Faculty Guide: Ed Hanzlik Sponsors: Dr. Mario Gomes EPA P3 Project - - PowerPoint PPT Presentation

William Lentlie – Project Leader (ME) Tim Buckner – Lead Engineer (ME) Hope Alm – Mechanical Engineer Shauna Traxler – Mechanical Engineer Andres Santizo Matheu – Industrial Engineer

Faculty Guide: Ed Hanzlik Sponsors: Dr. Mario Gomes EPA P3

• Project overview
• System design
• Actual design summary
• Testing
• Conclusions
• Recommendations
• Questions

http://www.cityofsouthlake.com/waterconservation

• To build a small scaled version of tethered

hydrofoil to compare with a simulation provided by Dr. Mario Gomes in MATLAB.

• Create a tow tank capable of moving a platform

at a constant specified speed over the top of a stationary body of water in order to recreate a river flow passing over a hydrofoil.

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Importance Description How its being Accomplished 9 Tow tank must be able to tow a platform above the surface of a stationary body of water at a constant speed Tank size meets specification Motor Speed controlled with driver Driver has different speed ranges Calculated from F=ma+Fdrag 3 The platform must allow an attachment of two different instrumented systems, a set of stationary hydrofoils and a model of a translating hydrofoil system Tank size meets specification Tank weight is below required by floor Interface allows for different attachments 9 Tow length needs to be large enough to achieve steady state Tank size meets specification Tank length = 16ft Driver will control speed and accel/decel can be set for 0-30sec 9 System size should allow for appropriately scaled model testing Tank size meets specification Total approximate weight = 150lbs Calculated from F=ma+Fdrag 3 Platform should be above or to the side of the water with no moving parts under water Cart has multiple attachment points

Importance Description How its being Accomplished 9 Platform must allow for bolting of the instrumented model away from the wall of the tank Cart has multiple attachment points 9 Measurements should be of high quality and should be made with appropriate sampling rates and resolution Encoder, DC driver speed sensor Deflection calculations performed in ANSYS Measurement device should match specification DC drive accuracy ± 1/2 rpm, encoder mounted Measurement device should match specification Measurement device should match specification Timed in Labview 9 The tank must be safe for the operator and those around them Ergonomics was considered in the height of tank 9 The tank must not damage the surroundings Membrane or sealant will be used to stop leaks 3 The tank must be cost effective Cost meets budget 3 Easy to use and to train new users Labview useability will be a priority Users Manual / Video will be provided 9 Tank should not interfere with operation of models P12463 is aware of the size constraints

Specification Value Size <= 19ft in length and 50in in width Weight 300 lbf/ft^2 System Cost < $2000 Distance Cart Travels 16ft Velocity of Cart 3.28 ft/s Towing Velocity Variation 0-3.28 ft/s Towing Force 60lbs Max Sideways Deflection of Rail System 1/32" Center of Platform From Edge of Tank 1 <= 8 in Data Sampling Rates 500 Hz Resolution of Velocity Data (0.032 +/- 0.164) ft/s Resolution of Force Data (.1 +/- .2) lbf Resolution of Distance Data (3/8 +/- 1 7/8) in Resolution of Time Data (0.001 +/- 0.01 s) Setup Time (By User) < 30 min Can Test Different Models and Hydrofoil Sets > 2 sets Compliance with Accepted Safety Protocols and Regulations In Compliance with All Standards Tank is Designed so Model is Not Restricted in its Motion Tank does not Interfere with Model Tank assembly does not damage its surroundings Tank causes no Damage Training Time (1st Time) < 60 min

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Sept 11 • Planning: Customer Needs & Engineer Specs Sept 11 • Concept Development: Brainstorm, Concept Evaluation Oct 11 • System Review: Pool vs. Tank, System Architecture Nov 11 • Detail Design Review: BOM, Feasibility Analysis Dec 11 Jan 12 • Manufacturing: Mini-Tank, Full Scale Tank Feb 12 • Testing: Functionality, System Interaction Feb 12 • Final Product: Delivery, Final Presentation

Proposed concepts for the tank materials.

• Wood structure and

wood panels

• Steel structure and

wood panels

• Steel structure and steel

panels Proposed concepts for rails and cart

• Angle iron rails and

skate bearings

• 80/20 linear motion

system

• Machined bottom

supported rail

Forces applied

• Hydrostatic Force at

maximum height

• Point load of 200 lbf

(889.64 N) Constraints

• Deflection: 1/32”

(7.94e-4 m)

• Yield Stress: 50 ksi

(345 Mpa)

Dimensions [in] FOS Stress FOS Deflection Angle Iron 2x2x.125 (Length) 6.42 2.25 Length with -100lbf point load 0.67 0.28 Length with +100lbf point load 0.83 0.37 Angle Iron 2x2x.375 with 2x2x.25 20.45 9.64 Length with -100lbf point load 4.39 1.93 Length with +100lbf point load 6.34 3.09 Length with -200lbf point load 2.38 1.06 Length with +200lbf point load 2.85 1.34

• 3/8 in (9.525 mm) thick, 2” SQ. (5.080 cm)

Angle iron

• 1/4 in (6.350 mm) thick, 2” SQ. (5.080 cm)

Angle iron

• 3/4 in (19.050 mm) thick Plywood
• 16 feet (4.877 m) long 80/20 Aluminum
• 3/4 hp (559.270 w) Motor
• 1/16 in (1.588 mm) diameter Aircraft Cable
• 6 in (15.240 cm) diameter Pulleys

• Tanks dimensions: 16 feet (4.877 m) long, 2.5 feet (0.762 m) wide,

and 2 feet (0.610 m) high.

