EDSGN497D Senior Multidisciplinary Capstone Project: Development of an Automated Helicopter Rotor Wake Survey System Sponsored by The Boeing

Company Design Specifications Report 21 March 2013

Team Name: WhirlyBirds Team Members: Bill Boggs Steven Drew Ryan Hammerschmitt Scott Hromisin Joseph Oberholtzer Dylan Wynn

No Intellectual Property Rights Agreement No Non-Disclosure Agreement Executive Summary:

The objective of this project is to measure the rotor wake of a helicopter below the rotor at a minimum of eight azimuthal angles, three heights and five radial positions. The local pressures will be measured using a pressure probe and then passed to a computer for data reduction and visual representation. It is essential that the pressure probe never touches the rotor blade in order to avoid risk of injury. The Boeing Company is supplying a stand, a drive system with a rotor and a test probe for testing the pressure change under the rotor. The rotor is six feet in diameter and is run by a 1.5 horsepower motor. The design process began with a Gantt chart to plan out the timetable of the project. The Gantt chart is essential to project planning because it sets deadlines for different aspects of the system. The Gantt charts first section is the research and brainstorming stage, which defines the path in which the project will go. Many different possible solutions to the problem have been brainstormed, analyzed and rated to see which design will provide the most overall efficiency. After the analysis, the best design is selected and a CAD model is created, for every different theater of the system. This includes the azimuthal design, which moves the pressure probe stand a full 360 degrees in order to measure any point around the test stand. The radial system is designed to move to any radial position under the rotor and the vertical system will move the pressure probe in the y direction. After CAD model creation and construction, the initial design undergoes extensive testing. Software is also tested to make sure that the signals sent to the system for motor movement are accurate. Three stepper motors move the system to the coordinates specified by the user of the software, so software testing and mechanical testing are done in conjunction to fully verify the accuracy of measurement. Tests are done to make sure the pressure probe is reading accurate pressures following verification of the accuracy of the mechanical system. After the testing analysis and second design is constructed, correcting the mistakes that were seen in the first design. Currently the team is under budget and on schedule to test the second design iteration. To validate the capabilities of the system, individual components were tested as they were constructed and finally the whole system was tested. The modular design allowed discrete testing of the mechanical motion systems. Testing of the sensing capabilities was performed with a manometer and then in the Penn State wind tunnel. Finally real world testing with a rotor test stand was used to evaluate the entire system performance. The system ultimately proved its ability to meet and exceed customer needs. With the customer needs met, additional design iterations should be used to refine the design for manufacturing and ease of use.

Table of Contents Table of Contents ............................................................................................................................ 3 1. 2. 3. 4. 5. 6. 7. 8. 9. Introduction ............................................................................................................................. 4 Customer Needs Assessment................................................................................................... 4 External Search........................................................................................................................ 7 Engineering Specifications .................................................................................................... 11 Concept Generation and Selection ........................................................................................ 16 System-Level Design ............................................................................................................ 24 Special Topics ....................................................................................................................... 25 Changes to the Statement of work ......................................................................................... 36 Final Discussion .................................................................................................................... 69

10. Conclusions and Recommendations ...................................................................................... 76 11. References ............................................................................................................................. 80 12. Appendix A: Survey For Analytical Hierarchy Process ....................................................... 81 13. Appendix B: External Search URLs .................................................................................... 83 14. Appendix C: Concept Generation ......................................................................................... 84 15. Appendix D: Concept Generation ......................................................................................... 88 16. Appendix E: Resumes ........................................................................................................... 90 17. Appendix F: Changes To The Statement Of Work ............................................................... 91 18. Appendix G: Calculations for Design Analysis .................................................................... 98 19. Appendix H: Shop Drawings .............................................................................................. 114 20. Appendix I: Bill Of Materials ............................................................................................. 120

1.

Introduction

Testing of model helicopter rotor systems typically consists of measuring loads on the rotors to determine the aerodynamic effects of speed, angle of attack, and blade shape. Current testing methods, however, have no way of measuring what is happening below the rotors. Measuring and analysing the flow properties beneath the rotor could provide researchers with beneficial information regarding the performance of the rotor.

Initial Problem Statement Boeing has challenged our team with designing, building, and testing an apparatus to position a pressure probe at any point in 3D space below a rotor test stand. The testing apparatus to be designed will allow valuable information to be collected about the properties of a helicopter downwash. Objectives The system must be able to take an input from a user, specifying the location at which the measurements are to be taken. The apparatus must then move the probe to the desired location. The system to be designed will be motorized and fully automatic, being able to move to the positions specified by the user with no additional human interaction. Pressure readings will be taken using a pitot-static probe with a pressure transducer, and these readings will be transmitted to a computer. The computer will reduce the data and plot the results in three dimensions. The team will deliver the designed mechanism, all relevant drawings and CAD files, data reduction and plotting software, and instructions for use. 2. Customer Needs Assessment Gathering Customer Input We will be able to determine our customer needs through weekly interactions with our client. Via weekly conference call, we will be able to assess the customer needs by asking questions. The first few conference calls will be dedicated developing a complete understanding of our customers wants and needs. Boeings most basic needs are listed clearly in the project statement on the Penn State Learning Factorys website. Using these most basic needs as a springboard, the team was able to generate a long list of questions for our project sponsors in order to more truly understand their needs. During the first conference call on January 29th, 2013 the team received objective answers to each and every one of the questions. Through the questions a list of formal customer needs could be developed.

1.1.

1.2.

2.1.

The Boeing Company Customer Needs 1. The pressure sensor has multiple positions 2. The pressure sensor is accurately positioned 3. The pressure sensor is positioned in the rotor wake 4. The pressure sensor position can be changed remotely 5. The pressure sensor reads any pressure in the rotor wake 6. The pressure data captures the constantly varying pressure 7. The pressure data is accurate 8. The angular velocity of the rotor is collected 9. The system includes data visualization software 10. The system includes sensor control software 11. The system must include an instruction manual 12. The system must be reliable
All pertinent customer statements are recorded by several team members in notebooks during conference calls. Not only does this give us a level of redundancy but it also helps to avoid misinterpreting customer statements because we compare our notes after every call-in. As many of the statements are quantitative answers to our questions, developing customer needs and design metrics is very straightforward. Any new statements by the customer at this point will be assumed to be wants and not exactly needs unless they tell us otherwise. This will ensure that as our target design criteria remain constant as product design, building, and testing begins in the upcoming weeks.

Weighting of Customer Needs To ensure that our sponsors needs were being properly considered, a moderate length survey was sent to them. The survey compares every need against every other need on a 5-3-1-35 scale. For example: Need A 5 3 1 3 5 Need B Selecting 1 means needs A and B are of equal importance. The values of 3 and 5 on the left correspond to Need A being of higher importance than Need B, and vice versa. The results of this survey may be found in Appendix A: Survey For Analytical Hierarchy Process. The results of this survey could be directly inputted into a hierarchical list of customer needs (AHP) matrix. This matrix calculates the relative importance each customer need with respect to every other customer need. Development of this matrix is discussed in great detail in Ulrich & Eppinger. Our AHP matrix may be found in Table 1.

2.2.

Table 1. AHP Matrix of Customer Needs to Determine Weighting for Customer Needs Ease of building Ease of implementation

Time to build

Versatility of components

Durability

Simplicity

Aesthetics

Accuracy

Simplicity Accuracy Cost Durability Ease of building Ease of implementatio n Versatility of components Time to build Aesthetics Total

1.00 3.00 1.00 1.00 1.00

0.33 1.00 0.33 0.33 0.33

1.00 3.00 1.00 3.00 3.00

1.00 3.00 0.33 1.00 1.00

1.00 3.00 0.33 1.00 1.00

0.33 3.00 0.20 0.33 0.33

1.00 3.00 0.33 1.00 1.00

0.33 3.00 0.33 3.00 0.33

5.00 5.00 1.00 5.00 5.00

11.0 0 27.0 0 4.87 15.6 7 13.0 0 26.3 3 13.6 7 15.0 0 6.20 132

0.08 2 0.20 3 0.03 6 0.11 8 0.09 7 0.19 8 0.10 2 0.11 3 0.04 6 1

0.08 0.20 0.04 0.12 0.10

3.00 1.00 3.00 0.20

0.33 0.33 0.33 0.20

5.00 3.00 3.00 1.00

3.00 1.00 0.33 0.20

3.00 1.00 1.00 3.00

1.00 0.33 0.33 0.20

3.00 1.00 1.00 0.20

3.00 1.00 1.00 0.20

5.00 5.00 5.00 1.00

0.20 0.10 0.11 0.05

Definitions for the customer needs can be found in Appendix A: Survey For Analytical Hierarchy Process proceeding the answered customer survey. The results of this AHP matrix show that positional accuracy and ease of implementation are the most important criteria, whereas aesthetics and cost are relatively unimportant. The results of this AHP, while helpful in most regards, are somewhat dubious. Our project sponsors completed the survey which fed directly into this matrix. They work for Boeing, a billion dollar company, so for them, cost is virtually a nonissue. However, our team is working on a very limited budget of $1000. For us, cost has a lot of weight. We may design a state-of-the-art system, but if we can only afford two parts for it, our design will be no good. We need to make sure that what we design not only meets their most important needs but also does not exceed out budget.

Rounded

Weight

Sum

Cost

3. External Search
An extensive external search is being carried out by all members of the group. We need to see what sort of prior art is already out there, that is, on the market or patented. Given our budget of $1000, we also had to understand typical traversing and data acquisition (DAQ) capabilities as a function of cost. The final results of the external search follow.

3.1.

Patent Search

The first level of searching includes researching patents relevant to our product. It is imperative so understand what is patented so that the final product does not infringe upon the rights of another individual or company. Table 2. Results of the Team Patent Search for Existing Prior Art Patent Name Patent Number 6466643 4976136 8256284 7284420 6938472 Filing Date

High speed digital radiographic inspection of aircraft fuselages Method of testing for fuselage cracks Flight air data measuring system Air data system and method for rotary aircraft Static pressure calculation from dynamic pressure for rotary airdata system and methodology therefor

Aug 22, 2000 Oct 13, 1989 Aug 22, 2006 Jul 13, 2004 Dec 10, 2003

Existing Products The second part of the search involves documenting what kinds of products are on the market. Understanding what products are out there, and their costs and capabilities, will help give the team a good understanding of performance as a function of cost. Knowing this relationship assists the team in setting acceptable performance goals within the given budget. Table 3. Existing Traversing Systems, Controls, and Other Related Products Currently on the Market Product Helicopter Air Data System Description - Measures airspeed across the complete flight envelope. - Swiveling pitot probe Price Professional/Militar y grade (i.e. very high) *URL 1

3.2.

- Flow angles - Air temperature Curved Rail Sliders Curved Rail System - Three cam roller bearings per slider assembly - preload adjustable - Arc length 180 degrees - 0.5m 1.25m radius - 1.57m 3.927m rail length - Holes for mounting Telescoping Pitot Probe USB to I2C Converter - Extends from 8in to 38in $305 4 $78 - $101 2

$360 - $890

-Support the dual interface: I2C interface and Serial interface. - Standard 100Kbps and Fast 400Kbps I2C interface. - 8 Bit Data Port. - Data Port pins may be individually selected to be digital input / output, analog input or PWM output. - 10 Bit ADC, up to 5 analog inputs - 13 bit - 4 channel - USB output for Windows XP and higher - 10000Hz sampling rate max

$15

Low-Cost Dataq Start Kit

$150

Teensy USB-based microcontrolle r development system

- USB-based microcontroller development system Processor - Flash Memory: 131072 - Analog in: 12 - I/O: 34, 3.3 Volt

$16 - $24

Stepper Motors

- 200 steps/revolution - Current: 280mA 1200mA - Voltage: 2.7V 10V - Torque: 180 g-cm - 3.17 kg-cm

$13 - $20

Geared Bipolar Stepper Motor

-Gear Ratio: 26.85:1 - Gearbox rated for sustained torque of 30 kg-cm - Maximum speed of 22 RPM @ 12V (with 1063 motor controller) - Circuit board to control stepper motors

$39

Stepper Motor Driver Velmex Traversing Stages

$10 - $20

10

- Precision linear traversing stages - Manual or motor-driven options - Screw drive, free sliders, and rotational

Manual: $160 - $ 800 Motor: $360 $3400

11

Hobby Projects and Open-Source Products Some of the most intriguing results from the external search are the capabilities of many do-ityourself projects. Using simple and relatively inexpensive supplies, some people were able to make novel traversing and DAQ systems.

3.3.

Table 4. Do-It-Yourself (DIY) and Open-Source Products / Systems Project Description Projected *URL Cost $20 12

Arudino DAQ controller

- 500Hz Sampling Rate - 10 bit resolution - 1kHz serial, 25khz-50khz with overclock and I2C

Radial Dolly Track

Smooth rolling, easy to build DIY curved dolly track with plans and instructions Allows interchangeable sensors without a change in the output voltage Open source plans for a CNC machine well controlled machine automated movement Simple, cheap, easy-to-build camera slider that can be modified for automated movement

$30

13

Simple Pressure Sensor Signal Conditioning Circuit Schematic Open Source CNC plans

n/a

14

free

15-16

Horizontal/Radial DIY slider

$15

17

* Corresponding URLs may found at the end of this paper in Appendix B: The external search is proving to be quite fruitful. The team has discovered a diverse array of products. There are many existing products for straight-line motion, as it is a widely used feature in many data-collection scenarios such as flaw detection in a part. Linear motion can be as inexpensive as $20 for some sliders or upwards of $3400 for higher end, motorized systems. For azimuthal motion (that is not a small, rotating disk), there are significantly fewer products on the market. Those products that do exist can cost upwards of $400. That is outside the price range for any single product given the $1000 budget. In terms of capability per unit dollar, the most intriguing products appear to be do-ityourself slider systems for cameras. The slider systems can move smoothly in linear or circumferential directions. Moreover, the parts to build these systems can be bought at local hardware stores for a few dollars. As testament to this, the team has already built a firstgeneration prototype using all store-bought hardware. The prototype moves in all three cylindrical dimensions and only cost $50 to make.

