Daimler Wind Tunnel Project

Project Review

Capstone Team Andre Nylund Chris Grewell Craig Lechtenberg Fadel Al Jutail Matt Melius Mufeed Yacoub

Team Advisor Dr. Raul Bayoán Cal

Customer Daimler Trucks North

America

Project Review

Tunnel Details 12,000 sq. ft. facility Wind speeds up to 65 30ft long test section

21ft wide

26ft tall

Project Review

Tunnel Details Pressure sensitive floor for

calculating trucks drag coefficient.

Smoke wand for flow visualization

Rotating floor panel to test various angles of attack

Project Review

Mission Statement: Improve smoke testing methods Increase the testable area within the wind tunnel

Increase stability of the system

Deliver smoke to location of interest accurately

Electronically controlled system to eliminate human error

Provide these requirements while maintaining negligible aerodynamic impact to test region

Delivery of final product by June,16th

Mile Stone Progress

PDS completion – January 30th Two axis motion

• 20’ Horizontal travel• 17’ Vertical travel

Zero residual impact when not in use• Removes itself form wind tunnel completely when not in use

Aerodynamic Profile

External and Internal Search – February 17th

External Search

Test Subject

Pressure ProbeAir Flow

Typically, traversing systems are used to study the airflow behind a test model (ex. pressure probe is downstream of the test subject)

External Search

Traversing systems commonly use linear actuators for precise motion control.

Common Applications Flow field and wake survey

behind test section Small test sections

scale models etc.

External Search

Roof Mounted Traversing Probe

Traversing Volume 3m x 4m x 6m

Positional Accuracy +/- 1mm

External Search

Roof Mounted Traversing Probe full size automotive wind tunnel downstream probe

Traversing Volume 5m x 12m x 13m

Positional Accuracy +/- 1.5mm

External Search

Floor mounted track Singly supported

Range of travel dictated by rail length

External Search

Linear Actuators Pre-fabricated Sealed Unit

Reliable

External SearchRail and Linear bearing systems

High precision offers accurate placement of carriage

External Search

Motion Control Stepper Motor Servo Motors and Drives Gear Boxes

External Search

Internal Concept: Vertical Floor Rail

Wind tunnel wall

Vertical Rail and Carriage

Smoke wand

Horizontal Rails and Carriages

Wind Tunnel

X

Z

Internal Concept: Vertical Floor Rail

Smoke Wand

Vertical Rail and Carriage

Horizontal Rail and Carriage

Truck profile

Wind Tunnel

Horizontal Rail and Carriage

Wind tunnel wall

X

Z

Internal Concept: Cantilever

• Possible project scope change

Wind Tunnel

Wind tunnel wall

Vertical Rail and Carriage

Horizontal Rail and Carriage

Cantilever cable support

Carbon Fiber Smoke Wand

X

Z

Mile Stone Progress

PDS completion – January 30th Two axis motion

• 20’ Horizontal travel• 17’ Vertical travel

Zero residual impact when not in use• Removes itself form wind tunnel completely when not in use

Aerodynamic Profile

External and Internal Search – February 17th

Concept selection – February 22nd Cantilever

Detailed Design– February 22nd to May 18th

Fabrication completion – May 31st

Product delivery – June 16th

Detailed DesignLoad Calculations

Gravity on the Horizontal rail 355 N

Gravity on the smoke wand 107 N

Wind load on the smoke wand Distributed load of 361N Moment of 990 N*m at wand support rollers

Weight of the entire system

Horizontal Rail

Smoke Wand

Vertical Rails

Horizontal Carriage

Wind Tunnel Wall

Vertical Carriages

Drive MotorWand Support Rollers

Wind Tunnel

X

Z

Detailed Design

Mechanical Component Selection Horizontal rail and carriage Vertical rail and carriage Lifting mechanics

Lifting motors

Structural Design Vertical rail supports Baseplate mounting Structure stabilization

Detailed Design

Control System Safety

Operational safety Limit switches

Human interaction Zero energy state Vertical motion lockout

Questions