length on each side (lathe)The holes where the shoulder bolts will be inserted should be drilled (mill)Next the outer features will be cut followed by the center hole (lathe)

0

1.00

5.00

6.00

0

3.50

4.00

0.500.50

0.20 THRU

1/4-20 UNC - 2B 0.502x 0.20 1.00

1.00

ManufacturingThis part will be donethe same as the top insulation portion

PROHIBITED.

5 4


TOLERANCING PER:

SCALE:

1


Front - Back insulation

MATERIAL

INTERPRET GEOMETRIC

TOLERANCES:

1

FRACTIONAL

OF 1:2

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

SHEET

ANGULAR: MACH

CHECKED

Ceramic

3


C.H.

1

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY


TWO PLACE DECIMAL

BEND

2

FINISH

DRAWN







2

"

0.94"

2.50

3/8"

Crank Handle

6473K76Aluminum

NUMBERPART

http://www.mcmaster.com© 2006 McMaster-Carr Supply Company

Unless otherwise specified, dimensions are in inches. Information in this drawing is provided for reference only.

3.49"

0

2.00

4.00

6.00

0

3.00

6.00

0

0.75

6.00

3.00

1.01

05.25

2.001.68

0.51

Manufacturing This part should be cut to the general size of the block (mill)Once this is done the holes can be drilled from the same setup. The top portions should be taped first and the holes for the Cartage heater drilled last.The final step is the surface finish of the section directly in Contact with the thermal electric

This drawing is subject to change dueto the change in electrical heaters

1/4-20 UNC - 2B 0.502x 0.20 0.65

3 X 0.25

2 X 0.04

.001

1

C.H.


Heating Block


SCALE1: 3

DWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

CopperFINISH

2

INTERPRET GEOMETRIC

MATERIAL

345

THREE PLACE DECIMAL

TOLERANCING PER:


TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

Senior Design

9.65

10

.85

1/4 Threaded

0.75

0.25

5.004.75

10-32 Thr

0.15

The ends will be cut to the proper outer diameter of a ¼ -20 thread (lathe)

Structure Support Shafts

The part will then be threadedFinish process to make sure it screws in tightly to the base and top

Manufacturing11 in sections will be cut form the main 2 foot stock (band saw)Both sides of the cut section will be faced off (lathe)

needs to be threaded from the bottom upThread lenght should be up to 3.4 inchesHowever this may need to be ajusted

Senior Design



Main support shafts

1:5

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

SteelFINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

12345

THREE PLACE DECIMAL


TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

C.H.

CHECKED

DRAWN

ENG APPR.

MFG APPR.

Q.A.

5 4 1

Senior Design

Pressure Concept

SHEET 1


SCALE: 1 OF 1:5

REVDWG. NO.

ASIZE

TITLE:

3 2

THREE PLACE DECIMAL

COMMENTS:

DATENAME


TOLERANCES:

FRACTIONAL

ANGULAR: MACH BEND

TWO PLACE DECIMAL

C.H.

17

18

1910

7

1215

11

20

8

5

14

26

1632421

23

27

22

9

4

Part discripton with numbers indicate McMaster specific part93615K16

Materials extimate from MetalsDepot.com Ultra-High Temperature Moldable Sheets

ITEMNO. PART Discription Cost

EachQTY.

1 Base Plate 86 12 cooling plate 350 13 TE 189 14 Top spring mount 50 1

5 Compressing Spring9588K21 7 4

6 Main support shafts 22 47 Top Plate 75 1

8 Nut and Flange95072A109

70 1

9 acme shaft .5-10 0 110 Bushing 2872T2 4 211 MSHXNUT 0.250-20-S-C 5 412 MSHXNUT 0.138-40-S-C 0 313 Bottom spring restraint 50 114 Flange shaft Conector 0 215 Al crank Handle 6473K76 23 116 7/8 Standard Connector 217 Aligning shaft 0 4