10

While many existing products and patents have already been found, the external search is still ongoing. Most of the benchmarking up to this point has focused on physically large portions of the system i.e. azimuthal, radial, and traversing systems. Much research is now going into the details of the motion that is, controllers and motors.

4. Engineering Specifications
4.1. Establishing Target Specifications With a strong understanding of the customer needs and the relevant existing technologies, design metrics will be used as the known parameters of the detailed design. Metrics provide well defined criteria by which existing solutions can be benchmarked and the success of the solution can be quantified. The metrics are developed from the customer needs and specifications established through additional communication with the customer. Meeting all of design metrics exactly is ideal. However, due to time and budget constraints, along with performance issues, may make reaching all of metric values impossible. Therefore, it is wise to develop a range of values our system must perform between; that is, a high and a low, or an ideal and minimally acceptable (metric) value. Most of the acceptable and ideal product specifications were determined primarily through communication with the customer. Other specifications required additional research and analysis such as the sampling rates, sampling resolution and frequency analysis.
Table 5. Acceptable and Ideal Values for System Metrics Metric Pressure Sensor Manipulation Radial Sensor Positions - Quantity Radial Sensor Positions - Accuracy Radial Sensor Positions - Range Azimuthal Sensor Positions Quantity Azimuthal Sensor Positions Accuracy Azimuthal Sensor Positions - Range Vertical Sensor Positions - Quantity 5 +/- 0.05 6 to 24 >50 +/- 0.005 6 to 43 Acceptable Value Ideal Value

8 +/- 0.05 0deg to 180deg 3

>80 +/- 0.005 0deg to 360deg >30

11

Vertical Sensor Positions Accuracy Vertical Sensor Positions - Range Dimensions of Automated Movement Pressure Sensor Performance Pressure Sensor Range

+/- 0.05 12 to 24

+/- 0.005 6 to 36

0 psi to 2.5 psi 10 Bit (0.0024 psi) 160 Hz +/- 15 degrees

0 psi to 2.5 psi

Pressure Sample Resolution Pressure Sampling Rate Pressure Sensor Flow Alignment

13 Bit (0.00031 psi) 2000 Hz +/- 5 degrees

Rotor Angular Velocity Sensor Performance Sampling Rate 80 Hz 400 Hz

Data Reduction and User Interface Software Pressure on 3D Plot Sensor Positioning Software Included User input for each position change Not Included Included User defined test sequences

Frequency Analysis Instruction manual Positioning mechanism

Included

Procedure

Procedure, Replacement Part Construction, Troubleshooting Procedure, Changing/Adding Code, Troubleshooting

Output Software

Procedure

12

Setup of System

Procedure

Procedure, Troubleshooting

Duration of System Performance Hours of Testing 3 Hours >9 hours

Relating Specifications to Customer Needs While developing an AHP matrix and a list of product metrics are worthwhile and even necessary practices, the product design process will all be for naught if the finish product does not meet a customer need. In the ideal case outlined in Ulrich & Eppinger, there will be one metric that corresponds to each customer need and satisfies that need. In practice though, this is not always the case. Due to feasibility issues or complex needs, needs may be met only with the use of two or three metrics. To keep the needs-metrics relationships organized in a clear and concise manner a needs-metrics method is used (Table 6). In this method, each row of the matrix corresponds to a customer need and each column corresponds to a metric. A mark is placed at the intersection of a need and the metric(s) that satisfies it. If there is a mark in every row then we can be sure that our list of metrics is broad enough to meet all customer needs. Our needs-metrics matrix is in Table 6. From it, we found that every row has at least one mark in it. Therefore, we are confident that we can meet of our sponsors needs if we build a product to meet our current metrics.

4.2.

13

Table 6. Needs-Metrics Matrix using QFD Method for the Rotor Wake Survey Project Our customer needs were developed through a survey that was completed by the customer. The information provided by the customer in the survey was then translated into a set of needs with corresponding metrics. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 20 21 Hours of Testing
14

Customer Needs

1 Pressure sensor has multiple positions X Pressure sensor is 2 accurately positioned Pressure sensor is 3 positioned in the wake Sensor position can 4 be changed remotely Sensor reads any 5 pressure in the wake System captures 6 pressure in real time 7 The pressure data is accurate 8 Angular velocity of

Sensor Radial Metrics Positions Sensor Azimuthal Quantity Positions Sensor Vertical Quantity Positions Sensor Radial Quantity Positions Sensor Azimuthal Accuracy Positions Sensor Vertical Accuracy Positions Accuracy Radial Sensor Positions - Range Azimuthal Sensor Positions - Range Vertical Sensor of Dimensions Positions - Range Automated Movement Pressure Sensor Range Pressure Sample Resolution Pressure Sampling Rate Pressure Sensor alignment to flow Rotor Velocity Sampling rate Pressure on 3D Plot Sensor Positioning Software System Operation Instructions Setup of System Instructions X X X X X X X X X X X X X X

10 11 12

the rotor is collected System includes data visualization software System includes sensor control software Instruction manual is included The system must be reliable

X X X X

15

5. Concept Generation and Selection

Problem Clarification Before generating concepts for our automated rotor wake surveying system we need to know, in general, how the system is going to work; what it is going to do. Another way of putting is to ask ourselves: what are the inputs? What are the outputs? What are the basic steps in between the two? Best way to answer these questions is visually: with a black-box model showing system inputs/outputs and the energy flow through the system. A diagram like this contains invaluable information to assist in brainstorming and system-level design. This is because the diagram defines what goes into our system, what our system must output to meet customer needs, and the critical sub-functions in between. It is these sub-functions that we will have to design, build and interface with each other in order to achieve our target outputs. Our black box model is shown in Figure 1. All black box functions are enclosed in a dashed box. The largest black box is that of the system: inputs go in, and the rotor wake data is the output. The smaller black box is the positioning of the probe step. This reads in the desired position, goes to it, takes a measurement, and passes the analog data along for processing.

5.1.

Figure 1. System Level Black Box and Energy Flow Design The system level design is straightforward from Figure 1. The user input will run through an encoder, the encoder will instruct the motor create a movement for the probe, which will record data, and send feedback. Multiple iterations of our project will allow us to fix any flaws in our prototype design. Each design will be selected through a selection matrix based on customer needs. The needs will be weighted and applied to our design selection table discussed in Section 5.3.

16

Concept Generation Concept generation is a very critical stage for our project. If done properly, some very intriguing design ideas are generated. These ideas propagate on to concept selection and a novel, working system will be chosen. Concept ideas come from two majors sources: external searches and internal searches. The teams external search is described in Section 3.0. The team has been conducting multiple internal searches, i.e. group brainstorming sessions as well. During these meetings, ideas are bounced back and forth of each other. We consider the pros and cons of certain designs and list then alongside sketches of the idea. Discussions typically focus on traversing systems, as this is where we have the most flexibility. However, we also discuss different motors and software platforms we are considering for the system.

5.2.

Figure 2. Typical design idea during a brainstorming session

More images from brainstorming sessions may be found in Appendix C:. Once brainstorming is complete we move on to a more formal concept generation stage. Here ideas are discussed in more detail. Ideas are more practical and well thought out and the drawings become more technical. Some results from concept generation meetings are:

17

Figure 3. Vertical motion concept scissor lift system

Figure 4. User Interface Concept MATLAB control GUI

18

Figure 5. Combined motion radial and vertical system

More concept generation results may be found in Appendix D.

5.3.

Concept Selection

Following the guidelines set forth by Ulrich & Eppinger, our concept selection process consists of two steps: 1) concept screening and 2) concept scoring. Concept screening is a qualitative process in which we compare our ideas against a reference product and for a given list of criteria we decide if our idea is better, equal to, or worse than the reference. For our concept screening process, we opted to use existing products as our references. Our concept screening matrix can be found in Table 7. It can be seen from Table 7 that some concepts are relatively close in score while some are at the bottom of barrel with a very low score. Any concepts with a value of -6 or less will not move on to the concept scoring matrix. The concept scoring matrix is designed to calculate the best concept for each of our five subsystems: azimuthal motion, radial motion, vertical motion, data acquisition, and software. To do this, the rows of the matrix are the concepts and the columns are the customer needs previously discussed in Section 2.2. Moving across the columns, each concept is scored on a scale of 1-10 on how well it meets that particular customer need, with 10 being extremely well. The score is then multiplied by the corresponding weight for that need. The weights were determined using the AHP matrix in Section 2.2. The scores for each column are summed together. The concept from each of the five subsystems that has the highest total score will be the concept that gets implemented in our final design. The concept scoring matrix can be found in Table 8.

19

Table 7. Concept Screening Matrix

Reference(belt drive rail)

rail system Camera Reference(Commercial Rail)

Reference(LabVIEW)

Reference(Screw lift)

Rail rack and pinion

Concept

center shaft support

equipment Loaned Reference(Micro controller)

vertical turn table

Rail wheel drive

Rail screw drive

Radial Motion

rac n pinion

mechanical

Scissor lift

roomba Azimuthal

Software

turntable

roomba Vertical

mag lev

Di-155

C/C++ -1 1 0 0 -1 0 1 -1

piston

Simplicity Accuracy Cost Durability Ease of building Ease of implemen tation Versatility of componen ts Time to

0 0 0 0

1 1 0 1

1 0 -1 -1

1 -1 -1 -1 0 -1 0 0 -1

0 -1 1 -1

0 0 0 0

-1 0 0 0

1 -1 1 -1

1 -1

0 1 -1 0

0 0 0 0

1 1 0 0

-1 1 -1 -1

0 -1 -1 1

1 1 1 1

0 0 0 0

1 1 0 1

0 0 0 0

1 0 0 0

0 -1 -1 -1 1 1 -1 0 0 -1

1 -1

-1

-1

1 -1

-1

-1

-1

-1

1 1

-1

1 -1

-1

-1

0 0

1 -1

1 -1

0 1 -1

1 1

0 0

-1 -1

-1 -1

-1 -1 -1 1 -1

1 -1

0 0

0 0

-1 -1

-1 -1

0 1

0 0

1 1

0 0

-1 1

java -1 -1 -1 -1 -1 -1 -1 -1
20

Selection Criteria

MATlab

Data Aq

build Aesthetics Sum 0 0 0 4 0 -2 0 1 0 2 0 0 0 -5 -1 -1 -1 -1 -1 -4 2 -7 1 1 0 0 -1 -1 0 -6 1 -1 1 7 0 0 0 6 0 0 0 2 0 -1 1 -7

3 -4

21

Table 8. Concept Scoring Matrix with Wining Concept Highlighted Simplicity Accuracy Cost Durability Radial Motion Rail Screw Drive Rail Wheel Drive Belt Drive Rail Camera Rail Azimuthal System Commercial Rail Vertical Scissor lift Screw lift Loaned equipment Micro controller Di-155 Software LabVIEW MATlab C/C++ Ease of build Ease of impl. Vers. of comp. Time to build Aesthetics Total

7 4

2 4

5 5

3 4

6 5

5 4

5 4

7 6

5 5

4.64 4.41

5.1

5 5 5

1 6 5

5 4 5

5 3 5

5 4 5

5 8 5

5 7 5

5 4 5

5 6 5

4.9 5.56 5

Data Aq

6.74

5 6 5 7 3

5 7 5 5 6

5 5 5 4 6

5 7 5 6 4

5 7 5 8 2

5 5 5 6 4

5 8 5 4 6

5 7 5 7 4

5 5 5 6 5

5 6.44 5 5.91 4.45

22

Weights:

0.08

0.2

0.04

0.12

0.1

0.2

0.1

0.11

0.05

23

6. System-Level Design
The high-level system design will combine all of the top concepts from the concept scoring matrix. The rotor wake survey system will be a curved azimuthal track on top of which a dolly will sit. The dolly will be attached a curved rac and pinion gear system to control its motion. On top of the dolly will be a linear camera rail system to move radially. A scissor lift will be mounted on top of the radial system to move the pitot probe vertically. Both the radial and vertical components will be powered by screw drives. A MATLAB user-interface will be the front end for the software to set the measurement positions and display the collected data.

Figure 6. Azimuthal camera rail system

Figure 7. First-Generation alpha-prototype of the system

24

7. Special Topics
Budget Below is the teams up to date budget. It accounts for all recent expenses along with the expected expenses for traveling, prototyping, and final product construction. Table 9 Current Project Budget Part Estimated Data acquistion system Travel Cost Prototyping Cost Final Product Cost Poster 150 224 100 224.3 70 1 1 1 1 1 150 224 100 224.3 70 0 n/a n/a n/a n/a n/a n/a Price($) Quantity Total Vendor

7.1.

Actual 1x1x7 Premium Furring Str 3/4 INX1OFT PVC Pipe EMT Conduit 5ft 1x2x8 Premium Furring STR DRYWALL SCREW CRSE 2'' 1/2 Compression Con 3/4" SCH40 TEE

6.88

6.88

Lowes

4.36 3.3

1 1

4.36 3.3

Lowes Lowes

1.12

1.12

Lowes

4.37 2.28 1.38

1 1 1

4.37 2.28 1.38

Lowes Lowes Lowes

25

3/4" Coupling Hex Bolt 1/2 x 1-1/2 Hex Nuts Skateboard wheels

0.54 3.84 0.88 1.25

1 1 1 8

0.54 3.84 0.88 10

Lowes Lowes Lowes Penn Skate Home Depot Home Depot Home Depot Home Depot Home Depot

Wooden Dowel Rod Handy metal conduit boxes 0.75in PVC tee couplings

1.42

1.42

1.64

3.28

0.47

1.88

12in threaded rod

1.17

1.17

24in threaded rod Stepper Motor, Unpolar/Bipolar, 200 steps/rev Stepper Motor, Bipolar, 200 steps/rev A4988 Stepper Motor Driver Carrier

1.76

1.76

19.95

19.95

Pololu

12.95

25.9

Pololu

9.95

3 Total Budget:

29.85 1000

Pololu

Sales tax to be applied to all expenses

Sales Tax: Remaining Budget Amount Spent:

0.06

53.9924 946.0076

26

Gantt Chart In order to keep ourselves organized we are keeping all of our documents in a shared group folder on Google Doc. We found a useful Gantt chart program written specifically for Googles spreadsheet feature. Knowing the start and end dates of a project, if the Percent Complete value changes, then the Gantt chart automatically updates. It is a very powerful program. However, its code is not compatible with Excel and the spreadsheet is too large (in length) to export as a reasonably-sized picture. Table 10 has the first and most informational portion of our Gantt chart. Table 10 includes all project tasks, their respective state and end dates, percent complete, and who is in charge of each task. Table 10. Gantt Chart

7.2.

