Detailed Design Review
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Transcript of Detailed Design Review
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Detailed Design Review
Tethered GliderP14462
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Outline• Engineering Requirements• Glider Status• Tether Design• Base Station Design• DAQ System• Bill of Materials• DOE ANOVA Analysis• Test Plan• MSD II Plan• Work Breakdown• Risk Assessment
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Engineering Requirements
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Glider Status
• Art’s Planeo Suffered Multiple
Crasheso Totalled
• 1st Bixlero Few flights on first
dayo Missing in swamp
• 2nd Bixlero On order
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1st Bixler
• Learned how to glue glider and set up receiver
• Needed to be modified due to poor manufacturingo Drilled out interfering
plastic/wood
• Bixler was tail heavy
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Tether Design
• DynaGlide Throw Lineo Material: Dyneema with Vinyl Coatingo Vendor: WesSpuro Diameter: 1.8mmo Tensile Strength: 1000 lbo Highly Visibleo Price: $39.00 for 200 feet
http://www.wesspur.com/throw-line/zing-it-throw-line.html12/10/2013 14462
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Tether Drag
• Numerical Approximation
• Calculates:o Tether Drago Tension Changeo Tether Angle
Change
Rajani, Ashok, Rajkumar Pant, and K. Sudhakar. "Dynamic Stability Analysis of a Tethered Aerostat." Journal of Aircraft 47.5 (2010): 1531-538. American Institute of Aeronautics and Astronautics. Web. 7 Dec. 2013. <http://arc.aiaa.org/doi/pdf/10.2514/1.47010>.
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Tether Drag
Total tether drag of DynaGlide tether: 27.063 NNegligible force compared to the lift and drag
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Tether-Wing Attachment Setup
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Tether-Wing Attachment
• Tether may rip EPO foam if attached directly
• Design plate to rest on top of wingo Distributes loado Foam is minimally
damaged
• Tethered over carbon fiber spars
• Material: Polycarbonate12/10/2013 14462
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Tether-Wing Attachment Setup
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Tether-Wing Attachment Stress Analysis
Plate material: PolycarbonateMax stress: 38.4 GPaMax allowable: 55 GPa
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Tether-Wing Attachment Displacement Analysis
Plate material: PolycarbonateMax deflection: 0.002 in
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Bridle Setup
• 3 point bridle with extra support line• Use crimps for permanent attachments• Adjustable fuselage tether to change bridle angle
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Bridle Setup
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Base Station - Week 6 Concept
● Concept from week 6, selected by week 9
● Consists of 2 potentiometers and 1 load cell
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Base Station - Detailed Design
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Base Station - Detailed Design
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Exploded View of Upper Portion
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Design Focus - Upper Portion
• Wanted minimal flexing on the shaft in order to prevent bearing seizure
• Wanted to prevent screw pullout
• Wanted minimal plywood flexing
• Ensure top bolt did not tear through plywood due to loading
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Shaft Selection
T=1200 lbf
RR=600 lbfRL=600 lbf
x
y
● Wanted to minimize deflection, bending stress, and moment of inertia of shaft
● Utilized Excel and varied L and R and calculated corresponding deflections and max stress
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Shaft Selection Continued
¾” x 7’’ AISI 1566 Steel shaft
● Only 4” of the shaft will be between the bearings, which is the length used for deflection and stress calculations.
● With these values the shaft will deflect 0.0036” under the max loading of 1200 lbs
● The thicker shaft allows for tapping in order to connect the load cell
Selection:
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Pillow Block Screw Pullout T=300 lbf
x
y
Selection:
4 #12-10 machine screws¾” C-D grade plywood
http://www.grabberman.eu/Media/TechnicalData/452.pdf
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Plywood Flexing
● Modeled as an isotropic material, although wood is anisotropic
● Showed max deflection of 0.503E-05 inches
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Bolt Tear Through
● Wanted to prevent the bolt from tearing through the plywood
● A 3 inch washer was added to distribute the loading on the face of the plywood
1200 lbf
170 psi
Without Washer: Compressive stress on the plywood of 8692 psi. The maximum allowable compressive stress for loading perpendicular to the face grain is between ~ 900 – 1500 psi
With Washer: Compressive stress on plywood of 170 psi, within the allowable stress
1200 lbf
8692 psi
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Source: www.buildgp.com/DocumentViewer.aspx?repository=bp&elementid
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Pillow Block Bearings
Selection:
● Shaft will insert and then be screwed down with set screws
● Do not need to be thrust bearings, as platform will rotate
¾” Stamped-Steel Mounted Ball Bearings—ABEC-1
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Exploded View of Lower Portion
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Design Focus - Lower Portion
• Wanted to ensure sleeve bearing did not deform under worst-case scenario loading
• Wanted to prevent screw pullout
• Ensure sheet metal flexed minimally under applied load
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Sleeve Bearing
T=1200 lbf
hsb
H
RL
RR
Selection:
0.752” x 1” Ultra Tough Oil Lubricated Bronze Flanged Sleeve Bearing
● Utilized Excel to calculate various reaction forces for different hsb, and compared versus the max allowable force on the inner walls of the bearing
● For worst case scenario chosen bearing will see 5100 lbs and it is capable of handling 6016 lbs.
