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Team Railtech

Team Railtech. 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.

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Team Railtech

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  1. Team Railtech CDR October 9, 2008 Mike Oertli Jonathan Karnuth Jason Rancier

  2. 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

  3. Block Diagram Pneumatic Starter System Keypad Voltage Sensor Inductor Railgun Encoder Capacitor Array Voltage Sensor MSP430F169 LEDs LCD Power Supply Kill Switch

  4. Budget

  5. Safety Features • Voltage sensors on rails, cap bank, & source • Kill power if out of expected range • Plexiglas casing • Keep user isolated from high voltages and short circuited rails • Pressure Regulator • Added ability to safely release tank pressure

  6. Power System Diagram

  7. Capacitor Battery • 50x 450V 3.7mF Capacitor • Donated by CDE • Array of 3 banks of 16 in parallel • Overall: 1350V ~ 20mF

  8. Capacitor Battery

  9. Basic Charger

  10. Power Parts • 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

  11. 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

  12. Machined & Fabricated Parts

  13. Compressed Air Injector Adapter

  14. Injector Adapter Drawing

  15. 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”

  16. Projectile • Metal: Aluminum • Composite: 2011 • Temper: T3 • Part #: 88615K411 • Melting point: 540oC • Electrical Conductivity: 45% IACS • Electrical Resistivity: 3.8µΩ/cm • Diameter: 7/8” • Length: ~1”

  17. 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

  18. Injection System

  19. Complete System • Compressed Air Tank • Compressor • Solenoid Valve • Ball Valve • Pressure Regulator • Manufactured Parts • Railgun Adapter • Tank Adapter • Compressor Adapter

  20. Electromagnetic Solenoid Valve

  21. 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

  22. Chassis Specs

  23. Parts List- Control System • Voltage Sensor • MM74C922 16 key encoder • Keypad, 3-line LCD • Master kill switch • “Hot” switch

  24. Parts List- MCU • MSP430F169 • 2 ADC • 1 RS232 • Voltage regulator • LEDs

  25. Interfaces RS232 MSP430F169 Matlab Wire-wrap/Solder Wire-wrap/Solder MSP430F169 Key Encoder Keypad Wire-wrap/Solder MSP430F169 3-Line LCD P6 I/O (ADC) MSP430F169 Voltage Sensor

  26. Keypad Pin Layout 1 2 3 4 5 6 7 14 13 12 11 10 9 8

  27. Key Encoder • MM74C922 • 16 Key • Debounce • Continuous row scan

  28. Keypad & Encoder Schematic

  29. Keypad Demo

  30. 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

  31. MCU Logic

  32. Software- Matlab • Plot time domain analysis of sensor readings • Keep test-run information • Inputs: Data from MSP • Outputs: GUI showing data • Interface: RS232

  33. Questions?

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