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Emergency Generator Arm Project: Design, Construction, and Testing

The project involves designing and building an Emergency Generator Arm across engineering disciplines, using AutoCAD for electrical aspects and Visual Analysis for civil components. Mechanical tests, load cell design, and spring analysis are key parts. Cost analysis includes selling options to Boeing and Leopard's. Acknowledgments to professors for input and guidance.

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Emergency Generator Arm Project: Design, Construction, and Testing

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  1. Chris Harty George Lyons Garret Nicodemus Heather Trumbour

  2. Goals: • The design and construction of the Emergency Generator Arm • Build a part of the project in each of the four major engineering disciplines Constraints? Prior Knowledge Variables Restrained Simplicity

  3. Electrical • Use of AutoCAD • Assembly of Circuit Board

  4. Circuit Board Schematic

  5. Circuit Board Layout Piecing together the Circuit

  6. CIVIL • Use of Visual Analysis • Design of Cross Members • Force Testing VisualAnalysis 3.12.EDU Report May 12, 2006 4:46 PM Project: Generator Arm Test File: H:\Generator Arm Test files\Original setup.VAP Engineer: Christopher Harty Billing: For Educational Purposes Only Default Units: Inches, Pounds, Degrees, ºFahrenheit, Seconds. Nodal Displacements —————————————————————————————————————————————————————————— Node Load Case DX DY RZ in in deg —————————————————————————————————————————————————————————— N2 Service Case 2 0.0009 -0.0484 -0.2752 ——————————————————————————————————————————————————————————

  7. Member Visual Analysis Tests for Cross Bracing Support

  8. Test Results

  9. Mechanical • Designed load cell using AutoCAD • Made the load cell with a CNC machine • Tested springs • Used spring equation

  10. Parts Custom Cut Aluminum Parts used in arm

  11. Load Cell AutoCAD and Gibbs Design used for CNC program

  12. Overall Length (inches) Wire Diameter (inches) Spring Diameter (inches) Spring Rate (lbs/inch) Initial Tension (lbs) Weight (ounces) Force (lbs) 2.5 0.028 5/16 .64 .42 .168 3.22 3 .048 7/16 2.81 1.62 .450 13.93 3.5 .48 7/16 2.21 1.62 .552 11.3 Spring Placement

  13. Spring

  14. Chemical Pitot Tube Equations Used in Final Analysis Simplified Equation:

  15. Completed Design

  16. Analysis Increased Air Velocity = Greater Power Output 3 mW at 30 mph on each resistor 100  ,470  , 1000 Goal:

  17. Results Circuit Schematic for testing arm in wind tunnel

  18. Results 100

  19. Results 470

  20. Results 1000

  21. Cost Analysis • Two Options to sell products to Boeing • Purchase from Leopard's • Manufacture ourselves *Guaranteed $15,000 a month from Leopard’s *Range between –$1,097 and $19,720 profit if manufactured ourselves

  22. Improvements SINCE: 960 meets the set goal per generator Better Propeller, Bigger or more Aerodynamic Spring is too fast, needs lock mechanism

  23. Acknowledgments Professor William Haller Professor Scott Hummel Professor Daniel Lewis Professor Scott Moor Professor Rebecca Rosenbauer Professor Edmond Saliklis Professor David Veshosky

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