PowerPoint Presentation

Adam HertzlinDustin BordonaroJake GraySantiago MurciaYoem Clara

P14651: Drop Tower for Microgravity Simulation Project SummaryProblem GoalsDesign & Build Drop TowerVacuum Piping StructureCost EffectiveEffective Cycle TimeAesthetically PleasingPrecision in MeasurementsEducational User InterfaceAccess for Object TransferAdaptability for Future DevelopmentConstraintsLocation and design approval from the dean(s)Material availability/size (ex. tube, pump)The device is aesthetically pleasing The tower 6 12 DiameterThe device can be operated year round.The system is safe to operate.The project budget is $3,000. Team must justify the need for additional funds.The project must be completed in 2 semesters.

Project DeliverablesInstalled drop towerDetailed design drawings and assembly manualBill of materialsUsers Guide for operationDesigned Lab ExperimentsDetermine gravity in the vacuum within 1% errorCompare drag at different pressures and drag vs. accelerationAdditional vacuum related experimentsFun and Educational Experience for Middle School StudentsTechnical Paper Poster

AgendaCustomer Meeting UpdatesCustomer RequirementsEngineering RequirementsProposed Concept DesignIsolation Valve Cost AnalysisList of experimentsConcept and Architecture DevelopmentSystem BlockSub-systemsSummary Risk AssessmentTest PlanBill of Materials

Customer Meeting Notes Account for Pipe Fitting Leaks in calculationsHow does Ultimate Pressure change with Leak Rate?Limit design to one towerSimple PrototypeFit two objects in one towerAllow for lift mechanismDesign Concepts to Future Tower Development Go with 6-8 in. Diameter, approx. 10-15 ft. Tall TowerMeasure new location heightsDr. K LabTalk with Mark Smith about using MSD spaceDoes Ultimate Pressure Effect object drop timesFeather vs. Ball BearingUse only one laser when dropping items to measure gravityKeep the educational aspect in mind

Customer RequirementsCustomer Rqmt. #ImportanceDescriptionCR19 Appropriate Tower HeightCR29 Allow for Adjustable PressureCR39 Display Tower PressureCR49 Drop 2 objects simultaneouslyCR59 Drop objects with no horizontal motionCR69 Demonstrate standard local gravity within 1%CR79 Display important outputs accuratelyCR89 Allow full drop visibility and limit distortionCR99 Demonstrate drag vs. pressureCR109 Allow objects to be changed outCR119 Safe/Intuitive operationCR129 Educational and InspiringCR133 Display Tower TemperatureCR143 Design considers noise and power requirements and limitsCR153 Components are properly maintained and storedCR163 Aesthetically pleasingCR173 Generate object lift mechanism concepts for future MSDCR183 Allow for further static experimentsEngineering RequirementsRqmt. #I Engr. Requirement (metric)Unit of MeasureMarginal ValueIdeal ValueSR19 Measure Relative Object Positionft0-15>Tower HeightSR29 Measure Relative Object Drop Timesec0-2 SR39 Measure Pressurepsi0-14.70 - 14.7SR49 Cycle Run Timemin1-10 mins1 minSR59 Pressure Leak Rate Minimizedpsi / sec0-?0SR69 Aesthetic Structure with SupportsYes / NoYesYesSR79 No Horizontal Motionin0 - ?0SR89 Tube Collapse PressureFOS0-55SR99 Timing difference of object releasemillisecond0 - ?0SR103 Tower Heightft10-1515SR113 Tower Cross - Section (Diameter)in6-88SR123 Pump Flow Rateft3/min2-1010SR133 Measure Temperature% Error0-10SR143 Impact Energy Dissipation MethodJoule0-(mmaxvfinal2/2)(mmaxvfinal2/2)SR153 Air Intake - Tower Pressure Change Rateft3/min0 - ??SR163 Minimal Error in Calculations% error0 - 1%0%SR173 Aesthetic Data DisplayYes / NoYesYesSR183 Platform for Stationary Experimentsin(0.50*ID)-(0.99*ID)(0.99*ID)7Tube Diameter SelectionWeighted Pros and Cons of Tower Diameter% WeightCriteria6" Dia8" Dia10" Dia20%Low Cost43110%Object Size23410%Lift Mechanism Implementation Ease23415%Evacuation Time43110%Component Design (Drop Mechanism)23315%Component Availability32110%Accessability to Objects2345%FOS for Implosion4435%Support Structure444100%3.052.952.35Current Selection: 6" Diameter TubeList of ExperimentsDropping two objects simultaneously Measure Gravity Measure DragBalloon ExpansionMarshmallow ExpansionSound InsulatorPlastic Bottle Compression

Note: The following slides will attempt to justify the required tower pressure and size to complete these experiments CONCEPT & ARCHITECTURE DEVELOPMENTProposed Concept Designs

Proposed Base Structure

Selected Concept Designs (part 1)

Selected Concept Designs (part 2)

Continuous Lift Concept #1Continuous Lift Concept #2

Use pressure to control the up and down movement of a piston. The piston would transport the objects back to the top of the tower post drop.