18 IN-HHMS0.138-40x0.75x0.75-C 0 2

19IN-HHMS0.138-40x1.25x1-C 0 1

20HX-SHCS0.25-20x1.25x1.25-N 5 4

21 Heating Block 475 1

22HX-SHCS0.25-20x2.25x1.25-N 3 2

23 pipe 224 Side insulation 225 Front - Back insulation 226 MSHXNUT 0.138-32-S-C 4

27HX-SHCS0.25-20x0.875x0.875-N 8

9/32" 3/16"1/2"

5/32"

1/8"

.138

#6-32 Thread

94045A529Precision Shoulder Screw

Type 18-8 Stainless Steel Phillips


http://www.mcmaster.com(c) 2003 McMaster-Carr Supply Company

NUMBERPART

0

2.00

6.00

8.00

0

4.00

3.50

0.20 1.00

1/4-20 UNC - 2B 0.50

2x

2 X 0.50

1.00

C.H.


Side insulation

123

1


OF 1:1

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

Ceramic

FINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

1SHEET

45

PROHIBITED.

THREE PLACE DECIMAL

APPLICATION

USED ONNEXT ASSY


TWO PLACE DECIMAL

BEND ANGULAR: MACH

FRACTIONAL

TOLERANCES:








2

Manufacturing (mill)Manufacturing of this will be the same as The top portion of the ceramic isolationNote there are two of these peaces whcihmust come from a single slab

Fits 1 1/4"Hole Size

Fits 5/8"Rod Size

1 1/2"

.286WireWidth

.200Wire

Thickness

9588K21Die Spring

Chrome-Silicon Steel


http://www.mcmaster.com(c) 2003 McMaster-Carr Supply Company

NUMBERPART

00.75

3.75

5.25

6.75

9.75

10.50

00.75

2.53

4.03

5.53

7.308.05

ManufacturingThis is from a 1 square foot steel sectionThis is purely millPart should be cut to length for over all dimensionsHoles are drilled then tapedFinal part is removal of chamfers

0.75 0.02

0.37 THRU

2


Top Plate

C.H.


3

1:5

REVDWG. NO.

ASIZE

TITLE:


COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

Steel

FINISH

MATERIAL

SCALE:

TOLERANCING PER:

INTERPRET GEOMETRIC

45

PROHIBITED.


TOLERANCES:

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APPLICATION

USED ONNEXT ASSY


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FRACTIONAL







1

THRU ALL4 0.45

THRU ALL0.37

x

4x 0.16 THRU ALL

0.50

0

1.00

3.55

2.50

3.55

4.00

5.00

0

1.00

1.46

5.00

2.50

4.00

1.46

0

2.50

1.00

4.00

1.46

4.00

5.00 0

2.50

3.55

1.001.46

3.55

5.00

Senior Design

Top Spring MountManufacturingThe top spring mount is a peace form the 1X2 foot section (mill)It will cut with .5 inch of leeway. This is purely a milling processOnce the edges are defined the holes can be drilled and taped

2 1


Top spring mount

3

TOLERANCES:

1:2

REVDWG. NO.

ASIZE

TITLE:

NAME DATE

COMMENTS:

Q.A.

MFG APPR.

ENG APPR.

CHECKED

DRAWN

AL 6061FINISH


SCALE:

MATERIAL

45

PROHIBITED.


TOLERANCING PER:PROPRIETARY AND CONFIDENTIAL

THREE PLACE DECIMAL

APPLICATION

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BEND ANGULAR: MACH

FRACTIONAL

INTERPRET GEOMETRIC







C.H.

0.75

0.53

1.25

THRU

3 X

0.20x THRU ALL1/4-20 UNC - 2BTHRU ALL

4

1.28 0.130.16 THRU

4 0.20 THRU ALLx

THRU ALL

1/4-20 UNC - 2BTHRU ALL

4x 0.16

0.53

Documents

P07441 Detailed Design Review - EDGE