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ME 492: Product Design SpecificationsDaimler Wind Tunnel Smoke Controller

(Daimler-TrucksNorthAmerica.com)

Sponsoring Company: Daimler Trucks North America

Contact Engineer: Matt MarkstallerProduct Validation(503) 745-68575160 N. Lagoon Ave.Portland, OR 97217

Team Members: Fadel Al JutailChris GrewellCraig LechtenbergMatt MeliusAndreas NylundMufeed Yacoub

Academic Advisor: Dr Raùl Bayoàn Cal

Table of ContentsIntroduction......................................................................................................................................1Purpose of the PDS..........................................................................................................................2Mission Statement...........................................................................................................................2Project Plan......................................................................................................................................2Customers........................................................................................................................................2Initial interview with customer........................................................................................................2Product Design Specifications.........................................................................................................3House of Quality..............................................................................................................................3Technical Risk Management...........................................................................................................4Conclusion.......................................................................................................................................4Appendix..........................................................................................................................................4References........................................................................................................................................5

Product Design Specifications 2

Introduction

In 2004, Daimler Trucks North America constructed

an open loop wind tunnel in Portland, OR to test

the aerodynamics of their medium and heavy-duty

trucks. The wind tunnel’s test section, which is 26ft

wide, 21ft tall, and 30ft long, is built to

accommodate a full sized Freightliner cab as shown

in Fig. 1. Prior to testing, the truck cab is parked in

the tunnel and is connected to a permanently

installed mock-trailer. During testing, air is drawn

into the contraction zone by 10, 250hp industrial blower

fans where it accelerates to velocities of up to 65mph

and forms a nearly uniform velocity profile [1]. The force exerted on the truck by the incoming airflow is

tested with pressure sensors in the floor, which aid in determining the overall drag coefficient of the

truck.

In addition to measuring drag forces, Daimler uses smoke visualization techniques to analyze flow

characteristics such as boundary layer separation points. The smoke is generated and piped to a manual

smoke wand that discharges fluid tracking particles 2ft upwind of the desired region of the truck. Areas

with undesirable separation points are identified and adjustments to the truck’s external design are

made to lower the overall drag coefficient and ultimately improve the fuel economy of their medium

and heavy-duty trucks (Fig. 2).

Daimler has identified three major limitations

of their current smoke testing system for our

capstone team to improve. First, their smoke

wand is 15ft long which restricts the range of

the testable area, highlighted by Fig.3. The

second issue is the inability to consistently

repeat tests on areas of interest because of

the manual positioning of the smoke wand.

Lastly, the smoke wand deflects over 5in

Product Design Specifications

Figure 1: Rendered view of the Daimler wind tunnel (Anne Saker, The Oregonian).

Figure 2: Smoke testing at the Daimler wind tunnel (Ross William Hamilton, The Oregonian)

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under its own weight and oscillates under wind loading leading to unacceptable levels of inaccuracy.

Daimler has requested that our capstone team design an improved system that eliminates these

problems with their smoke testing system.

Figure 3: Illustration of Limited Smoke Wand Range with Daimler’s current smoke system.

Mission Statement

Currently, Daimler is using a manual smoke testing

system for their visual aerodynamic analysis and

they would like to implement an automated

system. The purpose of this project is to replace the

current method of manual smoke wand placement

with an electronically controlled system capable of

traversing the projected face of a typical

Freightliner medium and heavy-duty truck, 8.5ft by

14ft (Fig. 4). The system will also discharge smoke

at desired locations while maintaining a minimal

flow disturbance of the testing region. The goal of

the capstone team is to produce all fabrication, installation, and operation documentation to Daimler by

the end of the spring term, which concludes on June 16th, 2012.


Figure 4: The projected area of the largest truck Daimler tests at their wind tunnel.

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Purpose of the PDS

The purpose of this document is to establish what the final product is intended to do by fully defining its

end user requirements. This is done by establishing a full set of specifications that address the

customer’s needs in a quantitative manner while allowing multiple solutions to be pursued once the

design phase has begun. The specifications consist of the priority of importance, metric, target, basis,

and a means to verify the specification. The priority of each parameter is scaled from high to low. The

metric is the unit of measurement that will be verified based on the target that the customer has

deemed acceptable, and accepted by the specific verification method.

