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Project Sponsor: Mechanical Engineering Department Team Members: Cliff Cummings Allison Studley

Multidisciplinary Engineering Senior Design Project 05002 Micro Turbine III 2005 Critical Design Review May 13, 2001. Project Sponsor: Mechanical Engineering Department Team Members: Cliff Cummings Allison Studley Joe Calkins Mark Fazzio Team Mentor: Dr. Jeff Kozak Acknowledgements:

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Project Sponsor: Mechanical Engineering Department Team Members: Cliff Cummings Allison Studley

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  1. Multidisciplinary Engineering Senior DesignProject 05002 Micro Turbine III2005 Critical Design ReviewMay 13, 2001 Project Sponsor: Mechanical Engineering Department Team Members: Cliff Cummings Allison Studley Joe Calkins Mark Fazzio Team Mentor: Dr. Jeff Kozak Acknowledgements: Jon Ross, Dr. Fuller, John Bonzo, Borce Gorevski,Dave Hathaway Kate Gleason College of Engineering Rochester Institute of Technology

  2. Background • Current battery technology causes the battery to be up to half of the weight of the MAV. • Research into lighter weight power generation methods led to micro-turbine generators. • Third generation RIT Senior Design project 05002 Micro Turbine III Senior Design

  3. Mission Statement We will design and build a microturbine generator that can be integrated onto a micro air vehicle airframe and power the vehicle’s accessories. The microturbine will be a continuation of the previous team’s project with the application of their design to be used for MAV power production. 05002 Micro Turbine III Senior Design

  4. Primary Objectives • Produce a minimum constant 5 watts of power • Minimum flight time of 3 minutes • Overall weight of less than 45 grams • Integrated onto the MAV airframe 05002 Micro Turbine III Senior Design

  5. Research Methods • Preliminary Research • Review of last year’s design • Additional Research 05002 Micro Turbine III Senior Design

  6. Feasibility Assessment • 2 Options – Direct Comparison • >2 Options – Weighted Comparison 05002 Micro Turbine III Senior Design

  7. Feasibility Assessment Considerations • Ability to meet the objectives • Overall Size • Total Weight • Availability of procured items • Ease of Manufacture • Cost of procurement/manufacture 05002 Micro Turbine III Senior Design

  8. Efficiencies and Costs • 2-D Pelton Wheel • Typically 15% efficient • Approx. $100 • 3-D Pelton Wheel • Approx. 80% efficient • Estimated above $1,000 • Axial Impulse (Katholieke University, Belgium) • Approx. 20% (for mechanical, 10% total) • Over $1,000 • Francis (large scale turbine) • 80-90% 05002 Micro Turbine III Senior Design

  9. Turbine Feasibility 05002 Micro Turbine III Senior Design

  10. Housing Concept • Cross flow design • 2 Inlets – 2 Outlets • Tight tolerances to prevent flow from going around the turbine. • 30% Fiberglass reinforced Nylon material • Overall Size: 1.25” OD 0.6” Depth 05002 Micro Turbine III Senior Design

  11. Housing Design • Cross flow design at 45o • 2 Inlets – 2 Outlets • 0.005” – 0.010” tolerances on all critical diameters. • 30% Fiberglass reinforced Nylon material • Overall Size: 1.25” OD 0.75” Depth 05002 Micro Turbine III Senior Design

  12. Housing Feasibility • Smaller OD ( 1.25” vs. 1.875” ) • Lighter weight ( 15g vs. 30g ) • O-Ring seal vs. Gasket seal • Inlet/Outlet redesign • Designed for manufacturability 05002 Micro Turbine III Senior Design

  13. Housing Analysis Load: 300 psi Maximum Stress: 1921.75 psi Safety Factor: 10.49 05002 Micro Turbine III Senior Design

  14. Housing Analysis Load: 300 psi Maximum Stress: 4130.67 psi Safety Factor: 4.88 05002 Micro Turbine III Senior Design

  15. Propellant System Feasibility Fuel • Compressed CO2 Cartridges • Compressed N2 Cartridges • Compressed Air Tanks Tubing • Flexible Nylon lines • Rigid metal lines Regulator • Bellows regulator to decrease the inlet pressure • Micro nozzle to maintain a choked flow • Pressure Regulator • Piercing device 05002 Micro Turbine III Senior Design

  16. Other Design Concepts/Considerations • Bearings: Sealed Air Shielded Magnetic • Seals: Neoprene O-Ring at 40% compression Paper / Cork Gasket 05002 Micro Turbine III Senior Design

  17. Safety Precautions • “Safety Box” for protection during preliminary testing • Mount for fuel canister during prototype testing • (picture) 05002 Micro Turbine III Senior Design