27

28

29

Risk Management Given the nature of this project with its high-speed, large-diameter rotor, and complex traversing system, there are significant risks involved in properly designing the system. The most critical risks associated with this project are personnel safety and equipment safety: in operation, the 6ft. diameter rotor will be spinning at approximately 2400rpm. This can cause significant harm to any persons or the probe should either come in contact with the blade. To alleviate this risk, the system will be designed such that the probe can get close to the rotor blades but it can never come in contact with the blades. For user-safety, this system will only be used by trained

7.3.

30

professionals/students in a controlled testing environment so as a first-level precaution we will require all personnel maintain a certain safety radius away from the system. We will look into installing a safety cage or similar object around the system to keep people from coming in contact with the rotor blades. If funds or time are short, we will look into borrowing a safety cage. Table 11. Risk Plan Table Risk Change in Customer needs Level Low Actions to Minimize - Keep sponsors always up to date on project developments and design decisions Fallback Strategy - Additional money required - Factored in 3 different design-build-test stages into project schedule - Install sensors or barricades to prevent probe motion - Install a protective cage around the entire system

Rotor blades harm equipment or people

High

- Design traversing system such that the probe can never come in contact with the blades - Require operators to stand a specified number of feet away while rotor is in operation - Do not allow bystanders to come near rotor blades - Do not operate around untrained professionals

Traversing system cannot move in 3 dimensions as designed

Moderate - Test early and often (3 designbuild-test iterations factored into schedule) - Consult with sponsors and other professionals on the selection and implementation of hardware to ensure proper choices are made - Use proven technology

- Manually position probe - Design for minimum requirements outlined in project description

Sponsors not satisfied with the system

Low

- Constantly keep in contact with sponsor and reiterate via e-mail what is discussed in meetings so there is a written copy to avoid

- Discuss how to fix/workaround problems

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confusion Schedule Delays High - Constantly track and report on progress - Try to work ahead on simple tasks - Make a small number of large orders not a large number of small orders Stand is incompatible with traversing system Rotor wake shakes probe and traversing arms Data acquisition system does not function as designed Moderate - Discuss modifications to stand with sponsors. - Make parts ourselves - Contact supplier to express urgency (e.g. the squeaky wheel gets the grease) - Pick it up ourselves - Buy locally - Redesign system to work with the stand

Low

- Design traversing system as rigid - Operate at sufficiently low as possible. speeds such that the rotor wake buffeting is minimal - Avoid cantilevered arms in design - Purchase a functioning data acquisition system - Design to minimum requirements - Use multiple software systems for inputs and outputs - Build hardware ourselves - Negotiate with vendors for lower prices/donations

Moderate - Consult with professionals on proper use of hardware and software to ensure compatibility - Test often to make sure controls and sensors work as designed

Project runs over budget

Low

- Extensively research existing products to ensure we purchase the best-value product - Avoid buying wrong hardware - Minimize orders to minimize shipping costs

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A majority of the other risks associated with this project are of moderate intensity or greater. These risks deal with everything from scheduling delays to probe positioning and data acquisition issues. To avoid as many issues as possible we plan to keep in constant contact with our sponsors and consult with seasoned professionals on hardware and software designs. Moreover, to further take into account time constraints and operational issues, we have implemented three different design-build-test iterations into our project schedule, as seen in Section 7.2: Gantt Chart. At the recommendation of Professor Dennis McLaughlin, we divided ourselves into six different, two-member teams. The teams are outline in Table 12: Table 12. Sub-Teams Team: Azimuthal Motion Radial Motion Vertical Motion: Data Aq & Controls Signal Conditioning, Circuitry, & Power Software & GUI Development Leader: Scott Hromisin Ryan Hammerschmitt Dylan Wynn Joe Oberholtzer Steven Drew Bill Boggs Assistant: Joe Oberholtzer Dylan Wynn Ryan Hammerschmitt Steven Drew Bill Boggs Scott Hromisin

Teams were chosen based on everyones strengths. Each sub-team will design, build, and test their subsystem at least three times, as outlined in the Gantt Chart. By developing functional subsystems in parallel, the entire system will come together in a shorter amount. Thus maximizing the amount of time to fine-tune the final design and correct any unforeseen errors. The final step in alleviating risks is a project map. The project map is a block-diagram model of our entire project. It shows, qualitatively, what parts of the project run in parallel and which are in series. The benefit to such a map is that it clearly defines the critical path for our project. The critical is the path in the project map, from project start to project end, defined by the activities that have the longest duration. These tasks define the length of our project. All of the tasks not on the critical path make take longer or shorter than expect yet not necessarily have any effect the end date of the project. In Figure 8, the critical path is marked as bold arrows.

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Figure 8. Project map with Critical Path in bold

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Ethics Ethics are a very important part of any project. Many problems have arisen from a lack of ethics. A lack of ethics includes anything from stealing someone elses data to not using the necessary safety precautions. Our team has made sure that we are doing everything as safe as possible. We have also conducted a patent search for every different aspect of our design to make sure we are not taking someone elses idea. We have referenced every idea that we have loaned or acquired from someone else and we will continue to maintain this responsibility.

7.4.

7.5. Environment The environmental impact of the solution is important and will be incorporated into the design and manufacturing. Hazardous materials of grease, oil, and fuel are used in the test stand but are easily avoided in the solutions design. Power consumption of our device should be relatively small as minimal electronic circuits and small motors will be used. The manufacturing techniques and material selection will be driven primarily by our limited budget, this complements the effort towards sustainability as abundant and easily accessible materials and tools are typically eco-friendly.
Communication with Sponsor To ensure the success of the project we try to keep in constant contact with our project sponsors Jason Steiner and Rob Spencer. We have set aside one hour a week on Tuesdays from 1:002:00PM in which we all gather for conference call. During this call we formally report in on our progress and ask any questions we may have. During the call, the note taker records what has been discussed. After the call, the teams point of contact sends out an e-mail to the sponsors stating what has been discussed/ decided so there is a written confirmation to avoid confusion and possible disagreements. Should any other issues arise during the week, our point of contact will e-mail Jason and Rob to resolve them. If immediate contact is necessary, the team has Jason and Robs work numbers. All of our work is kept on a Google Doc that we have shared with our sponsors so they have immediate access to it. They can see exactly what we have done. As of now we have no plan to visit the site. The team, or at least part of the team, will most likely need to make a visit to the site in the future to acquire the rotor stand. We will need it to make sure it is compatible with our system.

7.6.

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8. Changes to the Statement of work

8.1.1 Introduction
No changes were made to this section.

8.1.2 Customer Needs

No changes were made to this section.

8.1.3 External Search

The External Search, Section 3, has been updated to include a short introductory paragraph before each table of search results.

8.1.4 Engineering Specifications

Per sponsor request, the target specifications for the design metrics were modified (Table 22).

8.1.5 Concept Generation and Selection

After further discussion and brainstorming with project sponsors Jason Steiner and Rob Spencer, the concept design for azimuthal motion has been updated to use a lazy Susan style bearing. Details are shown in Appendix F.

8.1.6 System Level Design The system level design using the new azimuth mechanism was incorporated in the detailed design (Figure 27). 8.1.7 Special Topics
The Gantt chart was updated for greater detail in the final design, build, test, and presentation stages (Figure 50). The remaining funds are budgeted for anticipated needs (Table 23). The updated Bill of material for the project is detailed in Appendix I.

8.9.

Design Specifications

8.9.1 Manufacturing Process Plan The system for rotor wake surveying is being developed primarily as a proof of concept article. Due to the complexity of the system, the goal is to keep the design as simple and cost-effective as possible. That means few parts, fewer custom parts, simple materials, standard part dimensions. The team has a limited budget for the entire project so it is imperative that any one subsystem not cost more than its fair share of the budget. Time is also very limited on this project, less than fifteen weeks, so component lead times and manufacturing time must be as short as possible. Moreover, even though comprehensive planning goes a long way into designing a successful product, it cannot completely replace prototyping and testing. The need for rapid development results in parallel phases of design, manufacturing, and testing is critical.

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8.9.1.1 Azimuthal Drive The azimuthal drive was designed to be as inexpensive and as quick to build as possible. Many of the parts can be purchased from a local hardware store or from a single supplier such as McMaster-Carr. Two of the aluminum parts have a large hole in the center to accommodate the test stand. To machine these they will need to be water jet cut. While this will cost extra, many of the parts will be complete within a few minutes. They will need no other machining other than tapping the screw holes. Total machining time is estimated to be 66 hours. This system is being designed to be used in-house by Boeing. The azimuthal motion system has taken this into consideration in that the entire project can be built in a machine shop with similar capabilities as Penn States Learning Factory. The tools necessary to machine this system are: a mill, miter saw, hand drill, band saw, and water jet cutter. The detailed manufacturing process plan is outlined in Table 13.

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Table 13. Azimuthal Drive Manufacturing Process Plan ASSEMBLY NAME Base MATERIAL TYPE 6061 Aluminum RAW STOCK SIZE 3 x 4 x sheet 2 x 2 x sheet OPERATIONS Water jet cut shape and holes for stand and screws Table saw cut to size, jig saw hole for test stand and drill screw holes for legs and aluminum Cut legs to length on miter saw

Plywood

Pine wood

1 x 2 stock

Azimuthal Arm

6061 Aluminum (arm- 3 x 4 x sheet bearing coupling) Plywood (arm) 1 x 4 x sheet

Water jet cut to size, tap screw holes Table saw cut to size, drill screw holes

Caster Wheel Arm Support Stand

6061 Aluminum

3 x 4 x sheet Diameter x 12 cylindrical stock

6061 Aluminum

Mill to size, bore hole down center, mill screw slots, tap bore Mill to length, bore hole down the center, tap bore

Lazy Susan Bearing

Aluminum

n/a

Tap through holes for screws, tap side hole, drill and tap a second side hole

Timing Belt

Neoprene and Fiberglass

n/a

Cut to length, drill holes for mounting

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Table 13.1. Azimuthal Drive Manufacturing Process Plan Cont. Stepper Motor Bracket and Shaft Support 6061 Aluminum 3 x 4 x sheet Water jet cut to size and tap screw holes

6061 Aluminum

3 x 4 x sheet

Water jet cut to size, drill screw holes in bottom and tap screw holes Cut to rough length on band saw, mill to final length, bore center hole

6061 Aluminum

Diameter x 12 cylindrical stock

Final Assembly

Screw base pieces and legs together using standard 2 wood screws and washers Attach timing belt to bearing with screws Screw bearing to base with 1 wood screws and washers Screw arm pieces together with 3/8 348 socket head cap screws Screw stepper motor to arm with screws provided with the motor Screw ball bearing into cylindrical arm support piece, slide cylindrical piece into

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the end of the rectangular support piece and screw together with threaded knob, washers and hex nut Bolt arm support to arm with a 3/8-24 1 screw.

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8.9.1.2 Radial Drive In prototyping the design it is important to create a cost effective solution for moving the probe in the radial direction with as much accuracy as possible. For this reason a design based on a camera rail is being pursued that can be adapted to the project needs. This design is cost effective and allows a quick proof of concept. Most of the components for the build can be acquired at a local hardware store. Since most components of the design were store bought it will be easy to mass produce the design. However, in case the project will be a proof of concept and will not need to be reproduced. A few parts will need to be custom made for the design to be completed. Keeping simple parts and accurate shop drawings will allow for easy rebuild and help the sponsor to utilize the design as effectively as possible. Two journal bearings, a coupler, and a drive will need to be fabricated for the radial portion of the project (shown below). The design for these pieces is created with simplicity in mind to reduce manufacturing and material costs. These parts will take approximately 11 hours of machining time to create and implement into the radial system. Using a lathe, drill press, and a few hand taps it will be easy to create the parts required. Since most machine shops have this equipment, the parts can be manufactured almost anywhere. The following breakdown will show the work needed to prepare the system for assembly.

Figure 9. Radial Drive Close-Up

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Table 14. Radial Drive Manufacturing Process Plan ASSEMBLY NAME Slide Rails MATERIAL TYPE RAW STOCK SIZE X 5 Hollow Cylinder OPERATIONS

Electrical Conduit

Cut to length on metal bandsaw

Sand on belt sander to clean edges Affixed threaded coupler End Piece Slide Platform Electric Box Wood, 4 pvc tees, wood screws 2 X 4 Steel 5 X 1 Plywood Board Purchased two Trim to size

Drill hole locations and mount pvc with wood screws, sand smooth Motor and Coupler Stepper Motor, Aluminum Stock " X 6 Round Turn to size on Lathe

Drill 0.2 hole through center then 1/2 hole from other side use cut off tool to remove from lathe

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Table 14.1. Manufacturing Process Plan Example (Contd) ASSEMBLY NAME Drive MATERIAL TYPE Aluminum stock RAW STOCK OPERATIONS SIZE Square X 4 drill two 59025 holes from side into center on drill press Deburr on flywheel Tap 4235 holes into side of coupler for set screws Journal bearing Aluminum 1 X 4 Round Turn to size on Lathe Cut notch for retaining ring Drill 1/2 hole Use cutoff tool to remove from lather, deburr with flywheel Drive Aluminum " Sq x 4 Cut to size using band saw drill two holes for bolt fastening Drill, debur, and tap 13 drive hole for threaded rod

8.9.1.3 Vertical Drive The components for the prototype scissor lift for the vertical motion component are manufactured using a combination of manual machining and water-jet cutting, with a drill press to drill the holes and hand taps to tap the threads. The manufactured pieces are then assembled by hand, using standard fasteners. The mass production version uses CNC machining processes in place of the manual machining processes, drilling, and hand tapping used for the prototype. In order to simplify the manufacturing of the components, stock material sizes are used wherever possible. This will cut down considerably on machining time, and reduce the overall cost of the design.