Air SealSub-SystemsRelease MechanismRelease system CalculationsError PropagationUltimate Pressure SensorsAir ControlEvacuation time Leak Rate AnalysisCatching MechanismEnergy dissipation CalculationsPiping systemCritical external PressureStructure Tower height calculationsSupport Buckling

Tower Height DistributionCritical heightsTotal height drop at Dr. Kandlikar: Height of lab= 11 7 = 139With a ceiling clearing of 12 Drop height = 93.5 = 7.791 FtDrop time= 0.696 SecondsWith a ceiling clearing of 22Drop Height = 83.5 = 0.657FtDrop Time = 0.657 SecondsTotal height required for a 10 Ft drop height:H=13.79 FtCritical Length of pipe lengths L1 and L2Assuming a clearing of 12Assuming L1= 1 Ft L2= 7.692 FtAssuming L1= 2 Ft L2= 6.693 Ft

Engineering Analysis Release Mechanism

Base Specifications1.51.50.3754.00.3756.0Polycarbonate Diameter = 6.0 inThickness = 0.375 in = 1.22 g/cm3 (0.0441 lb/in3)

Hatch Doors Length = 1.5 in Width =4.0 inThickness = 0.375 inElectromagnet SpecificationsElectrical Specifications12 VDCOperating temperature of -40F to 140FHolding Force 4.5lbsPhysical SpecificationsWeight 0.06lbsDiameter 0.75inHeight 0.62inOther SpecificationsQuick Release Mechanism

Hinges Specifications

Physical Specifications Height 3.5in Width 1.5in Depth 0.21in Radius 5/16in (0.3125in)Pin Specifications Length 3.5in Radius 9/16in (0.5625in)FBD

Important ResultMaximum object weight before magnets will disengage prematurely5.6 lbsDoes not include Factor of Safety Weight of both object combined Engineering Analysis StructureTower HeightFree Fall No Air Resistance (Vacuum Conditions)Free Fall Air Resistance (Atmospheric Conditions)Free Fall Vacuum vs. Atmospheric ConditionsEngineering Analysis - Air Control Ultimate Pressure & Gravity Error EffectGravity Calculation with 1% ErrorFree Body Diagram of Object

Drag Force (Air Resistance)Objects to calculate gravity Not all objects may be suitable for gravity calculationsObjects vary by their mass, projected area and drag coefficientAssumptions:Max Tube Height = 15 ftIdeal GasRoom TemperatureStandard GravityError in Time vs. Chamber Pressure is as follows for each object:

Pressure (Pa)210501005001013251.625" Steel Ball0.0000%0.0000%0.0000%0.0001%0.0005%0.10%1" Steel Ball0.0000%0.0000%0.0001%0.0002%0.0008%0.16%Ping Pong Ball0.0002%0.0010%0.0049%0.0099%0.0495%10.25%Feather0.0023%0.0117%0.0585%0.1169%0.5855%106.83%Paper0.0130%0.0650%0.3254%0.6514%3.2801%352.56%% Error in Time vs. Chamber Pressure (Graphically)Engineering Analysis Laser SensorSensorSpecsMicro-Epsilon ILR-103015m Range4-20mA Output10ms Response time

ToleranceError in position +/- 5 mm (0.0164 ft)Error in timenone

Laser Distance Sensor

% Error in Gravity Summary2 Pa10 Pa50 Pa100 Pa500 Pa101325 Pa8ft15ft8ft15ft8ft15ft8ft15ft8ft15ft8ft15ft1.625" Steel Ball0.205%0.109%0.205%0.109%0.205%0.109%0.205%0.110%0.206%0.110%0.404%0.309%1" Steel Ball0.205%0.109%0.205%0.109%0.205%0.109%0.205%0.110%0.207%0.111%0.529%0.433%Ping Pong Ball0.205%0.110%0.207%0.111%0.215%0.119%0.225%0.129%0.304%0.208%20.704%20.609%Feather0.210%0.114%0.228%0.133%0.322%0.226%0.439%0.343%1.376%1.280%213.863%213.767%Paper0.231%0.135%0.335%0.239%0.856%0.760%1.508%1.412%6.765%6.669%705.326%705.230%Engineering Analysis - Air Control Evacuation TimeConductance