Once the PDS is complete the external and internal search can begin which will be followed by the

detailed design phase. During the design phase, this document will be used as a reference to constrain

the final product to the customer’s needs and ensure all requirements are met.


Project Plan

Table 1 illustrates tentative dates and major milestones of the Daimler Wind Tunnel Smoke Controller project. The dates given are subject to change based on the needs of the customer, unforeseen complications, or design changes. A more detailed project schedule can be found in Appendix C.

Table 1: Major milestones


Customers

External Customers:

External customers are those who are vested in the completion of this project and are not associated with PSU. This project is specifically designed for Daimler’s wind tunnel in Portland, OR and will not be sold or manufactured anywhere else. Therefore, Daimler is the only external customer:

Daimler Trucks North America

Interest: a complete product that meets or exceeds all of Daimler’s specifications

Internal Customers:

Internal customers are those who are vested in the completion of this project and are associated with PSU; they are as follows:

The PSU Capstone Program

Interest: the capstone team delivers a satisfactory product to the project sponsor with professionalism and the proper representation of the PSU mechanical engineering program

Dr. Etesami, Mechanical Engineering Capstone Coordinator

Interest: the design process should be followed systematically and project presentations/reports completed on time and at a satisfactory level

Capstone Team

Interest: to deliver a complete product on time that meets or exceeds all of Daimler’s specifications while highlight the team’s ability and competencies

Initial interview with customer The birth of the project developed from the need to evaluate the aerodynamic performance of Daimler’s medium and heavy-duty trucks with a more efficient and accurate method than the one currently being used. Matt Markstaller, the Product Validation engineer and wind tunnel manager at the Daimler facility, wants an automated wand in the wind tunnel that would be controlled remotely in their instrumentation analysis room. Through our initial meeting with Mr. Markstaller and the other Daimler engineers (Bruno Banceu and Carlos Cosme) the team has been able to gather the proper information and requirements to determine the specific design criteria of the desired smoke control system. Future visits to the wind tunnel facility and observation of the current equipment and process will be used to further clarify and direct the completion of the final product.



The following tables represent the product requirements divided into High Priority, Medium Priority, Low Priority and Not Applicable categories:

Criteria Customer Requirements Metrics Targets Basis VerificationX-Direction X = 0-25’Y-Direction Y = 0-17’

- Aerodynamic StructureTurbulence near testing

location nullified2-3'

Group Decision with Customer Input

Design Analysis

- Ease of Operation Training Required <2 hGroup Decision with

Customer InputTesting

DTNAHigh Level of Repeatability

Follows Repeatable Pattern +- ½” Customer Feedback Testing

- Accuracy X-Y Motion +- ½” Customer FeedbackDesign Analysis and

Testing

- Smoke DeliveryProper smoke consistency

and flow rate at wandminimum pipe

area .75 in2 Customer Feedback Testing

DTNA Water ResistantSusceptible to Rust/Corrosion

0 partsGroup Decision with

Customer InputStudy of Material

Properties

- Strength Deflection +- ½” in x, y, zGroup Decision with

Customer InputStudy of Material

Properties

DTNA Two Axis of Motion Group Decision with Customer Input

Design Analysis

High Priority

Performance

Quality and Reliability

Materials

Table 2: High Priority product design specifications

Criteria Customer Requirements Metrics Targets Basis Verification

DTNA Low Maintenance Maintenance Interval 100 hours Customer FeedbackSimilar System

Comparison

DTNA Few Service IntervalsAccelerated Wear

Components520 hours Customer Feedback

Similar System Comparison

Installation Project Team Installation Time Budget Time to install and Test 5 Business DaysGroup Decision with

Customer InputSimilar Procedure

Comparison

Safety DTNA Safe Operation Limit switchstopping

immediatelyGroup Decision with

Customer InputPart Selection and

Testing

Life in Service DTNAContinued Operation for

Foreseeable FutureExpectable Remaining

Lifetime15 Years Customer Feedback

Parts and Process Analysis

Size and Shape DTNAMinimal obstruction of

wind tunnelStores Flush to Wall Flush Customer Feedback Measurement

DTNAElectrical codes and

standardsViolated Codes 0 violations Safety Standards Inspection

OSHA Workplace Safety Codes Violated Codes 0 violations Safety Standards Inspection

