april 12, 2018 dr. luis a. rodriguez milwaukee school of ......target specifications sprint race...
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Midway Review & UpdateMilwaukee School of Engineering
Dr. Luis A. RodriguezApril 12, 2018 1
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Table of ContentsIntroductions………………………………………………………………………………………………………………………….3Problem Statement and Design Objectives…….…………………………………………………………………………………4Target Specifications………………………………………………………………………………………………………………...5Research……………………………………………………………………………………………………………………………...6Frame Selection……………………………………………………………………………………………………………………...7Fluid Power Circuit Design………………………………………………………………………………………………………….8Design Formulas……………………………………………………………………………………………………………………..9Selection of Hardware..…………………………………………………………………………………………………………….11Manifold……………………………………………………………………………………………………………………………...12Simulink Model……………………………………………………………………………………………………………………...14Finite Element Analysis…………………………………………………………………………………………………………….16Virtual Prototype…………………………………………………………………………………………………………………….18Manufacturing...................................................................................................................................................................19 Data Acquisition................................................................................................................................................................20Lessons Learned……………………………………………………………………………………………………………………21
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Introduction
3From Left to Right: Nick Herche, Chris Gloeckle, Paul Stran, Rob Lancaster, Juan Casiano
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Problem Statement and Design ObjectivesProblem Statement:
● Design and build a human powered vehicle that uses fluid power to transfer and store energy
Design Objectives:● Integrated Design
● Simple Design
● Develop a competitive vehicle that is capableof placing in the top three designs for all events
● Reduce weight and complexity from previous team’s design
● Improve the ease of how the rider operates and enters the vehicle
● Allow for a system that can be readily modified for future Senior Design teams to improve upon
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Target SpecificationsSprint Race
● Achieve top speed of 25 MPH. ● Complete a 600ft course in less than 30 seconds● Be able to pump the system to working pressure in less than 10 minutes
Efficiency Challenge● Obtain efficiency challenge number no smaller than 150● Achieve a system efficiency of 80%
Endurance Race● Complete the entire race in under 4 minutes● Be able to maneuver and turn easily ● Must be reliable enough to finish entire endurance
course without needing any repairs during the event
Figure 1 Danfoss Track
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Research● Hydraulic Components
● Hydraulic Systems
● FPVC Designs○ Includes other teams and previous MSOE team
● Regenerative Braking
Figure 3 Regenerative Braking System6
Figure 2 MSOE Fluid Bike Design from 2013
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Frame SelectionTable 1 Vehicle Frame Selection Matrix
Figure 4 Selected Vehicle Frame 7
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Fluid Power Circuit Design
Figure 5 Annotated Hydraulic Circuit
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CXAA - Check ValveDLDM - 2W2P ValveNCBB - Check/Choke ValveNFBC - Needle ValveRDBA - Pressure Relief Valve
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Design Formulas
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Table 2 Motor System Displacement
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Selection of Hardware● Zwei Inc.
○ Displacement 7 cc/rev
● Parker Hannifin 1L Gas Piston Accumulator○ 4000 psi Capacity
● 2 Port 2 Way Rotary Valve
● Aluminum Reservoir○ Weight Reduction
1.66lb vs. 4.92lb○ Heat Dissipation
Figure 7 Aluminum Reservoir
Figure 6 Parker Hannifin Accumulators
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Manifold Circuit
Figure 8 Hydraulic Circuit Sent to Sun Hydraulics
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CXAA - Check ValveDLDM - 2W2P ValveNCBB - Check/Choke ValveNFBC - Needle ValveRDBA - Pressure Relief Valve
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Manifold
Figure 9 Manifold CAD with Annotations
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Figure 10 Manifold
Figure 11 Manifold Motor, Pump, and Accumulator Ports
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Simulink Circuit Model
Figure 12 Simscape Model 14
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Simulink (Cont.)
Figure 13 Block Parameters Figure 14 System Response 15
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Finite Element Analysis
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Figure 15 Sprocket Figure 16 Accumulator Mount
Figure 17 Motor Mount Figure 18 Pump Mount
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FEA on Motor
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Figure 19 Motor Mount Revision and Final Implementation
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Virtual Prototype
Figure 21 Isometric View
Figure 20 Side View
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Manufacturing● Materials
○ A36○ 1018○ 1020 - 1026○ 6061
● Processes○ CNC○ Milling○ Welding○ Turning
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Figure 22 Frame and Components
Figure 23 Pump Test Fit
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Data Acquisition • Reed Switch
• Arduino Uno
• SD Card Shield
• Sampling at 1 KHz
• Verified Velocity Data
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Figure 24 Arduino
Figure 25 Sample Test Results
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Lessons Learned● Tolerances
○ Leave room for tubing and fittings
● Replacement parts○ Make sure parts are easily acquired
● Hydraulic nuances, not just high level stuff○ Learn Rules of Thumb early
● Time Management○ Leave time for mistakes and problems
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Questions?
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