SYSTEM LEVEL DESIGN REVIEW P16318 Gaseous Mass Flow Rate Controller Luke McKean, Lianna Dicke,...
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Transcript of SYSTEM LEVEL DESIGN REVIEW P16318 Gaseous Mass Flow Rate Controller Luke McKean, Lianna Dicke,...
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SYSTEM LEVEL DESIGN REVIEW
P16318 Gaseous Mass Flow Rate ControllerLuke McKean, Lianna Dicke, Selden Porter, Schuyler Witschi
?
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Agenda● Phase I Review
○ Problem Statement○ Updated Phase I Documentation○ Review P15318’s Prototype
● Phase II Tasks○ Shared Vision○ Functional Decomposition○ Concepts and Development○ Feasibility Analysis○ Proposed Test Plan○ Risk Assessment
● Phase III Plans
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Problem Statement• Environmentally and economically CNG
makes sense as an alternative fuel• Delivering a precise portion of Compressed
Natural Gas is necessary for an engine to operate
• Current device done by previous MSD team has functional limitations
• New design will deliver a precise amount of CNG
• Use a PID control algorithm • Designed for use in an automotive
environment
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Updated Customer Requirements
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Updated Engineering Requirements
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Updated House of Quality
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P15318’s Prototype Test Results
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P15318’s Design Decomposition
Temperature Sensor
Position Sensor
Rotational Actuator
Pressure Sensor
Output Fitting
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P15318’s Design Decomposition
Known Issue: Leak rate when fully closed
Suspected Cause: Plastic on Metal face seal failure
High mfg tolerances required
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P15318’s Design DecompositionKnown Issue: Slow response time
Suspected Cause: Friction in the system due to face seal, Issues with microcontroller and software.
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Shared Vision:
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Shared Vision:
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Shared Vision:
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Functional Decomposition
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Functional Decomposition
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Functional Decomposition
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Functional Decomposition
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Functional Decomposition
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Morphological Chart
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Morphological Chart
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Concept GenerationValve ideas in detail
Ball/Cam
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Concept GenerationValve ideas in detail
Poppet Valve
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Concept GenerationValve ideas in detail
Rotational Disc
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Concept GenerationValve ideas in detailNeedle/Seat
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Concept Selection
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Pugh Analysis Results
• All concepts are variations of the same concept• Each component type independent of the others• Need to analyze components in detail in Subsystem
Design Phase
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System Architecture
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System Level Flowchart
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Feasibility QuestionsWill we be able to model the flow as incompressible?
• Incompressible flow is fairly accurate for M < 0.3• Spoke with Dr. Liberson• Using:• • Calculated M at the outlet of the valve, resulted in M=1.709• To accurately model the flow it must be considered compressible, and
it is supersonic at the exit.• Need to verify next steps to flow modelling with Dr. Liberson
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Feasibility QuestionsWill a metal-on-metal seal be able to prevent leak (< 25
sccm)?• Experience with testing EGR valves:
• Steel poppet/seat was able seal with leakage much less than 25 sccm
• Need to determine how to model leakage• Talk with ME faculty
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Feasibility QuestionsIf our system is required to ‘unseat’ a valve, will our
current actuator have enough torque?
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Feasibility QuestionsIf our system is required to ‘unseat’ a valve, will our
current actuator have enough torque?
Assumptions Needed:● Neglecting Friction (for now)● Cam Profile is linear ramp● Valve is sealed only by air pressure● Cam diameter● No spring assist
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Feasibility QuestionsIf our system is required to ‘unseat’ a valve, will our
current actuator have enough torque?
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Feasibility QuestionsQuestion: Are thermistors, or resistance temperature detectors feasible
for our temperature sensing needs?
*Thermocouples were not included in this feasibility study, but will be added for consideration in the sub-system design phase.
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Feasibility Questions�Question: Is it feasible to use a general purpose, flush diaphragm, or PCB
mountable pressure transducer?
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Feasibility QuestionsQuestion: What technologies might be feasible for our positional sensing needs?
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Feasibility QuestionsQuestion: How much power will our system consume?
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Feasibility Questions
Can a microcontroller be used for this project?
Some requirements are:Operating Voltage: 1- 5VTemperature Range: -40 to 85 degrees CelsiusSpeed: > 20MHzI/O Pins: >20
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Feasibility Questions:
http://www.cypress.com/sites/default/files/inline/fckImages/myresources/CY8CKit-049_full_img.jpg
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Feasibility QuestionsCan a microcontroller be used for this project?
We are still researching potential ways to optimize microcontroller response:• the use of lookup tables vs real-time calculation• processing speed/power vs available memory
Careful attention to price
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Proposed Test Plan
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Proposed Test Plan★Test Valve
○ Run compressed air through device and open and close valve★Test Microcontroller
○ Generate values to simulate varying sensor readings★Test Response Time
○ Have the microcontroller open and close the actuator★Test with Installed Sensors
○ Vary sensor variables to test microcontroller response★Test Voltage Regulator ★Test Leakage
○ Pressurized system and measure amount lost due to leakage★Test Flow Rate Accuracy and Repeatability
○ Connect device to compressed air tank and measure output
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Risk Assessment
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Risk Assessment continued
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Risk Assessment continued
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Next Phase Plans