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Table 15. Vertical Drive Manufacturing Process Plan ASSEMBLY NAME Base/top side MATERIAL TYPE 6061 Aluminum RAW STOCK SIZE 1' x 2' x 1/4" OPERATIONS Cut on waterjet Sand edges Base/top connector 6061 Aluminum 1/2" Sq x 48" rod Cut to size w/ bandsaw Sand edges Arm 6061 Aluminum 1' x 1' x 1/4" Cut on waterjet Sand edges Arm connector 6061 Aluminum 1/2" round x 48" Cut to size on lathe rod Sand edges Drill & tap holes in ends with #8-32 tap Drive arm connector 6061 Aluminum 1/2" Sq x 12" rod Cut to size w/ bandsaw Sand edges Drill & tap holes in ends with Drill & tap hole for threaded rod with 5/16" - 18 tap Motor mount plate 6061 Aluminum 1' x 1' x 1/4" Cut on waterjet Sand edges

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Table 15.1. Vertical Drive Manufacturing Process Plan (contd) ASSEMBLY NAME Base Top Scissor mechanism Motor mount MATERIAL TYPE RAW STOCK OPERATIONS SIZE Weld base sides to base connectors Weld top sides to top connectors Connect scissor arms to arm connectors using #8-32 screws Mount stepper motor to mounting plate using screws Attach motor mounting plate to base connector Drivetrain Connect coupler to stepper motor Connect threaded rod to coupler Thread rod through driven scissor connector Final assembly Mount top assembly to scissor mechanism Mount scissor mechanism to base assembly

8.9.1.4 Data Acquisition & Controls For the data acquisition and controls are elements of the modular electronics design. The complete electronics package consists of data acquisition, controls, signal conditioning and power supply modules. Ideally each module is a commercially available component and the design is performed at a systems level. However, in practice custom components are needed at the intersections of the modules. The circuit design is complete and is tested on a breadboard. In parallel the printed circuit board design is completed and manufactured. The mass manufactured model will likely integrate the data acquisition, controls, and signal conditioning into a single system to optimize for manufacturing and reduce costs.

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Table 16. Data Acquisition & Controls Manufacturing Process Plan ASSEMBLY NAME Pressure Sensor MATERIAL TYPE Silicone Tubing Pitot Probe Pressure Transducer Mother Stepper Motor Drive Circuit Pin Header RAW STOCK SIZE 1 ft x 1/8 in 4mm Diam x 11cm MPXV7002DP 0-2.5psi 48 Male Pins OPERATIONS Cut tube into 6in sections Attach one half to each outlet Attach one half to each inlet

Stepper Motor Driver Carrier Capacitors

A4988 100uF, 50V

Solder header pins to carrier Solder components to Mother Driver PCB per Figure 23

Mother Driver PCB DAQ and Controls (Finished Assy)

Figure 23 Assemble Per Figure 65

8.9.1.5 Signal Conditioning and Power Initially, while the signal conditioning and a power supplying circuit is in the design phase, it is simulated with both circuit simulator software, Multisim, which was produced by National Instruments, and breadboard configurations. Then, for manufacturing purposes, the design is transposed into a printed circuit board using Ultiboard software. With Ultiboard we are able bring our design from a basic prototype, to a more scalable product. Our plan is to use low power consumption to reduce the cost of the electrical design.

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8.9.1.6 Software/GUI Development The objective of the initial prototype was to figure out the most cost effective way to create the software needed for the system. The software design calls for programming a microcontroller to control motor motion, position a pressure probe at the users request, and read data obtained from a pressure probe. An Arduino Mega 2560 microcontroller is being implemented to control the motors and read data from the pressure probe. Software design for the system involves two different parts: Motor control and pressure probe reading. The prototype starts with communicating with the Arduino through a graphical user interface (GUI). The GUI prompts the user of the program to enter three coordinates: The Azimuthal coordinate, Vertical coordinate and Radial coordinate. Once the three coordinates have been entered by the user, a c++ language software program obtains the input and sends the data through the serial port of a computer to the Arduino Microcontroller for interpretation of the data sent. The microcontroller coding then translates these data values to integer values and transfers control to another c++ program that sends signals to digital out pins on the Microcontroller. These digital out pins send data to the stepper motor driver, which then converts the signal to a value of voltage that can move the motor. After the azimuthal, radial and vertical motors move to their respective positions, the pressure probe takes the pressure of the location. This pressure value is sent to the Arduino in analog form for the Arduino to interpret. The Arduino software code then sends this pressure data to the computer and the software on the computer outputs the pressure data to the GUI. If this product were to be mass produced the prototype GUI must evolve to a more user friendly program. More tests are being run to make the software more fool proof. Table 17. Manufacturing Process Plan ASSEMBLY NAME Graphical User Interface (GUI) Languauge C++ coding CODE SIZE Around 150 lines of code OPERATIONS Ask the user what lengths they want to move the Azimuthal, Radial and Vertical Length Code makes sure the user doesnt input and invalid option Outputs a graph of the measured data from the pressure probe Motor Control C++ coding Code Roughly 500 lines of code Moves the Azimuthal, Radial and Vertical motors Arduino code sends data through the serial port to the computer The code takes in the serial data from the

Pressure probe C++ - Matlab N.A. reading code

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Arduino and graphically represents it on the GUI 8.9.1.7 Finished Product The parallel development of the subsystems results in a modular completed product. The independent manufacturing lines feed into a simple final assembly. Assembly of the components can occur as the subassemblies are completed, preventing schedule delays in both prototype and bulk manufacturing. Table 18. Manufacturing Process Plan ASSEMBLY NAME Mechanical Assembly Electrical Assembly Final Assembly MATERIAL TYPE RAW STOCK SIZE OPERATIONS

Bolt together the azimuth, radial, and vertical drives. Connect the control, signal conditioning, and power supply modules to the DAQ (Arduino) Connect computer with software to DAQ (Arduino) Connect control module to drive motors

8.9.2 Analysis
8.9.2.1 Azimuthal Drive After designing the alpha prototype, the need for many improvements was realized. The biggest issue came in the form of the spacing between the outer and inner dolly rails. Each rail was not kept at exactly a constant radius so the spacing between the rails varied by over an inch over the span of 90 degrees. This caused the dolly to derail. The design was also bulky and required many parts. At full scale, the alpha prototype would have an 11ft diameter. A base this big would quickly prove to be quite cumbersome. Constructing accurate metal rails (instead of bent PVC pipe) would exceed the capabilities of most machine shops, including the Learning Factory. Thus, bending the rails would have to be outsourced to a vendor which would increase the projects overall cost and manufacturing time. In addition, the dolly system had a high profile at about 9 which limited the range of vertical motion for the probe. The new azimuthal system cuts that profile height down to 5.88: a 36% reduction in height.

48

Figure 10: Profile CAD drawing of azimuthal section with floor-arm height measured

Due to physical size and project time and cost, the alpha prototype would have only allowed for only 90 degrees of azimuthal motion. The new concept should allow for 178 degrees of azimuthal motion. This could easily be extended to 180 degrees but would require processes not available or affordable for students given timeline and budget constraints. The original concept was to create a third radial track, concentric with the other two and positioned between them. A timing belt would be cut and mounted to this third track with the teeth facing inward. It would act as a flexible rack. The pinion would be the timing belt pulley attached to the stepper motor and mounted to the underside of the dolly. While the concept is sound, a major issue with implementing it in the alpha prototype is the positioning of the third track. It needs to be almost perfectly concentric and very accurately positions so the pinion stays coupled to the belt and does not cause the system to jam. However, this fixed-belt concept works very well with the current design. The belt can be attached directly to the outer diameter of the lazy Susan bearing thus ensuring its concentricity with the rest of the system. An exhaustive engineering analysis was performed on the current system design. It is imperative to ensure to the design will actually work in practice before manufacturing begins. The goal of the calculations were to ensure a) the stepper motor could provide enough torque to turn the arm, b) the overhung load and bending moment on the motor shaft were sufficiently small, and c) the stresses and forces on the belt and pulley were not too large. To begin the calculations it was necessary to know the torque required to rotate the arm. In order to determine this accurately, a mock-up of the design was constructed in the Learning factory: the bearing was mounted on stilts and a 46 wooden arm with a caster wheel was attached to the bearing. Two 7lb, 3.5 bars were placed on the arm to simulate the weight of the radial and vertical systems. A 4lb force gauge was hooked to the end of the arm and pulled manually. The force indicated by the gauge at the onset of motion was recorded. This force multiplied by the arm length yielded the minimum torque the stepper motor had to generate. It was found that even 49

with the current belt-pulley gearing, the system could not be driven by the current stepper motor that was intended. A motor as strong as that currently being employed by the vertical drive would be ideal.

Figure 11. The motor used on the vertical drive (left) and the motor originally intended for the azimuthal drive (right). The vertical motor provides 1.73in-lb of torque whereas the radial motor supplies 0.70in-lb of torque. Photos courtesy of Pololu.com. To account for the predicted bending stresses on the motor shaft, a special shaft support assembly has to be installed on the system. The motor shaft will be coupled to a second shaft. This second shaft holds the pinion gear and is supported by two pillow block bearings to take the bending stresses off of the motor shaft. The final results of all calculations are listed in Table 19. Complete calculations with all work and assumptions can be found in Appendix G. Table 19. Final Results of System Analysis Calculations Variable Torque Required Tangential Contact Force between Belt and Pulley Radial Contact Force between Belt and Pulley Bending Moment on Motor Shaft Gear Ratio Minimum Motor Torque Required Bending Stress (Pinion) Surface Stress (Pinion) Bending Stress (Pulley) Surface Stress (Pulley) Bending Stress on Motor Shaft English Value 3.41 ft-lbs 4.06 lbs 3.15 lbs 0.26 ft-lbs 31.6 0.108 ft-lbs 814 psi 979 psi 814 psi 979 psi 12 ksi Metric Value 4.62 N-m 18.0 N 14.0 N 0.35 N-m 31.6 0.146 N-m 5.61 MPa 6.75 MPa 5.61 MPa 6.74 MPa 82.74 MPa

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8.9.2.2 Radial Drive From the alpha prototype it was quickly realized that accuracy needed to be improved significantly. The first model allowed the radial platform to wiggle significantly which combined with the scissor lift would make it difficult to find accurate results. To address this problem a tighter fit between the rail and the slide must be created. The prototype created proof that the radial design was plausible. The table was able to slide freely and the rails will be able to support the weight that is expected. The design is slightly over designed for weight since the electrical conduit will be able to support three or four times the weight of the pitot probe and scissor lift. For this reason no calculations for strength or bending were performed. Since the alpha prototype performed the necessary functions for the final design it will only need an added threaded rod to drive the lateral motion. This will keep the design process short and the design simple.

8.9.2.3 Vertical Drive No stress calculations or FEA were used as the scissor lift was designed with stability in mind. To maximize stability, all load-bearing components were over-designed, to the point that none of the loads experienced by these components will come close to the failure point. The torque required by the motor to turn the threaded rod was calculated using the following equation: ( )

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Where Tm is the required motor torque, W is the weight to be lifted (estimated), is the minimum angle of the scissor arms, and Req is the equivalent moment-arm of the threaded rod. From the initial prototypes, it was clear that stability was going to be an issue with the scissor lift. This will be remedied by using stiffer scissor arms and having cross-members connecting the scissor arms at every joint. We also learned that as the angle of the scissor arms gets smaller, the torque required to urn the threaded rod increases dramatically. This can be remedied by oversizing the motor, or by limiting the minimum angle to which the scissor arms can lower. The early prototypes also demonstrated the importance of having the connections for the scissor arms perfectly centered. If the center connection of the X portion of the scissor lift is not centered perfectly on the scissor arm, the mechanism will not function as desired. This issue will be remedied by using a water jet to cut the holes, assuring that the holes are centered perfectly on the scissor arms. 8.9.2.4 Data Acquisition & Controls The data acquisition capabilities of an Arduino and the motor control capabilities of an Arduino with the A4988 chip has been proven beyond the demands of our system. With real world validation of the design already available, only minor trouble shooting is expected. Basic analysis was performed to assure the combination of systems would not pose a problem. Ultiboard software determines the trace width and component placement for a printed circuit board.

52

8.9.2.5 Signal Conditioning and Power Noise filtering circuit: Instead of using active load, we deciding that using a passive circuit with resistors and capacitors would be more appropriate, and the necessary components are in the available inventory. Stock room capacitor available: 100uF : The time constant for the given circuit

: Resistance in series of load capacitor : Capacitance of load Capacitor

=16 The equations above apply for low frequency cut off point. Amplification Circuit: Using a simple non-inverting op amp configuration

53

=5 Av = Gain of Amplification Circuit With the amplification and noise filtering circuit coupled together, there seems to be a change in some of the characteristics, some good and some bad. For instance, when coupled together there appears to be an offset in the voltage, but that could be changed simply by applying an additional 1 volt voltage into the op-amp or to make simple adjustments. In terms of the bode plot, the amplitude decays faster for the unwanted frequencies, which is a plus. 8.9.2.6 Software/GUI Development Simple math equations were necessary to convert the three user inputted data points to an amount of step pulses for the Arduino Microcontroller to read. Testing the prototype creates an accurate measurement of how far in length a specified amount of motor steps actually goes. Measuring these lengths creates a conversion equation to change length to an actual amount of motor steps (amount of pulses that need to be sent out to the motor driver). Measuring the length of each motor step is essential to creating a reliable conversion equation. An Arduino microcontroller was used in conjunction with software design because it is an easy to use and reliable microcontroller. Coding an Arduino is simpler than other microcontrollers because of the vast open source Arduino coding community. 11 and visual studio c++ has the biggest Windows function code library. This gave c++ a slight advantage over other languages such as Java or Matlab. Features of the software design are divided into two large components: Motor control software and the pressure probe data acquisition software. Motor control software starts with the GUI and ends with actual motor movement. The pressure probe then reads the value of the pressure at the point the motors move to and sends the data to the Arduino microcontroller. Microcontroller coding reads the data, interprets it, and sends the interpreted data back to the computer for output on the GUI. The computer makes its own interpretation of the microcontroller data by software coding, which then translates this data to data understandable to the user.