ViscousMolecular

Equivalent Pipe LengthPipe fittings can cause losses within a piping systemThese include: elbows, tees, couplings, valves, diameters changes, etc.Tabulated values for Le/D can be used to adjust L in the conductance equationsD = Diameter of PipeLe = Equivalent LengthTotal Length = L + Le1 + Le2 + Le3 + . Effective Pump Speed Evacuation TimeVP6D CPS Vacuum Pump

2 Stage Rotary Pump15 micron Ultimate VacuumPump Speed 6.25 cfmPrice: $268.92

Engineering Analysis - Air Control Leak RateChamber Leak RateThroughput, QUnits: (Pressure * Volume) / TimePump Throughput, QP

Where: Seff = Effective Pump Speed P = PressureLeak Throughput, QL

Where: dP/dt = Differential Pressure V = Chamber VolumeConstants:Chamber VolumeTemperatureAtmospheric PressureLeak Area

Time Variables:Mass Flow RateChamber PressureLeakPumpFlow Regime ChangeNote: Assumes linear relationship (mass flow rate constant)Engineering Analysis - Catching Mechanism Energy DissipationCritical Dimensions of Impact Absorption material

Critical Dimensions of Impact Absorption materialAssuming a Object 1 mass of 2 lb.Assuming a Coefficient of Restitution of 0.712Assuming a Ball Radius of 2in.Mass= Volume x densityVolume= Area x HeightArea= Pi x Radius^2

Height of energy absorbing material= 4.19 in 5 inEngineering Analysis Piping System Critical External PressurePipe Critical Pressure CalculationsDesired Factor of Safety = 3-4

Pipe Dimensions Courtesy of Engineeringtoolbox.com

*Specifications for white PVCEngineering Analysis StructureSupport BucklingSchematicWorst case scenario:15 Long PVC Schedule 408 Diameter10 long square A513 tubeSo 10 of buckling lengthAssumptions:Weight of vacuum tube is split evenly between four connection points

TubeFramePipe Riser ClampPipe Riser ClampDepiction of Reaction Forces on Tube

10ftW/4 W/4W/4W/4W/2W/2Eccentric DistanceMethods using Matlab:>> Buckling_Bisection F (lbf) is: 1616 FOS is: 84 The percent error is: 0.038Parameters:10ft long steel tube1-1/2 square 0.120 wallA513 steel

>> Buckling_False_Position F (lbf) is: 1617 FOS is: 84 The percent error is: 0.006

Support Buckling ResultsWe achieve a FOS well over what we would ever need for the selected support frame in buckling under worst case scenario

Our frame can support the weight of the tube, and is feasible

We can, if desired, reduce frame cross-section size and thickness if further analyses show large FOS as well

Engineering Analysis StructureLeg Center DeflectionWorst case scenario:15 Long PVC Schedule 408 Diameter10 long square A513 tube1-1/2 0.120 wallA513 steel

Assumptions:Weight of vacuum is halved between the two legs, as is the upper frame structure1 foot long leg

SchematicReactions and DeflectionIn the diagram below, dimension a is the distance to the front support block and b is to the center of the wheel axel.F includes half the weight of the tube and the upper support structure

Result: ymax=-3.30E-04 inches

Engineering Analysis SummaryProposed Requirement MetricsTower height: up to 5 meters (~16ft)Tower size: 6 DiameterNumber of Towers: 1Pump Speed: 6.25 cfm Pump Type: 2 stage Rotary (mechanical roughing pump)Evacuation Time: 5.25 mins Ultimate Pressure: 15 microns (0.015Torr or 2Pa)Negative (Critical) Pressure Factor of Safety: 3.94No Isolation Valves Manual Object LiftingElectromagnetic Release MechanismMobile Support Structure

Test Plan#Test DescriptionComments/Status1Drop TestTest Fall Time of Selected Objects is Atmosphere2Energy Dissipation ControlDrop heaviest object 3Test Release MechanismDrop Object from any height 4Position sensor accuracy for objectsSensors can be mounted / tested without tube5Ultimate pressureConsidering pump size / leaks/ chamber volume6Pressure gage accuracyConnect vacuum to pressure gage only7Temperature gage accuracyCalibrate Sensor8DAQ device inputsPosition and time (from sensor(s))9Computer Software OutputsComputer outputs from on DAQ & human inputs10Tower stabilitySimulate maximum applied forces11Extra vacuum testsHow things react inside our vacuumDrop Tower Piping Schematic

Bill of Materials: 6 Diameter by 10ft Tall

Bill of Materials Cont: 6 Diameter by 10ft Tall

Final Total: $2558.56

Drop Tower Price ComparisonUsing the 6in diameter by 15ft tall tower as a datum, the chart shown below was produced.