Testing Project Team Perform All Necessary

TestsMotion and Smoke Output 100% Verified Group Decision Testing

DTNAWork within company

ordinancespolicy violations 0 violations Customer Feedback Inspection

-

DocumentationDTNA/ Project

TeamAll Designs Need Prints Undocumented Designs

0 missing documents

Customer FeedbackDocument

Verification

ME 492 Progress Report Reports Submitted 1 report Course Requirements Grade

ME 493 PDS Reports Submitted 1 report Course Requirements Grade

ME 493 Design Report Reports Submitted 1 report Course Requirements Grade

DTNAPrototype completion

and testingFunctionality 100% Functional

Customer Feedback and Course

Grade

Timelines

Medium Priority

Maintenance

Company Constraints and Procedures

Applicable Codes and Standards

Table 3: Medium Priority product design specifications


Criteria Customer Requirements Metrics Targets Basis Verification

Environment DTNAOperates in a Clean

EnvironmentContamination of

SurroundingsNo Detectable Contamination

Customer FeedbackMaterials and

Processes Histories

Weight DTNA Self supporting structureConnections to existing wind

tunnel structure0 Customer Feedback Design Verification

Low Priority

Table 4: Low Priority product design specifications

Criteria

Shipping

Packaging

Aesthetics

Legal

Disposal There are no plans to scrap components at the moment.

There are no appearance requirements.

Reason

Stationary piece of equipment.

Does not require packaging at this time.

Not Applicable

There are no unique legal constraints.

Table 5: Not Applicable product design specifications


House of Quality

The following House of Quality table illustrates the interaction between the different PDS parameters based on their associated Engineering Criteria ratings. The higher the criteria rating the more important the criterion is for that specific parameter. Also, the importance of each parameter is given a value relative to the importance of the other parameters which totals to 100.

* Both engineering criteria and importance parameters are subject to change.

Table 6: House of Quality

Legend: Each criterion is given an influence rating relative to each parameter. A * has little influence and **** mean a big influence. The Current Design category is ranked relative to other existing systems.


Technical Risk Management

The following Technical Risk Management table identifies risks that may result in failure of the final product to meet the design requirements.

Table 7: Technical risk management


Conclusion

This project presents our team with many challenges requiring us to draw from several engineering disciplines including fluid dynamics, controller design, and mechanical system design. In order to produce and install this system our team will need to create a design that accommodates our customer’s needs while remaining within our current capabilities as engineers. One of the largest challenges that this project presents to our group is the combination of the required smoke delivery accuracy in 60 mph winds while maintaining a low aerodynamic profile. This system must also be controlled electronically from outside the wind tunnel during testing and not hinder in any way the daily operation of the tunnel. Daimler’s ideal product would include a system capable of three-dimensional motion that moves the smoke wand through a series of programmable user inputs through the control platform LabView. In addition, the traversing system would also have mounting locations for cameras capable of capturing images at set locations.

The scope of the ideal traverse system poses many difficult challenges that our group feels is unattainable due to time constraints. An attempt to fulfill all of the ideal requirements may lead to an unsatisfactory result. Consequently, this realization has forced us to pare down the ideal system to an attainable, albeit still very difficult project. Instead of producing the ideal solution, our team’s objective is to create a two-dimensional traverse system that can be manually controlled from a location outside of the test section. This system at the minimum will meet or exceed Daimler’s nominal requirements, and provide them with a platform for implementing their ideal traversing system capable of traveling 8.5ft in the X-direction and 14ft in the Z-direction. The system will also discharge smoke at desired locations while maintaining a minimal flow disturbance of the testing region.

Our team is confident in achieving the goals of this project, and we have anticipated the main obstacle that may hinder our ability to complete this project will be obtaining the major components in a timely manner. Traversing 425 sq. ft. will require very unique components which could possibly need large lead times; meaning preordering the largest customized components before the construction or testing of the traverse system can even begin. Thus, we have decided that installation of the traverse system may have to wait until the summer following the completion of this course. Accordingly we have compromised with Daimler to change our final objective from a complete system install by June 16 th to a prototype of the desired traverse system with full-scale components deemed critical to proving the design concept.


Appendix

Appendices A: Current smoke delivery wand.

Appendices B: View of the current smoke wand location as seen from the inside of the tunnel.


References

(1) “The answers are blowin’ in the wind: new Freightliner facility targets improved truck aerodynamics”. Diesel Progress North American Edition. FindArticles.com. 27, January 2012.


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