8.9.3 Material Selection Process

8.9.3.1 Azimuthal Drive The primary materials being used for this design are aluminum and plywood. Three major factors in choosing materials for the azimuthal drive are a) both are relatively inexpensive compared to other engineering materials, b) they are readily available for use at the Learning Factory or can easily be procured from a local hardware store, and c) they have more than

54

sufficient strength properties for the given application. Another driving force is the machinability of the materials. Easily machined materials reduce manufacture time which is a big aid in making quick prototypes or testing an idea on the fly. It also means that if a major component does not work or breaks, it can be quickly replaced at a low cost. One tradeoff that exists lies in using the plywood. With the current shop facilities in Reber and the Learning Factory, wood products can only be made to about 0.1-0.2 of design specifications. This issue is mitigated by only using wood in parts that can afford to be less precise and not have a major effect on system performance. For joining pieces, screws, washers, and hex nuts readily available at the Learning Factory are being used. This reduces expenses and has no lead time. Less general screws that are needed will be purchased from McMaster-Carr or a local hardware store. 8.9.3.2 Radial Drive For this design electrical conduit and electrical boxes will be utilized to create the radial rail system. By punching out the three tables in our electric boxes we can us couplers to connect the conduit to them creating a rail system will create a stable platform to build off of. These parts are only sold in steel components. Since these parts will be easy to work with, the will not need to be any significant modifications. The threaded rod will also be made of low strength steel since this was the most cost effective solution that would still provide enough rigidity to avoid bowing. The rest of the components will be made of aluminum. This material is lightweight and easy to work with. After some quick research it was discovered that aluminum on steel will not bind. However since aluminum is so soft damage in journal bearing after the system is run for an extended period of time is imminent. Since this will be a proof of concept this concerned with damage will be neglected in the short term. In the future if the design is utilized it will be possible to make these bearings out of a harder material and the threaded rods can be either shave down or fitted with a sleeve. 8.9.3.3 Vertical Drive Aluminum stock was chosen for the prototype because of its availability, machinability, low weight, high strength, and low cost. Steel was also considered for its greater strength, but its greater weight and cost made aluminum a much more desirable option. Steel is also much more expensive to cut using a water jet, making aluminum the clear choice. 8.9.3.4 Data Acquisition & Controls For the printed circuit board the use of laminate, copper etching and prototype boards were considered. Etched copper board is used because of the greater manufacturing flexibility and shorter lead times than laminates. Copper etched board is also a more accurate representation of a mass produced board than a prototype style board. 8.9.3.5 Signal Conditioning and Power The signal conditioning circuit is configured such that the design could utilize parts from the Electrical engineering stock room. This minimizes the cost by using materials that are already readily available. The circuit will also be configured for low power considerations.

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8.9.4 Component Selection Process

8.9.4.1 Azimuthal Drive From the engineering analysis performed, the bending stress on the stepper motor shaft caused by the overhung load is on the order of 16 ksi, using a safety factor of 2. The stepper motor manufacturer did not list the shaft material so it was taken to be aluminum with a yield strength of 35 ksi. Even though the azimuthal system could function under these conditions, its life span would be compromised.. The motor was not specified an overhung load capability. This loading would result in faster degradation of the motor bearings and a shortened motor shaft life. To increase the robustness of the system, a special bracket and shaft support assembly is included in the design to take the bending stress off the motor shaft.

Figure 12. Motor attached to shaft support assembly The major tradeoff here is the increase in cost, complexity, and size of the system with the bracket included. Cost is expected to increase $50, six new custom parts are required, additional machining to the arm is necessary, and the arm is raised an additional 1.5 off the floor. The justification for using this bracket is that there is more than enough room in the budget to handle the added expenses. At week 9, with most major purchases made (before the cost of manufacturing the azimuthal drive), there is still $600 left in the budget. Moreover, the processes necessary to machine the extra parts are not overly complex: water jet cut, mill, drill, and tap. Manufacture time should not increase by more than 3 hours for someone decently-versed in the aforementioned machining processes. The increase in height still provides a 36% in height from the previous prototype. The height increase is further justified by the fact that the life span of the system is expected to increase significantly. An added bonus of this feature is that the pinion location is not variable. Using a system of four sets of screws, nuts, and washers, the pinion

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location can be moved radially and then fixed into place to ensure optimal coupling the timing belt. Another feature of the system is the variable height caster wheel arm support assembly. With the use of a level, this feature allows the operator to ensure the azimuthal arm is sufficiently horizontal before taking any measurements. The height is adjusted by the use of threaded knob and two hex screws. When loosened, the caster wheel can move vertically, and then it can be set to a fixed height by pinching the shaft to the support arm with the knob and screws. One issue that can arise with this feature is the knob coming loose and thus causing the arm to drop below the horizontal. To get around this problem, two hex nuts are used. The first one works in conjunction with the knob to provide the necessary pinch to hold the arm at a constant height. The second nut provides a level of redundancy: it is jammed against the first nut to prevent it from coming loose during operation.

Figure 13. Threaded knob to be used on caster wheel/arm support. CAD model courtesy of McMaster-Carr. The final and most innovative feature of the azimuthal drive is the fixed timing belt. The timing belt is cut and wrapped around the outer diameter of the lazy Susan bearing 356 degrees. The belt is held in tension with a screw at each end; this tension keeps the belt from moving during operation. The fixed belt acts as a flexible rack while the timing belt pulley becomes the pinion to crawl along the belt and move the arm. The curved belt also acts like a giant gear thus amplifying the torque stepper motor.

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8.9.4.2 Radial Drive Since the design process builds on the alpha prototype, most of the focus is on motorizing the radial design. Fitting the electrical boxes in the original design with journal bearing allows us to drive the radial table with a screw. The screw driven design allows the probe to move accurately and smoothly, however, this motion is slow. The journal bearings allow quick manufacturing since they are aluminum. However this is a trade off with strength since the journal bearing will only last for a short period of time. The coupler and drive that was selected is the simplest functioning design that could be created. Fewer parts make the system easy to maintain which is in the best interest of the sponsor. 8.9.4.3 Vertical Drive The design is made nearly entirely of machined aluminum stock. The use of stock material sizes reduces the amount of machining required, leading to a reduction in production time and ultimately a substantial cost savings. A stepper motor is used to drive the lift so that position can be accurately controlled without the need for a position sensor. Because the height of the scissor lift is a non-linear function of base separation, the software will need to be calibrated to accurately determine the position. 8.9.4.4 Data Acquisition & Controls The concept selected for the Data Acquisition and Control system is centered around the use of a loaned data acquisition system. However, the concept of a microcontroller based data acquisition is being used following logistical issues in loaning a data acquisition system. The design uses an Arduino microcontroller because of the significant documentation readily available on similar projects. The team also is positive past experience Arduino based systems. Specialized circuitry is required to control the stepper motors in the mechanism. Where possible the design uses commercially available circuits as opposed to custom circuitry. Commercial circuits provide a simple interface with the Arduino, reliability and comparable price to custom solutions.

8.9.4.5 Signal Conditioning and Power In the component selection phase simplicity, desired performance and available inventory are large drivers. Simplicity is necessary because for the tight time schedule. The desired performance is determined by the design metrics and the other systems with which the circuits are interfacing. With a significant available inventory, component selection is not heavily influenced by inventory. Matlab coding was originally selected to be the coding choice for software design. Since Matlab coding didnt have the needed built in functions for serial port communication, it was decided that the design use c++ coding. The c++ coding language has a vast library of GUI creation and has many built in functions that work with Microsoft Windows. Since the software is designed to run on Microsoft Windows, c++ coding was chosen. Another reason for using c++ is the arduino microcontroller. The microcontroller can be coded in c or c++ which makes it easier for compatibility purposes if the computer software is coded in c++.

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8.9.5 CAD Drawings

8.9.5.1 Azimuthal Drive Four different CAD drawing are provided to provide a general overview of the azimuthal system. Two drawings show the entire system while two more provide a more detailed view of the Caster Wheel Arm Support Assembly and the Stepper Motor Bracket and Shaft Support Assembly. More detailed drawings of specific components may be found in Appendix A: Shop Drawings.

Figure 14 Azimuthal System Isometric View

Figure 15. Azimuthal System Front View

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Figure 16. Azimuthal System Focus on Caster Wheel Arm Support Assembly (front)

Figure 17. Azimuthal System Stepper Motor Bracket and Shaft Support Assembly (isometric)

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8.9.5.2 Radial Drive

Figure 18. Radial Motion System

Figure 19 Radial Motion Motor Mount

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8.9.5.3 Vertical Drive

Figure 20. Vertical System Front View

Figure 21 Vertical System Isometric view

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8.9.5.4 Data Acquisition & Controls

Figure 22 Prototype Motor Control Circuit

Figure 23. Printed Circuit for Motor Control

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8.9.5.5 Signal Conditioning and Power

Figure 24. Noise Cancellation Circuit

Figure 25. Signal Amplification

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8.9.5.6 Software/GUI Development

Figure 26. I/O Software Diagram 8.9.5.7 Complete System

Figure 27. CAD Model of Complete Assembly

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8.9.6 Test Procedure Testing is an important tool used throughout product development. Early in the design process prototypes were used to explore concepts and test theories. These testes were used to narrow the design focus and validate concepts. With the completion of the detailed design and manufacturing of the final prototype, tests will conducted to compare theoretical expectations to actual performance.
The product naturally falls into 6 subdivisions; Azimuthal Motion, Radial Motion, Vertical Motion, Data Acquisition, Signal Conditioning & Power, and Software. The construction of these systems will be followed by systems checks and troubleshooting. These checks will be used to assure the system is functioning as intended. They will not evaluate the performance of the system. The performance tests for each system will be focused on the ability to meet the metrics and specifications. The needs of the customer will be satisfied following achievement of the specified performance values. The testing methods used are derived from test found in industries with similar systems. 8.9.6.1 Azimuthal Drive Two critical tests are being performed to accurately characterize the azimuthal drive. The first and most simple test is to ensure the stability of the arm during operation. With the other two drives mounted on the arm, or some weight representative of these drives, the arm is set to level using the adjustable arm support. The criterion for level is with respect to the floor. An electronic level is used at the arm tip to evaluate the angle. The arm is driven to 2020 different, randomly chosen positions. Afterwards, a level is placed on the arm to test whether or not the arm dropped outside the horizontal range. Different options will be considered to correct this problem if it proves to be recurring. The second test being performed determines the positioning error of the system. The system is driven to different azimuthal locations and the actual position is recorded. This true position is compared to the commanded position. The true position must be within from the commanded position. If there is a bias error of some then that can be factored into to the positioning algorithm to correct for the error. A final test is also being performed to orient the system with respect to the rotor test stand. Moving the system changes the arm with respect to the azimuthal drives zero-position. Since the entire system is independent of the rotor stand, their zero-positions do not necessarily line up. A standard zero-position needs to be set on the test stand and aligned with the azimuths zero so tests are consistent and repeatable.

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8.9.6.2 Radial & Vertical Drive Testing the drives positioning accuracy, stability, rigidity of the system, and speed are the most critical system evaluations. Positioning accuracy will be tested in two ways. First, the device will be placed in a calibrated position, moved to various positions and returned to the original position. A tolerance of an 1/8th of an inch is acceptable. The deviation from the original to the final position will be recorded as the system error. The test will be iterated to determine the operation conditions that will assure an accuracy of 1/8th inch or less. The second test will begin with the device in its calibrated home position. The device will then move to a different location. The actual and expected positions will be recorded. The process will be repeated until a representative sample has been taken. Accuracy is seen as an area of pivotal importance and will receive periodic testing throughout the build process. Stability and rigidity of the lift will be tested by fully extending the lift and applying a lateral force to the top of the lift. The deflection of the resulting oscillations will be measured. Stability and rigidity are very important to the positioning accuracy, as any oscillations in the lift will change the position of the probe. Again fluctuations of and must be kept to less than 0.1/8th inch are acceptable. magnitude when fully extended. Finally, the speed will be tested by timing the lift moving from the minimum position to the maximum position at maximum motor speed of .. The radial system will also perform a thermal test on the journal bearings. In this case we will be looking to see that the bearings arent smoking or binding up from excessive heat. There are concerns with the amount of heat and damage that will be produced by running the traverse system for extended amounts of time. By using a drill and running the table back and forth three times a max travel case can be simulated that will be six times what the table will ever experience in use. 8.9.6.3 Data Acquisition & Controls Testing of the data acquisition system will be conducted in stages. The analog to digital conversion stage will be tested by reading a known signal from a signal generator. A representative sample of the expected frequencies and amplitudes will be used in the testing. The second stage will involve the analog to digital converter reading signals from a pressure Figure 28. Pressure Transducer and Pitot Static Probe transducer. The pressure differential in the transducer will be provided by placing the pitot static probe in a wind tunnel with alongside a calibrated pitot static probe. Data from the calibrated probe will provide data with which the other probe can be calibrated. The controls will be evaluated during the radial vertical and azimuthal tests. 8.9.6.4 Signal Conditioning and Power The power supply circuitry will be tested with a known input from a calibrated power supply. Known loads will be applied to the system through the use of a resistor bank. An oscilloscope will monitor the output of the system for fluctuations in the supply. 67

8.9.6.5 Software/GUI Development The software will go through rigorous tests to make sure that any user input cannot make the program crash. Tests will also be done to make sure that the movement of the three stepper motors is accurate with what the user inputted. Pressure probe reading is important to test to make sure that the right data is being outputted on the three dimensional graph in the GUI. The first portion of testing, fool-proof testing is done by inputting invalid user inputs to the GUI, for instance, a value on the radial portion that goes beyond the three foot length. This is needed to test how the program reacts to invalid input. If there is a problem and the software crashes, every line of the program will be debugged and inspected to find the cause of the problem. Running through each line of code in debug mode will make it easier to pinpoint the problem at hand. Following fool proof testing comes accuracy testing. Accuracy testing will make sure that the motor is actually moving the user inputted length. In order to make sure the value was accurate a specified length is inputted to the GUI and then motor movement length is physically measured and compared to the inputted length. The third test, pressure probe accuracy, will be the toughest. A possible solution to this would be to find a working software program that has the same functionality and compare this software with the software created. That way the software of the system can be compared with software that has already proven to be affective.