Questions?

Crit. P_T Calc.Critical Pressure Calculations for Clear PVCMinimum Thickness Calc. for Clear PVCP 14.7psiFormulaP14.7psiv 0.37PCrit=(2*E/(1-v^2))*(1/((OD/t)-1)^3)v0.37 E 429000psiE429000psiSCH 40 Pipe Maximum Pressure FormulaSize (in)OD (in)Thickness (in)Max Pressure (psi)Factor of Safetytmin=OD/(((2*E)/(P*(1-v^2)))^(1/3)+1)66.6250.2885.435.81PCrit=(2*E/(1-v^2))*(1/((OD/t)-1)^3)88.6250.32257.983.94Pipe Minimum Thickness1010.750.36543.162.94Size (in)OD (in)Min Thickness (in)1212.750.40635.372.4166.6250.15988.6250.2071010.750.2581212.750.30514140.33516160.383SCH 80 Pipe Maximum Pressure Size (in)OD (in)Thickness (in)Max Pressure (psi)Factor of Safety66.6250.432337.4222.9588.6250.5231.6715.761010.750.593197.8313.461212.750.687183.6212.4914140.75180.2912.2616160.843171.0311.63

SCH 40&80 PVCPVC and CPVC Pipes -Schedule 40"PVC and CPVC Pipes - Schedule 40 & 80."PVC and CPVC Pipes - Schedule 40 & 80. N.p., n.d. Web. 06 Oct. 2013. .Nominal Pipe SizeOutside DiameterMinimum Wall ThicknessNominal Inside DiameterWeight(inches)(inches)(inches)(inches)(lb/ft)PVCCPVC66.6250.286.0653.533.8688.6250.3227.9815.395.811010.750.36510.027.558.241212.750.40611.93810.0110.8914140.43813.12411.816160.51515.43PVC and CPVC Pipes -Schedule 80Nominal Pipe SizeOutside DiameterMinimum Wall ThicknessNominal Inside DiameterWeight(inches)(inches)(inches)(inches)(lb/ft)PVCCPVC66.6250.4325.7615.425.8288.6250.57.6258.058.831010.750.5939.5641213.091212.750.68711.37616.51814140.7512.519.316160.84314.31425.44

Harvel Crit. Pressure"Negative Pressure Applications."Negative Pressure Applications. N.p., n.d. Web. 06 Oct. 2013. .Negative Pressure ApplicationsCRITICAL COLLAPSE PRESSUREis the maximum allowable pressure that can be applied externally to pipe, and is directly related to the wall thickness of the pipe selected. Examples of external pressure conditions can occur: when buried pipe issubjected to soil loads; underwater applications; vacuum service; and pipe installed on pump suction lines. The actual external load being applied to the pipe is the difference between the external pressure and the internal pressure which counteract each other. As a result, a pressurized pipe can withstand a greater external load than an empty pipe.Critical Collapse Pressure Rating of GF Harvel PVC and CPVC Piping in PSI (and Inches of Water) Based @ 73F with No Safety Factor

Size(in.)DuctSDR 41SDR 26SDR 21SCH 40SCH 80SCH 1206N/A17*74*126*9034372281017*74*126*58235N/A105.417*74*126*49217N/A12317*74*126*42199N/A142.517*74*126*40194N/A161.617*74*126*40181N/A18117*74*126*33162N/A201.317*74*126*28157N/A24117*74*126*25150N/A* SDR Series Pipe maintains the same collapse ratings for all sizes due to the wall thickness/O.D. ratio.Georg Fischer Harvel LLC recommends the use of solvent-cemented connections when using PVC/CPVC piping in vacuum service applications. Threaded connections are not recommended due to the greater potential for leakage when used in negative pressure applications.1 psi = 2.036 inches of mercuryDe-Rating FactorsPVC PipeCPVC PipeOperating Temp FDe-rating FactorOperating Temp (F)De-Rating Factor731731800.881100.72900.751200.651000.621300.571100.511400.51200.41500.421300.311600.41400.221700.291800.252000.2Appropriate temperature de-rating factors must be applied at temperatures other than 73F based on the material selected.Multiply the collapse pressure rating of the selected pipe at 73F, by the appropriate de-rating factor to determine the collapse pressure rating of the pipe at the elevated temperature chosen.

