multidisciplinary engineering senior design project 05002 micro turbine iii 2005 critical design...

Multidisciplinary Engineering Senior Design

Project 05002 Micro Turbine III2005 Critical Design Review

May 13, 2001

Project Sponsor:Mechanical Engineering Department

Team Members:Cliff Cummings Allison StudleyJoe Calkins Mark Fazzio

Team Mentor:Dr. Jeff Kozak

Acknowledgements:Jon Ross, Dr. Fuller, John Bonzo, Borce Gorevski, Dave

Hathaway

Kate Gleason College of EngineeringRochester Institute of Technology

Background

• Current battery technology causes the battery to be up to half of the weight of the MAV.

• Research into lighter weight power generation methods led to micro-turbine generators.

• Third generation RIT Senior Design project

05002 Micro Turbine III Senior Design

Mission Statement

We will design and build a microturbine generator that can be integrated onto a micro air vehicle airframe and power the vehicle’s accessories. The microturbine will be a continuation of the previous team’s project with the application of their design to be used for MAV power production.


Primary Objectives

• Produce a minimum constant 5 watts of power• Minimum flight time of 3 minutes• Overall weight of less than 45 grams• Integrated onto the MAV airframe


Research Methods

• Preliminary Research

• Review of last year’s design

• Additional Research


Feasibility Assessment

Last Year's Design 2 Inlet 2 Outlet ConceptCost 3 2Size 3 2Weight 3 3Availability 3 3Manufacturability 3 2

Average 3.00 2.40Normalized Average 1.00 0.80

• 2 Options – Direct Comparison

• >2 Options – Weighted ComparisonWeighting Air Bearings Magnetic Bearings Axial Bearings Radial Bearings

Cost 0.2 4 4 3 2Size 0.1 5 5 2 2Weight 0 3 3 3 3Availability 0.35 5 5 2 2RPM Rating 0.35 2 2 3 3

Weighted Average 3.75 3.75 2.55 2.35Normalized Average 1.25 1.25 0.85 0.78


Feasibility Assessment

Considerations• Ability to meet the objectives• Overall Size• Total Weight• Availability of procured items• Ease of Manufacture• Cost of procurement/manufacture


Efficiencies and Costs• 2-D Pelton Wheel

– Typically 15% efficient – Approx. $100

• 3-D Pelton Wheel– Approx. 80% efficient– Estimated above $1,000

• Axial Impulse (Katholieke University, Belgium)– Approx. 20% (for mechanical, 10% total)– Over $1,000

• Francis (large scale turbine)– 80-90%


Turbine Feasibility


Housing Concept• Cross flow design• 2 Inlets – 2 Outlets• Tight tolerances to prevent

flow from going around the turbine.

• 30% Fiberglass reinforced Nylon material

• Overall Size: 1.25” OD

0.6” Depth


Housing Design• Cross flow design at 45o

• 2 Inlets – 2 Outlets• 0.005” – 0.010” tolerances on

all critical diameters.• 30% Fiberglass reinforced

Nylon material• Overall Size: 1.25” OD

0.75” Depth


Housing Feasibility• Smaller OD ( 1.25” vs. 1.875” )

• Lighter weight ( 15g vs. 30g )

• O-Ring seal vs. Gasket seal

• Inlet/Outlet redesign

• Designed for manufacturability


Housing Analysis


Load: 300 psi

Maximum Stress: 1921.75 psi

Safety Factor: 10.49

Housing Analysis


Load: 300 psi

Maximum Stress: 4130.67 psi

Safety Factor: 4.88

Propellant System Feasibility

Fuel• Compressed CO2 Cartridges• Compressed N2 Cartridges• Compressed Air TanksTubing• Flexible Nylon lines• Rigid metal linesRegulator• Bellows regulator to decrease

the inlet pressure• Micro nozzle to maintain a

choked flow• Pressure Regulator• Piercing device


Other Design Concepts/Considerations

• Bearings: Sealed Air Shielded Magnetic

• Seals: Neoprene O-Ring at 40% compression Paper / Cork Gasket


Safety Precautions

• “Safety Box” for protection during preliminary testing

• Mount for fuel canister during prototype testing– (picture)


Prototype Financial Analysis


Part Price per Qty Line Price

Turbine $96.00 1 1 $96.00

Housing Material $5.78 foot 0.08 $0.48

Shaft $4.64 1 1 $4.64

O - Ring $8.25 50 1 $0.17

Bearings $5.00 1 2 $10.00

Tape $0.97 1 0.25 $0.24

Housing Connections $24.15 1 1 $24.15

Flow Split $18.44 1 2 $36.88

Tubing $0.71 1 1 $0.71

Nozzle free 1 1 $0.00

Fuel $18.15 1 1 $18.15

Puncture Device $22.15 1 1 $22.15

Fuel Connections (Puncture device to Regulator) $6.20 1 1 $6.20

Regulator $207.55 1 1 $207.55

Overall Cost $427.32

Overall Financial Analysis


Schedule


Testing• Three main phases of testing:

– Phase 1 (shop air)• Preliminary static testing

– No computer or nozzles

• Preliminary dynamic testing– No nozzles– LabView and DAQ system

– Phase 2 (shop air)• Dynamic testing with nozzles

– Phase 3 (fuel canisters)• Calibrate regulator• Repeat tests on best nozzles


Test Setup (Phase 1 & 2)

• Test initially using

laboratory supplied

compressed air to prove feasibility of design (without nozzles)

• Determine which nozzle produces optimal power

• Provide data for mass flow calculations

Incoming Air

Plenum

Turbine System

Flo

w M

eter

Pressure Meter

Thermocouple

Thermocouple

Thermocouple

Oscilloscope


Test Setup (Phase 3)

Turbine SystemFuel Canister

Thermocouple

ThermocoupleRegulator

Oscilloscope

• Replace shop air with compressed Nitrogen fuel canisters

• Duplicate test results from preliminary testing

• Prove feasibility of prototype


Final Design


Design Limitations

• Propellant cartridge & piercing device are 250g and 192g respectively

• Pressure regulator is an inefficient way of reducing the pressure from the canisters to the housing

• Miniature sealed bearings were unavailable at the required size

• Shrink tube coupling loses adhesion after extended use at 25,000+ rpm


Major Design Issues

• Lead times – Machining of housing and cap– Delivery of turbine and regulator

• Production in a small quantity• Weight of fuel system components

– Canister, piercing device, regulator all greater than 190g each

• Compared to last year, fewer team members and more aggressive goals


Analysis of Design• Outlet channels angled 45o to accommodate inlet/outlet

fittings

• Housing components tested using FEA and found to have a minimum SF of 4.88 using Nylon 6/6

• Cap contains the highest stress of the components at 4130 psi under a 300 psi load.

• Mass flow calculations were used to determine a nominal nozzle diameter of 100m


Testing Results

• Phase 1– Static (maximum)

• 4.42 watts at about 100 psi and 25,000 rpm

– Dynamic (maximum)• 9.08 watts at 120 psi and 26,300 rpm (5 resistance)• 7.26 watts at 130 psi and 43,000 rpm (8 resistance)

• Phase 2– 100 micron nozzles

• Pending

• Phase 3• Pending


Desired Outcomes• Produce 5 watts of power

• Weigh less than 45 g

• 3 minute run time (on N2 canisters)

• Integrate onto MAV airframe

Actual Outcomes• Produced a maximum of

9.08 watts of power

• System weight 48.9 g

• Run time pending final test

• Sized to fit onto MAV (without canisters and regulator)


Actual Results• Weight

– 48.9g• Max Power

– 9.08 watts• Run Time

– Pending final test• Cost (for prototype)

– $

Alternative Fuel Sources• Batteries

– Cost ($30 - 50)– Power (10 – 20 watts)– Run time (10 – 30 min)– Weight (30 – 90 g)

• MIT Gas Turbine– Cost ($15 mil budget)– 30+ Faculty– Power (10-50 watts)– Run time (approx. 3 second)– Weight 85g

• Stanford Turbine (still in development)– Cost (?)– Power (designed for 100 watts

at 800,000 rpm, reached 420,000)

– Runtime (designed for 100 hours, reached ?)

– Weight (50 g)


Conclusions


Future Recommendations


Questions?


Backup Slides and References


Data Acquisition GUI


Data Acquisition Set-up


FEA Analysis


Flow Calculations

RTMVexit

RT

Pflowflow


Nozzle Exit Velocity:

Flow Density:

Mass Flow: 22 nozzleexitflow AVm

Test Results (Phase 1)


Power Output vs. Plenum Pressure

0

1

2

3

4

5

6

7

8

9

10

60 70 80 90 100 110 120 130 140

Plenum Pressure (psi)

Po

wer

(W)

1 ohm

5 ohm

8 ohm

100 ohm

Housing Post-Machining

• Main Housing– Had to machine inlet and outlet holes separately– Deburr housing after CNC machining– Bearing holes were too small due to limited tooling– Turbine seat was not concentric due to CNC tooling

path


Preliminary Budget05002 Micro-Turbine III Project

Component Description Price per Qty Line PriceHousing Turbine $96.00 1 2 $192.00

Nylon rod $5.97 foot 1 $5.97machining $10.00 1 1 $10.00fittings $1.00 1 4 $4.00bearings $40.00 10 10 $40.00coupling $14.09 10 10 $14.09Mini Stainless Steel Shaft $3.93 1 1 $3.93O-Ring $4.00 100 100 $4.00Nylon cheese head screw $5.60 100 100 $5.60black nylon 6/6 nut $10.00 100 10 $1.00

Fuel Systems Ni Canisters $20.00 1 2 $40.00Connector $0.62 1 2 $1.24O-Ring $7.50 1 2 $15.00Puncture components $20.00 1 2 $40.00Jets $100.00 50 50 $100.00

Electrical Generator $200.00 1 1 $200.00

Overall Cost $676.83

Final Budget


Previous Design

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Previous Turbine DesignSenior Design Team 04013


multidisciplinary engineering senior design project 05002 micro turbine iii 2005 critical design...

Documents

senior design slide

micro turbine

senior design load

turbine feasibility

critical design review

microturbine generators

francis large scale

micro air vehicle airframe