8.9.7 Economic Analyses - Budget and Vendor Purchase Information Each subsystem: azimuthal, radial, vertical, dataq and controls, signal conditioning, and software, broken down their budget individually. The tables for each subsystems budget can be found in Appendix C. When possible, subsystems use components provided at no cost by the university. This helps keep costs down. It also helps manage team inventory. Buying three bags of 50 screws each becomes burdensome when only 5 of each are needed. Most teams have expenses under $90. This expected since the radial drive and vertical drive are derivations of low-cost hobby-shop projects. The power and software systems require little to no hardware, which are major drivers of cost. Data Acquisition requires several medium-priced items, putting it on the same level as the other systems. The most expensive system is the azimuthal drive. It was developed independently of any hobby projects and requires more components and more custom parts than the other subsystems. A condensed budget can be found in Table 20.

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Table 20. Condensed Team Budget by Subsystem Cost Subsystem Azimuthal Drive Radial Drive Vertical Drive Controls & Data Acquisition Signal Conditioning Net Total: Budget $ 261.64 $ 47.11 $ 87.54 $ 76.79 $ 42.00 $ 515.08

9. Final Discussion
9.1. Modifications to Statement of Work and DSR Sections

9.1.1 Introduction
No changes were made to this section.

9.1.2 Customer Needs

No changes were made to this section.

9.1.3 External Search

No changes were made to this section.

9.1.4 Engineering Specifications

No changes were made to this section.

9.1.5 Concept Generation and Selection

No changes were made to this section.

9.1.6 System Level Design

No changes were made to this section.

9.1.7 Special Topics The azimuthal system needed a more powerful stepper motor and a special connector to attach the new motor to the stepper-motor-bracket already in place on the system. Updates to the BOM may be found in Appendix I: Bill Of Materials on page 120.

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9.1.8 Detailed Design To account for the new stepper motor on the azimuthal system, a custom connector to the bracket and a wooden bracket support need to be fabricated. The manufacturing process plan to produce these two pieces are as follows:
Assembly Name Material Type aluminum wood Raw Stock Size 12 x 12 x 0.25 4 x 3 x 1.5 Operations

Stepper Motor Bracket Connector Bracket support

water jet part Cut block to 3 x 3 x 1.5 Cut a 0.5 high x 0.5 deep notch across the middle of block on one of the large faces on the band saw Cut a vertical 0.1 deep x 2 wide notch on the opposite face Drill 2 screw holes through the bottom of the piece

9.2.

Construction Process

9.2.1.1 Azimuthal Drive To assemble the azimuthal system first screw wooden legs onto the wooden back. Then attach the wooden spacer ring and lazy Susan bearing. Then attach the round arm connector ring and motor-bearing connector to each other and screw on to the inner race of the lazy Susan bearing. Attach the caster wheel assembly to the wooden arm screw to the round arm connector ring. For the stepper motor bracket: screw the stepper motor plate to the shaft support piece. Attach the mounted ball bearings to the bracket. Then screw the stepper motor shaft coupler to the stepper motor shaft. Attach the stepper motor connector to the stepper motor. Run the 4 screws through the connector and place 3 of the small, 0.1ID washers on each of the screws as spacers. Run the 4 screws through the 4 corresponding holes in the stepper motor plate. At the same time, line up the pinion gear with the ball bearing holes and run the shaft coupler through these holes. Tighten the stepper motor down to the bracket with 4 machine nuts. Attach the stepper motor bracket and bracket support to the motor-bearing connector with 4 screws.

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9.2.1.2 Radial Drive It was discovered that after the completion and assembly of our system that there was a wobble generated between radial and scissor lift. This allowed the probe location to vary when the conduit pipes bowed. To solve this we bought rigid conduit and quickly implemented it using the same manufacturing processes as before to remove this wobble from our system.

9.2.1.3 Vertical Drive Begin by assembling the top and base assemblies. Fasten base to base plate before continuing with assembly. Attach base plate to radial system. Begin assembling scissor cross members, making sure that both members that are fixed to the pivot end of the base are on the outside of the two that are mounted in the slots. Assemble scissor cross members fully before attaching to base. Attach springs to the top scissor connecting bars before placing the bars between the scissor cross members. Once the scissor assembly has been mounted to the base, connect the top assembly to the top of the scissor assembly. 9.2.1.4 Data Acquisition, Signal Conditioning & Controls Building the circuitry for the project requires only the simple components listed in the Bill of Materials and basic circuit building skills including soldering and crimping. Appendix H: Shop Drawings shows the schematic for the separate circuits. Appendix H: Shop Drawings also shows the layout used for our circuit board although a redesign is recommended (see Recommendations). During the build process we ran into several issues that required redesign. The passive filter weakened the signal significantly and was replaced with an active filter which functioned well but was ultimately eliminated with digital filtering being a possible alternative. The amplifier was then drawing too much current from the transducer which weakened the signal and the effective gain. Increasing the amplifiers input impedance resolved this issue. 9.2.1.5 Software/GUI Development Software construction involved microcontroller programming and computer programming. In order for the design to be successful, these two programs had to coordinate with each other for proper motor movement. The software construction began with a very simple graphical user interface program on the computer and a simple blinking LED program on the Arduino microcontroller. The Arduino microcontroller has an embedded LED on pin number 13 of the Arduino Mega 2560 which can be programmed to send voltage values through. This prototype was necessary in order to clarify that the initial software design on the computer was capable of sending the correct sequential signals to the microcontroller. The computer program was coded to access the serial port on both the computer and the microprocessor. Serial ports transfer data sequentially meaning that they cannot send data in parallel. This means that testing needed to be done in order to verify that the speed in which the data was being sent was fast enough to

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respond to constant user commands. The objective of the initial LED prototype program was to prompt the user of the graphical user interface how many times they would like the LED on the microcontroller to blink. Once the user inputted the amount of times they would like to see the LED blink, the data was then sent out through the serial port and read by the Arduino microcontroller. This is the portion of the code that had the most initial problems. The first few tests proved to be faulty with the LED blinking random amounts of time that were inaccurate with what the user had inputted. In order to debug the code, a series of print statements were put into both the graphical user interface and the microcontroller code. The purpose of the print statements was to show where the signal was in the code flow. This in a sense gave the signal a visual representation, tracking its movement with every step that it took. A solution was finally obtained to the LED program and the LED blinked accurately according to the amount of blinks commanded from the user interface. Once the simple prototype LED program was created it was time to move onto the real stepper motor coding. In a sense the stepper motor coding was very similar to the LED coding because the stepper motors also reacted off of signal pulses. The respective pins on the microcontroller had to go HIGH (which means outputting 5 volts to a digital output pin on the microcontroller) or LOW (outputting 0 volts to the output pin on the microcontroller). Doing this enabled the motor shaft to go from one position to another because the electric coils in the motor were charged at different times, therefore spinning the motor shaft. Initial testing of the stepper motor program design involved the usage of a voltmeter. This was necessary to verify first that the signals were correct before connecting the actual motors. Once the voltage outputs from all of the needed pins on the microcontoller were verified, the motors were connected. The initial microcontroller program moved the motors very slow in order to verify accurate movement. Once the movement was verified to be in the correct direction requested from the GUI, the motors speed was increased in order to move the design at a higher rate. After the motor control code was complete it was time to move on to coding three stepper motors all moving sequentially. In order to do this, more program debugging was needed to verify that each motor was running at the correct time and at a respectable speed. Some large problems were faced in this portion of the design. The prototype program moved the motors too fast at the beginning of the motor movement causing the three motors to skip steps. In order to get around this problem, ramp up functions were needed. The purpose of a ramp up function was to slowly increase the speed of the motors so that a high speed could obtained. Starting the motor movements slow and gradually increasing the speed gave the motor more torque to move the design. Upon completion of the stepper motor coding, a user friendly GUI was constructed. Motor movement calibration was necessary in order to code the GUI, which asked the user to input azimuthal, radial and vertical heights. The GUI took these three requests and made a decision on the amount of motor steps that were needed for this input, and the direction the motor needed to go. Limit switches were also installed onto the system and coded into the microcontroller to send 72

a signal to the microcontroller when the motor location was at its minimum value. Having a minimum value was very important for the programming aspect of the design because accurate user request values could then be used. Once the three motors all moved to their correct spots, the microcontroller program read in an analog voltage reading that had the pressure probes data. This data was interpreted by the microcontroller program and sent back to the graphical user interface wirelessly. The user had the option of inputting as many three dimensional locations that they wanted as long as they did not pass the minimum and maximum points allowed by the system.

9.3.

Test Results and Discussion

9.3.1.1 Azimuthal Drive Initially the azimuthal system did not fair well in testing. It was found that when the arm loaded with the radial and vertical systems the motor was not strong enough to turn the system. The excess drag of the system was not expected and thus the calculations underestimated the torque requirements of the motor. This lead to the purchase of a very high torque stepper motor. With the second motor installed, the next round of testing improved. The motor had more than enough power to turn the system. However, the shaft support bracket, designed to take the overhung load off of the stepper motor, was not designed for the increased radial forces. This cause the bracket to bend back during operation thus causing the pinion and timing belt to decouple. To correct for this a special wooden bracket support was fabricated to counteract this force. Once this bracket support was installed, the motor was able to drive the system for the most part. Unfortunately, the ball caster frequently locked up and needed to be replaced with a fixed caster wheel. After this replacement, the motor could drive the entire system azimuthally without issue. To calibrate the system, a board was laser cut on one side to have a cut-out the same diameter as the lazy Susan bearing. Along this cut-out, tick marks spaced at every degree from 0deg to 180deg were etched into the board. The system was accurate to within 0.05 degrees. 9.3.1.2 Radial Drive For the testing phase there were two main tests the radial system had to pass besides being able to be run by a stepper motor. These test were designed to determine the speed and accuracy of the radial system. The first test involved finding out the max speed at which radial could be run. This is important since radial is a large screw driven system that can take extensive amounts of time to run from end to end if not managed correctly. For this test we began running the stepper motors on a ramp up. This increased their speed as time went on. We then waited for the motors to skip. The motors would begin to skip at higher speeds where less torque was available to turn the threaded rod. Once the motors skipped we would lower the max rotational speed and try the ramp up again. Once we were able to run through the full ramp up with out skipping we new that we had reached our fastest traversing speed. The next test we preformed was a calibration test. This would allow us to know where we were positioned with respect to the center of the test stand. This test involved running a series of step amounts and measuring the distance traversed

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once we averaged these results we could compare it to the theoretic values of how many steps it should take to turn the threaded rod and move and object a certain distance. We found that it would require 13468 steps to move the radial portion one inch. This information was passed into our programing and we concluded the test. These test went generally as expected. The only thing that really stood out to us was the fact that we could run the systems with 46oz in of torque and only skip steps on occasion but when we upgraded our motors to twice the amount of torque we still were skipping steps just as much. We can explain the reasoning for this out side the fact that there were certain areas of the rod that had been damaged and just were going to skip no matter what the torque of the motors. 9.3.1.3 Vertical Drive The prototype performed extremely well during the testing phase. The scissor lift was able to position the probe accurately within 0.05. It also exceeded both our expectations and the customers needs for stability in the downwash of a rotor test stand. Even with the test stand at maximum speed, the tip of the Pitot-static probe showed no measurable movement. 9.3.1.4 Data Acquisition, Signal Conditioning & Controls Testing began with validation of the circuit function including steps to motors, signal amplification, clipping, and filtering. With some minor redesign the circuit worked as expected. Progressively more peripherals were added and tested including driver circuits, motors, pressure transducer, and pitot probe. Testing of the transducer was performed with a manometer and showed a linear correlation between pressure and output voltage (Figure 29: Calibration of Pressure Transducer with Manometer). The pitot probe was then connected to the transducer and testing in the Penn State wind tunnel (Figure 30: Comperison of Pressure Readings for Various Instruments). The correlation between pressure and voltage was not linear but a 5th order polynomial fit brought our data to within acceptable accuracy (Figure 31: Error of Pressure Sensing System Following Polynomial Fit).

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Figure 29: Calibration of Pressure Transducer with Manometer

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Figure 30: Comperison of Pressure Readings for Various Instruments

Figure 31: Error of Pressure Sensing System Following Polynomial Fit 10. Conclusions and Recommendations 10.1.1.1 Azimuthal Drive Ultimately, the azimuthal met all of the customer needs and performed quite well. In the future though, the system could be improved in several ways. The stepper motor bracket could be redesigned to fit the new stepper motor without the need of the coupler. Moreover, the bracket could be designed in a more robust fashion to be able to handle the increased radial force without the need of a bracket support. It is also suggested that the pinion be more firmly fixed to the motor shaft than with a set screw. During extended operation the screw had a tendency to slip. In the future a square or hex shaft, or a shaft with a key is recommended. To increase the robustness of the system and be able to withstand a more aggressive wake, the base, legs, and circular lazy Susan bearing support should be made of aluminum or steel. This design had the potential for 360deg motion. To allow for this, a custom metal gear system could be fabricated to replace the plastic pinion and neoprene timing belt. The caster wheel could be mounted on a vertical actuator to ensure the arm always remains horizontal regardless of what the floor is like. Lastly, it is recommended that more testing be conducted to better characterize the hysteresis in the system.