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Angle Iron Pullout and Shear
F=300 lbf
F=300 lbf
F=200 lbf Selection:
1”x1”x1/8” angle iron with #12 screws
6 vertical screws, and 4 horizontal
¾” C-D grade plywood
http://www.grabberman.eu/Media/TechnicalData/452.pdf
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Sheet Metal Plate• Max deflection of ~ 0.003 inches
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Base Station – Cross Section View
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Base Station AnimationBase Station Animation
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NI USB-6210
16 bit Resolution = 10/(2^16) = 0.000153
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3140_0 S Type Load Cell (100-500kg)
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1046_0 PhidgetBridge 4-Input
Resolution = 5/(2^24) = 0.000000298
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Potentiometers
• 2 pots required.• 1 turn ~ 270 degrees• Between 1K-10K Resistance• Linear• Bourns brand• Potentiometers from Gomes still need to be spec out
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DAQ Operational Flowchart
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DAQ Programming Flowchart
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Wiring Schematic for DAQ
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Bill of Materials - Full
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Bill of Materials – Already Have
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Bill of Materials – Need to Buy
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Bill of Materials - Possible Savings
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Glider Configuration for Experiments
Total configurations: 2590
Range: Beta = 90-98 [deg] Wind Speed = 4-10 [m/s] Tether Length = 20-30 [m] Flight Radius = 10-18 [m]
Force [lbs] Wind Speed [m/s]
Radius [m]
Beta [deg]
Tether Length [m]
334.3693 7 15 92 30
309.5235 7 16 92 30
349.0444 7 18 93 30
Filtered: Force = 300-350 [lbs] Wind Speed = 7 [m/s] Tether Length = 30 [m]
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Regression Analysis including Wind
Force = -1523.83 + 44.6977 WindSpeed - 22.0839 Radius + 16.3528 Beta +11.4661 TethLen
Analysis of VarianceSource DF Seq SS F PRegression 4 14445969 580.40 0WindSpeed 1 6413421 2006.60 0Radius 1 2623543 887.44 0Beta 1 2732563 524.19 0TethLen 1 2676441 430.13 0Error 2583 16072377Total 2587 30518346
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Why the high error ?
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2000-200-400
99.99
9990
50
101
0.01
Residual
Perc
ent
500400300200100
200
0
-200
Fitted Value
Resi
dual
140700-70-140-210-280
160
120
80
40
0
Residual
Freq
uenc
y
2400
2200
2000
1800
1600
1400
1200
10008006004002001
200
0
-200
Observation Order
Resi
dual
Normal Probability Plot Versus Fits
Histogram Versus Order
Residual Plots for Force
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DOE ANOVA Analysis
Analysis is based off of above equationExperiment was run using the following
Factor Type Levels ValuesRadius fixed 9 10, 11, 12, 13, 14, 15, 16, 17, 18Beta fixed 8 91, 92, 93, 94, 95, 96, 97, 98TethLen fixed 11 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30 Analysis of Variance for Force for TestsSource Seq SSRadius 1074979Beta 1039829TethLen 772033Radius*Beta 383755Radius*TethLen 263954Beta*TethLen 312236Radius*Beta*TethLen 818325Error 25853236Total 30518346
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Interaction plots for Tension
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Main effects on tension
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Graphical Sensitivity (contour plots) of each factor
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Graphical Surface plots
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Test Plan
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Test Plan
• Varied wind speed: Dependent on environment• Varied glider mass would be an additional test if time
allows
Component/System Tested Specification Tested
Responsibility Completion Date
Experimental Proof of Theoretical Model
Tension Team 02/28/2014
Varied Tether Length Model Sensitivity Team 03/14/2014
Varied Wind Speed Model Sensitivity Team 03/28/2014
Varied Beta Angle Model Sensitivity Team 04/04/2014
Varied Flight Path Radius Model Sensitivity Team 04/11/2014
Varied Glider Mass Tension Team 04/18/2014
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Risk Assessment - Full
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Risk Assessment - High Priority/New
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Project Plan
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MSD II Plan
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MSD II Plan (Continued)
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Work Breakdown Matt – Building glider, attaching bridal, flying tethered
glider Paul - Building glider, attaching bridal, flying tethered
glider Jon – Machine parts, assemble base station Kyle - Machine parts, assemble base station Bill – Create LabVIEW code, test DAQ equipment, Saj- Update project timeline, develop more detailed test
plans from DOE, maintain transparency between team and customer/guides
All – Assist in base station build
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Summary• Engineering Requirements• Glider Status• Tether Design• Base Station Design• DAQ System• Bill of Materials• DOE ANOVA Analysis• Test Plan• MSD II Plan• Work Breakdown• Risk Assessment
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Questions?
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