• Max cart towing velocity: 3.21 ± 0.10 ft/s (0.950 ± 0.025 m/s)
• Max volume of water: 599 US gallons (2,265 L)
• 2 modular pieces, capable of being disassembled, moved, and

reassembled by 2 people

• Velocity Range
• Distance Accuracy
• Start Up Transients
• Cable Wear

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Tank QTY COST Tank Walls 23/32" Plywood - 4' x 8' Sheets 4 $87.48 Tank Walls 23/32" Plywood - 4' x 8' Sheets - Mini-Tank Design 1 $21.87 Tank Walls #10 x 1in. Flat Head Phillips Drive Wood Screw (100 pcs) 1 $21.87 Tank Support 2" x 2" x 1/4" Steel Angle - 22-7/8" LG. - Mini Tank & Large Tank 4 $87.48 Tank Support 2" x 2" x 1/4" Steel Angle - 25-3/4" LG. 2 $43.74 Motor DC Motor Motion Transfer from Motor 1 $0.00 DC Drive Speed control and Power Supply 1 $0.00 Speed Sensor Feedback loop to DC driver 1 $0.00 Motion System 1/16" Cable Wire Rope - Aircraft Cable 1/16", 7x7, by the foot 100 $13.00 Drive Pulley Transfers Motion 1 $9.16 Pulley Pulley with plain bronze bearings 1 $10.50 Rail and Platform Length Rails 1" x 1" T-Slotted Extrusion 2 $64.88 Width Rails and Supports 1" x 1" T-Slotted Extrusion-97" 1 $29.08

Initial Budget: $2,000 Expanded Budget: $2,500 Final Expenses: $2,169.05

• Waterproofing plywood
• Liner management
• Leak detection
• Tow cable management
• Safety

Customer Needs and Objectives Importance Description How its being Accomplished

Comments Tank size meets specification Motor Speed controlled with driver Driver has different speed ranges Calculated from F=ma+Fdrag Need was removed by customer Tank size meets specification Tank weight is below required by floor Interface allows for different attachments Tank size meets specification Tank length = 16ft Cart cannot travel full 16 ft, because of boom arm length Driver will control speed and accel/decel can be set for 0-30sec Tank size meets specification Total approximate weight = 150lbs Calculated from F=ma+Fdrag CN5 3 Platform should be above or to the side of the water with no moving parts under water Cart has multiple attachment points CN6 9 Platform must allow for bolting of the instrumented model away from the wall of the tank Cart has multiple attachment points Encoder, DC driver speed sensor Labview motor control needs attention Deflection calculations performed in ANSYS

Measurement device should match specification

DC drive accuracy ± 1/2 rpm, encoder mounted

Measurement device should match specification Measurement device should match specification Timed in Labview

CN8 9 The tank must be safe for the

• perator and those around them

Ergonomics was considered in the height of tank CN9 9 The tank must not damage the surroundings Membrane or sealant will be used to stop leaks Liner does not satisfy concerns on leak prevention CN10 3 The tank must be cost effective Cost meets budget Went over initial budget of $2000, but stayed well under secondary budget of $2500 Labview useability will be a priority In process of creating Labview Directions Users Manual / Video will be provided CN12 9 Tank should not interfere with

• peration of models

P12463 is aware of the size constraints Needs were removed by customer CN7 9 Measurements should be of high quality and should be made with appropriate sampling rates and resolution CN11 3 Easy to use and to train new users CN3 9 Tow length needs to be large enough to achieve steady state CN4 9 System size should allow for appropriately scaled model testing CN1 9 Tow tank must be able to tow a platform above the surface of a stationary body of water at a constant speed CN2 3 The platform must allow an attachment of two different instrumented systems, a set of http://flowers.cdd5.com/showthread.php/amigo-semaforo/

1) Upgrade the plastic liner to a more durable material. 2) Upgrade tow cable and/or drive pulley. 3) Place windows in the tank walls to allow in water visibility. 4) Upgrade the plywood panels (walls) to sheet metal panels or glass panels 5) Improve rail mounting to tank

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• EPA P3
• Dr. Mario Gomes
• Prof. Ed Hanzlik
• Prof. John D. Wellin
• Dr. Steven Day
• Kelsey McConnaghy
• Rob Kraynik
• Jan Maneti
• Dave Hathaway
• FMS
• Mahany Welding Supply

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