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10.1.1.2 Radial Drive The radial portion of the project was an overall success for the budget. It could be done better and more reliably with linear bearings and polished guide rails but this design worked best for a proof of concept. It may have been a good idea to try to separate the rails by a greater distance to improve stability as well. However this would require a full overhaul of the electrical boxes at the ends as well. These pieces could have been cnc for this purpose and allowed for a sturdier platform but the current method was with in acceptable margin of error for probe positioning. A next version design could incorporate these friction and stability improvements as well as a lighter design to help improve the ability of the azimuthal component to rotate around the test stand. 10.1.1.3 Vertical Drive Although the scissor lift used in the prototype met all of the customer needs, the design can be improved. Adding a draw-wire linear position sensor to measure the height would further increase the positioning accuracy of the scissor lift and eliminate the need for stepper motors to determine the position of the probe. The base and top assemblies could also be modified to allow the scissor to collapse more fully, allowing the system to measure lower positions. The pieces of the top assembly could be streamlined to further reduce interference with the flow being measured. It would also be beneficial to add some components to reduce friction in the lift, such as bearings at the scissor cross intersections and the slots in the top and base assemblies. 10.1.1.4 Data Acquisition, Signal Conditioning & Controls After resolving the initial design deficiencies, as described in Construction, the controls, signal conditioning and data acquisition circuits performed nominally throughout most of the project. Motors, sensors and power supplies had simple connectors that made construction and troubleshooting easy. The most significant problems came from the Pololu motor driver circuits. The circuits would regularly overheat leading to failure and the current limiting potentiometer was difficult to properly adjust. Additionally, several changes were made to the signal conditioning circuit which resulted in a confusing layout. Future improvements should include alternate driver circuits or increased cooling for the Pololu chips (heat sinks from Ultimachine and fans) and a separate circuit board for signal conditioning so that new designs could be swapped out easily. 10.1.1.5 Software/GUI Development Overall the software turned out to be a success but there are definitely some areas for improvement. The most important area of improvement is the graphical user interface. The user interface worked but there was still some minor bugs in it that could be fixed. The speed and coordination of the running GUI could also be improved. Coding the Bluetooth module more extensively could speed up the connection time of the GUI with the Bluetooth module. It took a good amount of time for the program to connect with the Bluetooth module, meaning that the startup of the program was slow. This problem could be solved by improving the Bluetooth connection algorithm. 77

10.2. Self-Assessment (Design Criteria Satisfaction) The team was composed of six members, spanning four different engineering fields. Everyone had a unique set of skills. Initially, the scope of the project was thought to be too large for the short 15 week semester. The team pulled together incredibly fast, organized into six different teams of two and got to work on designing, testing, building, and fixing the system. This system allowed team members to focus their strengths on a few tasks to make sure those tasks were done properly. Team communication and collaboration was executed incredibly well. The diverse expertise of everyone in the group allows problems to be overcome quickly. A six member team also allowed the team to manufacture parts and circuits, and write computer algorithms quickly. By the end of the semester we were able to successfully put a third-generation, working system together that exceeded everyones expectations, especially the hard-to-impress Dr. McLaughlin of the Aerospace Engineering department who was quoted saying, Well boys, youve exceeded my expectations twofold.
With heavy focus on creating a successful design, documenting the progress and rapid design changes was a challenge for the team. To best meet the customer needs a sparsely documented but proven design is preferable to a well-documented design in its infancy. In the words of Charles F. Kettering, head of research at General Motors for 27 years It is easy to build a philosophy - it doesn't have to run.

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10.3.

Customer Needs Assessment

Table 21: Satisfaction of Customer Needs 1 The pressure sensor has multiple positions 2 120 positions were requested, millions were achievable 9/10 10/10

The pressure sensor is accurately positioned Accurate movement, but lacking documentation

The pressure sensor is positioned in the rotor wake Complete system envelope has not been tested

8/10

The pressure sensor position can be changed remotely Bluetooth and GUI make a simple & clean solution

10/10

The pressure sensor reads any pressure in the rotor wake 0 to 0.13 psi is all that is expected

9/10

The pressure data is accurate Accuracy is bottlenecked by transducer

8/10

The angular velocity of the rotor is collected Collected externally by hand held sensor

4/10

The system includes data visualization software Included in simple full featured GUI, limited testing

9/10

The system includes sensor control software Simple in GUI, periodic hardware failure

9/10

10

The system must include an instruction manual Final report includes manufacturing and troubleshooting

6/10

11

The system must be reliable Wind tunnel, Rotor Stand, 4hr non-stop test (showcase)

8/10

The completed design was in the 3rd generation. Many of the discrepancies that would hurt the products ability to meet the customer needs were eliminated through the design iterations. The many iterations made documentation difficult and allowed limited time for testing of the system.

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With additional time for documentation and testing need 7 and 10 in Table 21: Satisfaction of Customer Needs 11. References People Professor Catanach Professor McLaughlin Professor Palacios Brian Wallace
Sandeep Patel

11.1.

WCatanach@engr.psu.edu dkm2@engr.psu.edu jlp324@comcast.net bdw5003@psu.edu

sandy.patel@nasa.gov

Books engel, unus A., and ohn M. Cimbala. Fluid mechanics: fundamentals and applications. 2nd ed. Boston: McGraw-Hill Higher Education, 2010. Print. Kulakowski, Bohdan T., John F. Gardner, and J. Lowen Shearer. Dynamic modeling and control of engineering systems. 3rd ed. Cambridge: Cambridge University Press, 2007. Print. McCormick, Barnes Warnock. Aerodynamics, aeronautics, and flight mechanics. New York: Wiley, 1979. Print. Norton, Robert L.. Machine design: an integrated approach. 3rd ed. Upper Saddle River, N.J.: Pearson/Prentice Hall, 2006. Print. Ulrich, Karl T., and Steven D. Eppinger. Product design and development. New York: McGrawHill, 1995. Print.

11.2.

Web DAQ webinar sponsored by National Instruments http://app.demand.ni.com/e/es.aspx?s=639&e=7062782&elq=94cd8790a7b840308f9b25a1ebaae a59 DAQ products supported by MATLAB http://www.mathworks.com/products/daq/supported/data-acquisition-cards-and-boards.html http://www.freepatentsonline.com/6938472.pdf

11.3.

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12. Appendix A: Survey For Analytical Hierarchy Process

Simplicity Simplicity Simplicity Simplicity Simplicity 5 5 5 5 5 3 3 3 3 3 1 X 5 5 5 5 Accuracy Cost Durability Ease of building Ease of implementation Versatility of components Time to build aesthetics Cost Durability Ease of building Ease of implementation Versatility of components Time to build aesthetics Durability Ease of building

X 3 X 3 X 3 1

X 5

Simplicity Simplicity Simplicity Accuracy Accuracy Accuracy Accuracy

5 5

3 3

X 3 1 1

X 5 3 3 3 3 3 5 5 5 5 5

X 3 5 5 5 5

X 1 X 1 X 1 X 1

Accuracy Accuracy Accuracy Cost Cost Cost

5 5

X 1 X 1 1 1 1 1

3 3 3

5 5 5

X 3 5 5 5 3 3 3

X 5 X 5 3

X Ease of implementation Versatility of components Time to build aesthetics

Cost Cost Cost

5 5 5

3 3 3

1 1

X 5 X 5 5

X 3

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Durability Durability

5 5

3 3

X 3 1

Ease of building Ease of implementation Versatility of components Time to build aesthetics Ease of implementation Versatility of components Time to build aesthetics Versatility of components Time to build aesthetics

X 5

Durability Durability Durability Ease of building

5 5

X 3 3 3

5 5 5

X 1 1 1

X 3 5 3

X 5

Ease of building Ease of building Ease of building

5 5

3 3

X 3 1 1

X 5 3 5

X 3

Ease of implementation 5 Ease of implementation 5

X 1 X 1 1

3 3 3

5 5 5

Ease of implementation X 3 Versatility of components Versatility of components Time to build Definition of Survey Terms:

X 3

Time to build

X 3 X 3

1 1

3 3

5 5

aesthetics aesthetics

Simplicity: Minimalistic design with few moving parts, less maintenance, less complexity, possibly lower capability Accuracy: Positional tolerance of pressure probe and collect high quality data Cost: Price to build the system Durability: Lifespan of the product and chance for failure

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Ease of building: knowledge and skill required for the team to build the system Ease of implementation: How easily the final product can be integrated into an existing facility (i.e. the systems independence/standalone capability or will special accommodations need to be made for it.). Versatility of components: Interchangeability of system components. Ability to work with other test stands or be used for a different purpose other than rotor wake surveying. Time to build: The amount of time required to assemble the system Aesthetics: What the final design (both hardware and software) will look like 13. Appendix B: External Search URLs 1. http://www.meggitt-avionics.co.uk/pdf/MeggittAvionicsDataSheetHADs.pdf 2. http://onlinecatalog.tpa-us.com/viewitems/gories-cam-roller-guides-bsc-curved-rail-systems/bsc-curved-rail-systems-bsc-curved-rail-sliders? 3. http://onlinecatalog.tpa-us.com/viewitems/gories-cam-roller-guides-bsc-curved-railsystems/r-guides-bsc-curved-rail-systems-bsc43-curved-rail? 4. http://www.trutechtools.com/Telescoping-Pitot-Probe-8-in-to-38in_p_2226.html?gdftrk=gdfV26224_a_7c2772_a_7c10009_a_7c2226&gclid=CMG2tbWgbUCFUqf4AodYQcAEw 5. http://www.web4robot.com/USBI2C.html 6. http://www.dataq.com/data-acquisition-starter-kits/data-acquisition-starter-kits.htm 7. http://www.pjrc.com/teensy/index.html 8. http://www.pololu.com/catalog/category/87 9. http://www.robotshop.com/geared-bipolar-stepper-motor-3v-416-ozin.html?utm_source=google&utm_medium=base&utm_campaign=jos 10. http://www.pololu.com/catalog/category/120 11. http://www.velmex.com/pdf/m-cat-pdf/motorized-price-list.pdf 12. https://sites.google.com/site/measuringstuff/the-arduino 13. http://www.youtube.com/watch?feature=endscreen&v=03_SgU-AewA&NR=1

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14.http://www.digikey.com/Web%20Export/Supplier%20Content/MeasurementSpecialties_223/ PDF/msi-app01004.pdf?redirected=1 15. http://cncmentor.com/groups/gantry-8020-hybrid-full-plans/docs/ 16. http://www.kickstarter.com/projects/1738994529/kikori-open-source-cnc-gantry-router 17. http://www.youtube.com/watch?v=fR_-R2bS9ag

14. Appendix C: Concept Generation

Below are some pictures from the team brainstorming sessions:

Figure 32. Brain Storming

84

Figure 33. Brain Storming Continued

Figure 34. Brain Storming Continued

85

Figure 35. Brain Storming Continued

Figure 36. Brain Storming Continued

86

Figure 37. Refining of Brain Storm Concepts

87

15. Appendix D: Concept Generation

Figure 38. Vertical Motion Rail system with screw drive

Figure 39. Vertical Motion Piston

88

Figure 40. Azimuthal motion vertical rail track

Figure 41. Combined motion radial and vertical #1

89

16. Appendix E: Resumes

Resumes are on the following pages in alphabetical order: Bill Boggs Steven Drew Ryan Hammerschmitt Scott Hromisin Joseph Oberholtzer Dylan Wynn

90

17. Appendix F: Changes To The Statement Of Work Engineering Specifictions Table 22. Updated Design Metrics and Specifications Metric Presure Senser Manipulation Radial Sensor Positions - Quantity Radial Sensor Positions - Accuracy Radial Sensor Positions - Range Azimuthal Sensor Positions Quantity Azimuthal Sensor Positions Accuracy Azimuthal Sensor Positions - Range Vertical Sensor Positions - Quantity Vertical Sensor Positions Accuracy Vertical Sensor Positions - Range Dimensions of Automated Movement Presure Sensor Performance Pressure Sensor Range Acceptable Value 5 +/- 0.125 12 to 30 8 +/- 0.25deg 0deg to 90deg 3 +/- 0.125 12 to 24 0 Ideal Value >50 +/- 0.05 6 to 43 >80 +/- 0.1deg 0deg to 360deg >30 +/- 0.05 6 to 36 3 0 psi to 2.5 psi 13 Bit (0.00031 psi) 400 Hz +/- 5 degrees 400 Hz Included User defined test sequences Included Procedure, Replacement Part Construction, Troubleshooting

17.1.

0 psi to 2.5 psi 10 Bit (0.0024 Pressure Sample Resolution psi) Pressure Sampling Rate 10 Hz Pressure Sensor Flow Alignment +/- 15 degrees Rotor Angular Velocity Sensor Performance Sampling Rate 80 Hz Data Reduction and User Interface Software Pressure on 3D Plot Included Sensor Positioning Software User input for each position change Frequency Analysis Not Included Instruction manual Positioning mechanism Procedure

91

Output Software

Procedure

Setup of System

Procedure

Procedure, Changing/Adding Code, Troubleshooting Procedure, Troubleshooting >9 hours

Whole System Performance Hours of Testing 3 Hours * Changes since SOW are highlighted

Azimuthal Drive Concept Selection Team sponsors, Jason Steiner and Rob Spencer proposed a novel idea to use a large-diameter bearing as the center of rotation of the azimuthal system. The concept included mounting the test stand in the middle of the bearing and driving one race of the bearing with a timing belt and keeping the other fixed. The original concept model proposed by the sponsors may be found in Figure 42.

17.2.

Figure 42. CATIA model of lazy Susan concept proposed by Boeing with rotor test stand in the center

From this point, the team went through seven different design iterations until reaching the final, detailed design. As the design matured, the most successful aspects from previous design iterations were kept and upgrades suggested by both the project supervisor, Wallace Catanach and project advisor, Professor Dennis McLaughlin were included in the models. CAD drawings for all design iterations may be found in Figure 42 - Figure 49.