Old Equationt= d*(P*((1-v^2)/(2*E*10^3)))^(1/3)

Crit. P_T Calc.Critical Pressure Calculations for Clear PVCMinimum Thickness Calc. for Clear PVCP14.7psiFormulaP14.7psiv0.37PCrit=(2*E/(1-v^2))*(1/((OD/t)-1)^3)v0.37E429000psiE429000psiSCH 40 Pipe Maximum Pressure FormulaSize (in)OD (in)Thickness (in)Max Pressure (psi)Factor of Safetytmin=OD/(((2*E)/(P*(1-v^2)))^(1/3)+1)66.6250.2885.435.81PCrit=(2*E/(1-v^2))*(1/((OD/t)-1)^3)88.6250.32257.983.94Pipe Minimum Thickness1010.750.36543.162.94Size (in)OD (in)Min Thickness (in)1212.750.40635.372.4166.6250.15988.6250.2071010.750.2581212.750.30514140.33516160.383SCH 80 Pipe Maximum Pressure Size (in)OD (in)Thickness (in)Max Pressure (psi)Factor of Safety66.6250.432337.4222.9588.6250.5231.6715.761010.750.593197.8313.461212.750.687183.6212.4914140.75180.2912.2616160.843171.0311.63

SCH 40&80 PVCPVC and CPVC Pipes -Schedule 40"PVC and CPVC Pipes - Schedule 40 & 80."PVC and CPVC Pipes - Schedule 40 & 80. N.p., n.d. Web. 06 Oct. 2013. .Nominal Pipe SizeOutside DiameterMinimum Wall ThicknessNominal Inside DiameterWeight(inches)(inches)(inches)(inches)(lb/ft)PVCCPVC66.6250.286.0653.533.8688.6250.3227.9815.395.811010.750.36510.027.558.241212.750.40611.93810.0110.8914140.43813.12411.816160.51515.43PVC and CPVC Pipes -Schedule 80Nominal Pipe SizeOutside DiameterMinimum Wall ThicknessNominal Inside DiameterWeight(inches)(inches)(inches)(inches)(lb/ft)PVCCPVC66.6250.4325.7615.425.8288.6250.57.6258.058.831010.750.5939.5641213.091212.750.68711.37616.51814140.7512.519.316160.84314.31425.44

Harvel Crit. Pressure"Negative Pressure Applications."Negative Pressure Applications. N.p., n.d. Web. 06 Oct. 2013. .Negative Pressure ApplicationsCRITICAL COLLAPSE PRESSUREis the maximum allowable pressure that can be applied externally to pipe, and is directly related to the wall thickness of the pipe selected. Examples of external pressure conditions can occur: when buried pipe issubjected to soil loads; underwater applications; vacuum service; and pipe installed on pump suction lines. The actual external load being applied to the pipe is the difference between the external pressure and the internal pressure which counteract each other. As a result, a pressurized pipe can withstand a greater external load than an empty pipe.Critical Collapse Pressure Rating of GF Harvel PVC and CPVC Piping in PSI (and Inches of Water) Based @ 73F with No Safety Factor

Size(in.)DuctSDR 41SDR 26SDR 21SCH 40SCH 80SCH 120Max Pressure Rating of Schedule 40 PVC*, from HARVEL6N/A17*74*126*90343722Size (in)Max Pressure (psi)Factor of Safety81017*74*126*58235N/A6906.12105.417*74*126*49217N/A8583.9512317*74*126*42199N/A10493.33142.517*74*126*40194N/A12422.86161.617*74*126*40181N/A18117*74*126*33162N/A201.317*74*126*28157N/A24117*74*126*25150N/A* SDR Series Pipe maintains the same collapse ratings for all sizes due to the wall thickness/O.D. ratio.Georg Fischer Harvel LLC recommends the use of solvent-cemented connections when using PVC/CPVC piping in vacuum service applications. Threaded connections are not recommended due to the greater potential for leakage when used in negative pressure applications.1 psi = 2.036 inches of mercuryDe-Rating FactorsPVC PipeCPVC PipeOperating Temp FDe-rating FactorOperating Temp (F)De-Rating Factor731731800.881100.72900.751200.651000.621300.571100.511400.51200.41500.421300.311600.41400.221700.291800.252000.2Appropriate temperature de-rating factors must be applied at temperatures other than 73F based on the material selected.Multiply the collapse pressure rating of the selected pipe at 73F, by the appropriate de-rating factor to determine the collapse pressure rating of the pipe at the elevated temperature chosen.

Old Equationt= d*(P*((1-v^2)/(2*E*10^3)))^(1/3)