  18. Prototype Financial Analysis 05002 Micro Turbine III Senior Design

  19. Overall Financial Analysis 05002 Micro Turbine III Senior Design

  20. Schedule 05002 Micro Turbine III Senior Design

  21. Testing • Three main phases of testing: • Phase 1 (shop air) • Preliminary static testing • No computer or nozzles • Preliminary dynamic testing • No nozzles • LabView and DAQ system • Phase 2 (shop air) • Dynamic testing with nozzles • Phase 3 (fuel canisters) • Calibrate regulator • Repeat tests on best nozzles 05002 Micro Turbine III Senior Design

  22. Thermocouple Turbine System Oscilloscope Thermocouple Flow Meter Pressure Meter Thermocouple Plenum Incoming Air Test Setup (Phase 1 & 2) • Test initially using laboratory supplied compressed air to prove feasibility of design (without nozzles) • Determine which nozzle produces optimal power • Provide data for mass flow calculations 05002 Micro Turbine III Senior Design

  23. Regulator Thermocouple Turbine System Fuel Canister Oscilloscope Thermocouple Test Setup (Phase 3) • Replace shop air with compressed Nitrogen fuel canisters • Duplicate test results from preliminary testing • Prove feasibility of prototype 05002 Micro Turbine III Senior Design

  24. Final Design 05002 Micro Turbine III Senior Design

  25. Final Design 05002 Micro Turbine III Senior Design

  26. Final Design 05002 Micro Turbine III Senior Design

  27. Design Limitations • Propellant cartridge & piercing device are 250g and 192g respectively • Pressure regulator is an inefficient way of reducing the pressure from the canisters to the housing • Miniature sealed bearings were unavailable at the required size • Shrink tube coupling loses adhesion after extended use at 25,000+ rpm 05002 Micro Turbine III Senior Design

  28. Major Design Issues • Lead times • Machining of housing and cap • Delivery of turbine and regulator • Production in a small quantity • Weight of fuel system components • Canister, piercing device, regulator all greater than 190g each • Compared to last year, fewer team members and more aggressive goals 05002 Micro Turbine III Senior Design

  29. Analysis of Design • Outlet channels angled 45o to accommodate inlet/outlet fittings • Housing components tested using FEA and found to have a minimum SF of 4.88 using Nylon 6/6 • Cap contains the highest stress of the components at 4130 psi under a 300 psi load. • Mass flow calculations were used to determine a nominal nozzle diameter of 100mm 05002 Micro Turbine III Senior Design

  30. Testing Results • Phase 1 • Static (maximum) • 4.42 watts at about 100 psi and 25,000 rpm • Dynamic (maximum) • 9.08 watts at 120 psi and 26,300 rpm (5W resistance) • 7.26 watts at 130 psi and 43,000 rpm (8W resistance) • Phase 2 • 100 micron nozzles • Pending • Phase 3 • Pending 05002 Micro Turbine III Senior Design

  31. Desired Outcomes Produce 5 watts of power Weigh less than 45 g 3 minute run time (on N2 canisters) Integrate onto MAV airframe Actual Outcomes Produced a maximum of 9.08 watts of power System weight 48.9 g Run time pending final test Sized to fit onto MAV (without canisters and regulator) 05002 Micro Turbine III Senior Design

  32. Actual Results Weight 48.9g Max Power 9.08 watts Run Time Pending final test Cost (for prototype) $ Alternative Fuel Sources Batteries Cost ($30 - 50) Power (10 – 20 watts) Run time (10 – 30 min) Weight (30 – 90 g) MIT Gas Turbine Cost ($15 mil budget) 30+ Faculty Power (10-50 watts) Run time (approx. 3 second) Weight 85g Stanford Turbine (still in development) Cost (?) Power (designed for 100 watts at 800,000 rpm, reached 420,000) Runtime (designed for 100 hours, reached ?) Weight (50 g) 05002 Micro Turbine III Senior Design

  33. Conclusions 05002 Micro Turbine III Senior Design

  34. Future Recommendations 05002 Micro Turbine III Senior Design

  35. Questions? 05002 Micro Turbine III Senior Design

  36. Backup Slides and References 05002 Micro Turbine III Senior Design

  37. Data Acquisition GUI 05002 Micro Turbine III Senior Design

  38. Data Acquisition Set-up 05002 Micro Turbine III Senior Design

  39. FEA Analysis 05002 Micro Turbine III Senior Design

  40. FEA Analysis 05002 Micro Turbine III Senior Design

  41. FEA Analysis 05002 Micro Turbine III Senior Design

  42. Flow Calculations Nozzle Exit Velocity:Flow Density:Mass Flow: 05002 Micro Turbine III Senior Design

  43. Test Results (Phase 1) 05002 Micro Turbine III Senior Design

  44. Housing Post-Machining • Main Housing • Had to machine inlet and outlet holes separately • Deburr housing after CNC machining • Bearing holes were too small due to limited tooling • Turbine seat was not concentric due to CNC tooling path 05002 Micro Turbine III Senior Design

  45. Preliminary Budget Final Budget 05002 Micro Turbine III Senior Design

  46. Previous Design Back 05002 Micro Turbine III Senior Design

  47. Previous Turbine Design Senior Design Team 04013 05002 Micro Turbine III Senior Design

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