92

Figure 43. Original CAD assembly of lazy Susan bearing-based azimuthal drive.

Figure 44. Design Iteration 2 of azimuthal drive. A ball-caster wheel has been added and the bearing is flush with the board.

Figure 45. Design Iteration 3: A belt coupler has been added to the outer diameter of the lazy Susan bearing and the arm attaches to the bearing around the entire circumference.

93

Figure 46. Design

Iteration 4. The expensive bearing-belt coupler has been removed in lieu of fixing the timing belt like a curved rack as was proposed in the original, dolly-style design. The ball caster wheel has been attached to the arm with an adjustable-height support.

Figure 47. Iteration

5. The 2-piece aluminum arm has been replaced with a less expensive, easier to machine, 0.75 plywood arm.

94

Figure 48. Design Iteration 6. The large, expensive aluminum plate has been reduced in size to a smaller area support for the outer race of the bearing. The motor has been mounted to a special bracket and bearing assemble remove the overhung load from the motor shaft and internal bearings.

Figure 49. Design

Iteration 7, final design. The motor has been moved to the opposite side of the arm to allow the radial drive to move closer to the center.

95

96

17.1.

Special Topics

Figure 50: Updated Gantt Chart

Table 23: Allocation of Remaining Funds

97

18. Appendix G: Calculations for Design Analysis

18.1.

Azimuthal

Pinion Calculations Pinion Parameters:

Calculations:

Now, pitch for a gear is defined as the arc length between the teeth or,

If both equations are equated via

then the result is:

Solving for

: ( )

Knowing both the base pitch and tooth pitch for the gear (curved timing belt), the pressure angle between the pinion and gear may be calculated via the following relationship:

Solving for ( ) ( )

Assume both the curved timing belt and belt pulley act as spur gears

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Free Body Diagram of timing belt pinion mate:

Figure 51.Free Body diagram of timing belt and pinion contact. Wt and Wr represent the tangential and radial components of the transmitted force, respectively. From the FBD, it is clear there is a bending moment applied to the pinion (motor) shaft that is directed radially away from the gear coupling. Since the motor will be turning everything, the max possible torque the motor could output is the holding torque. The holding torque has a nominal value of 14 oz-in, or 0.099 N-m or 0.073 ft-lbs.

Torque Calculations Experimental Set-Up: A model of the azimuthal drive design was constructed in the Learning factory: the bearing was mounted on stilts and a 46 wooden arm with a caster wheel was attached to the bearing. Two 7lb, 3.5 bars were placed on the arm to simulate the weight of the radial and vertical systems. A 4lb force gauge was hooked to the end of the arm and pulled manually. The force indicated at the onset of motion was recorded. Calculations

99

Then, ( )

Since the pinion and timing belt act as gears, their mating provides a mechanical advantage to amplify the motors torque. This mechanical advantage is the gear ratio between the timing belt and the pinion. This ratio can also be calculated from the ratio of torques applied at the center of each gear. For the stepper motor and pinion, the start-up torque, or the max torque available when starting from rest is the known as the pull out torque. The stepper motor (part #1208 on pololu.com) has a nominal pull out torque of 11.11oz-in or 0.0579 ft-lbs. To add a factor of safety, the gear ratio required will be defined as the ratio between the required torque and 75% of the pull out torque. So, ( )

The pinion gear has 10 teeth so the required number of teeth on the timing belt is 770. The timing belt bought by the team only has 385 teeth, so that the,

The team will need to acquire a stronger motor in order to drive the azimuthal system. For a fixed tooth pitch, such as the case with the timing belt and pulley, the gear ratio becomes a function of the diameters of the gears. In this case, the gear ratio becomes the ratio between the outer diameter of the lazy-Susan bearing (to which the belt will be mounted) to the diameter of the teeth on the pinion. So the actual gear ratio for the azimuthal drive is: ( )

For this actual gear ratio, the minimum pull out required out of a stepper motor is:

On Pololu.com, the stepper motor #1200, with a pull out torque of 2000-2200 g-cm is the best candidate as a replacement motor. It will be assumed the motors pull out torque is 2000 g-cm.

100

Gear Bending and Surface Stress Analysis Using the spur gear analysis described in Machine Design: An Integrated Approach by Robert Norton, bending and surface stresses on the pinion and timing belt will be calculated. Pulley (Pinion) Bending Stress Calculations Norton defines the bending stress on the gear, in equation 12.15us, as: ( Where: ) ( )

The K factors will be defined as they are calculated. The tangential component of the force on the gear ( ( ( ) ( ) ) is: ) ( )

The diametral pitch (

) is:

Face width (F) has a nominal value of 0.5in. Assume the Bend Strength Geometry factor (J) = 0.4.

, ...attempts to account for internally generated vibration loads from tooth-tooth impacts induced by nonconjugate meshing of the gear teeth, (Norton 711). Assume the quality of the gears is low so that Furthermore, assume the pitch line velocity (vt) is 10 ft-min. Then, .

101

takes into account time varying transmitted load (Wt), such as in the start-stop cases the azimuthal motor will see. Assume the driving gear (pulley) experiences a light shock and the driven machine (timing belt) experiences a moderate shock. Then from Table 12-17.

attempts to take into account that actual parts may be larger and weaker than the small specimens from which the published fatigue strength data was collected. The AGMA has not yet established standards for size factors and recommends that Ks be set to 1 unless the designer wishes to raise its value to account for particular situations, such as very large teeth, (Norton 716). Assume Ks = 1.0.

takes into consideration any axial misalignments in tooth form. Misaligned teeth will cause the transmitted force to be unevenly distributed over the tooth face. From Table 12-16, for a face width (F) < 2in, .

factors in the thickness of the rim of a gear with respect to the tooth thickness. KB is a function of the ratio: ( Then, for mb >1.2: )

accounts for idler gears, which are subjected to more stress cycles. There are no idler gears present in the system so:

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Now, that everything has been defined, the predicted bending stress on the pinion may be calculated: ( ) ( )

Pulley (Pinion) Surface Stress Calculations

Norton defines the surface stress on the gear face, in equation 12.21, as: (( Where, ) ( ) )

The C factors, Ca, Cm, Cv, and Cs have the same values and definitions and values as their respective K factors on the previous pages. Therefore:

accounts for rough tooth surfaces. The AGMA has not yet established standards for surface-finish factors and recommends that be set to gears made by conventional methods. Assume convention manufacturing methods so .

considers that the gears may be made of different materials.

( )

Where,

[(

)]

Solving:

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( )

[(

)]

takes into account the pressure angle of the gear teeth and the radius of curvature of the teeth. The surface geometry factor is defined by AGMA as:

((

))

Since the azimuthal drive is set up as an external gear set the + sign will be used in the denominator. The radii of curvature may be calculated from the following equations: (( ( )) ( ) ) (( ) )

Where C is the center-center distance of the pinion and gear

Assume teeth on both the belt and the pinion are standard, full-depth teeth, so xp = 0. Solving for the radii of curvature: (( ( )) ) (( ) )

Solving for the surface geometry factor:

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((

))

Now, putting everything together, the predicted surface stress on the pinion gear may be calculated: (( ) ( ) )

Timing Belt (Gear) Bending Stress Calculations

The bending stress in the timing belt follows the same equation as before: ( ) ( )

Assume all of the K factors are the same as in the bending stress calculation for the pinion gear, as nothing would suggest otherwise. Then,

Therefore, the bending stress remains unchanged so,

Timing Belt (Gear) Surface Stress Calculations The surface stress on the timing belt follows the same formula as in the pinion gear calculation: (( ) ( ) )

Since all K factors were assumed to remain unchanged, then it will be assumed the C factors remains unchanged as well.

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Moreover, between the pinion and gear, the calculations for the elastic coefficient (Cp) and the surface geometry factor (I) also remain constant. Per AGMAs recommendations, Cf will still be taken as 1.0. Therefore, the surface stress remains unchanged so,

Motor Shaft Bending Stress Calculations

An important variable to know to properly characterize the azimuthal system is the bending moment on the unsupported motor shaft caused by the gear contact. This contact puts an overhung load on the shaft. The stepper motor was not rated/designed to be able to support an overhung load. This could cause accelerated wearing and premature failure of the motors internal bearings. There it is imperative to understand the expected magnitude of this load in order to decide in a special bracket/shaft support must be created to provide addition support to the motor shaft. The radial component of the transmitted force (Wr) is responsible for causing the overhung load. It will be assumed that this load is applied entirely at the end of the shaft. The bending moment is defined as:

Where,

Then, ( ( ))

Now, the bending stress on the shaft is:

Where,

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Assume the shaft is circular, then,

So, ( )

In order to ensure the system will run smoothly, a safety factor (SF) of 3 will be multiplied to this stress:

Motor Shaft Life Cycle Analysis The life cycle analysis performed on the shaft will follow the process outlined in Chapter 6 of Nortons Machine Design: An Integrated Approach. Without bearings to support the shaft loads, the stress on the motor shaft is:

It will be assumed that the bearings and bracket take off 70% of the bending stress on the shaft , so:

Furthermore, it will also be assumed that the shaft is made of 6061-T6 aluminum with:

Aluminum is a material that does not exhibit a knee in its Fatigue Strength (S) vs. number of load cycles (N) curve. Therefore, the equation governing the corrected fatigue strength for aluminum is given as equation 6.6 in Norton:

For

cycles:

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takes into account non-bending part loading. The published ratio for as a function of is for bending, rotating tests. If the part experiences some other form of loading during rotation, its fatigue strength will be compromised. Assume shear stresses in motor shaft are negligible. In the current application the motor shaft is only expected to experience bending so:

accounts for actual parts being larger that the small (about 0.3in diameter) test specimens from which data was published. For a shaft diameter (Dshaft 8mm):

considers the surface roughness of the part. Rougher surfaces result in a shortened fatigue life. may be calculated using equation 6.7e in Norton:

Where the coefficient A and exponent b are a function of the surface finish Since the motor shaft is smooth and reflective, it will be assumed to have a ground finish. Then, from Table 6-3:

So,

accounts for parts in higher-temperature operating conditions. Fatigue test data was published for room-temperature parts. The motor in this application will not experience high temperatures. So, from equation 6.7e:

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is chosen by the designer. It is a function of the % probability that the part meets or exceeds the calculated strength. For this application, 99.999% reliability has been chosen. From Table 6-4:

Now, multiplying everything together, the corrected fatigue strength of the motor shaft is:

From equation 6.10a, the fatigue strength (stress) as a function of part life (N) is:

Where, ( ) ( ) ( ) ( )

And

Therefore:

Now, calculating the estimated life, that is number of loading cycles, the motor shaft can experience before fatigue failure: Unsupported Shaft:

Supported Shaft: Under the expected operating conditions, the supported shaft can be expected to last 5 orders of magnitude longer than the unsupported shaft. The supported shaft can be assumed to have essentially infinite life. The azimuthal drive is designed with the shaft supported.

109

18.2.

Radial Calculations

Figure 52: Calculations for Screw Drive used in Radial and Vertical Motion

110

Figure 53. Calculations for Radial Screw Drive

111

18.3.

Vertical Lift Calculations

Figure 54. Calculations for Vertical Lift

112

Figure 55. Calculations for Vertical Lift Continued

113

19. Appendix H: Shop Drawings

19.1.

Azimuthal Drive

Figure 56 Lazy Susan Bearing Support

Figure 57. Stepper Motor Shaft Coupling

114

Figure 58. Azimuthal Arm

Figure 59. Bearing and Shaft Support

115

Figure 60. Caster Wheel Support Arm

19.2.

Radial Drive

Figure 61. Journal Bearing End Stop

116

Figure 62. Through Journal Bearing

19.3.

Vertical Drive

Figure 63. Scissor Lift Driven Cross Member

117

Figure 64. Scissor Lift Top and Bottom Side Wall

19.4.

Data Acquisition & Controls

Figure 65. Basic Wiring Schematic for Controls

118

19.5.

Signal Conditioning and Power

Figure 66. Circuit

Conditioning Circuit

119

20. Appendix I: Bill Of Materials Table 24. Azimuthal Drive Bill of Materials PART MATERIAL TYPE Plywood Aluminum Aluminum n/a Neoprene Acetyl Metal Plastic Plywood Plywood Pine Steel Steel Aluminum Steel Steel Steel Steel VENDOR COST

Azimuthal Arm Arm-Bearing Coupling Lazy Susan Bearing Stepper Motor Timing Belt Timing Belt Pulley Caster Wheel Level Wood Base - Square Wood Base - Circle Legs Threaded Knob 10-24 Hex Nut Caster Wheel Support Arm 3/8-24 x 1.5in threaded screw Wood Screws 10-24 x 1in Hex-Head Screws 10-24 x in Hex-Head Screws 10-24 x 5/16in HexHead Screws

Lowes Onlinematerials.com vxb.com pololu.com McMaster-Carr McMaster-Carr Lowes Lowes Lowes Lowes Lowes McMaster-Carr Learning Factory Learning Factory Learning Factory Lowes Learning Factory Learning Factory

$19 $40 $56 $20 $15.47 $7.4 $4 $4 $3 $3 $1 $1 2 @ $0 $9.97 1 @ $0 9 @ $0 3 @ $0 5 @ $0

Steel

Learning Factory

$0

120

-20 x 2.25 threaded screw 8-32 x 3/16in set screw Bearing and Arm Support Bearing Support Bracket Pillow Block Bearing -20 Hex Nut 0.4 ID 0.8 OD Washer 0.26 ID 0.69 OD Washer 0.2in ID 0.5in OD Washers 12V, 1.6A, 416oz-in Geared Bipolar Stepper Motor Stepper motor bracket connector 0.1in ID washers Wooden bracket support GRAND TOTAL

Steel

Lowes

4 @ $0.73

Steel Aluminum

Learning Factory Learning Factory

2 @ $0 $20

Aluminum n/a Steel Aluminum Aluminum

Learning Factory McMaster-Carr Learning Factory Learning Factory Learning Factory

$20 2 @ 17.44 4 @ $0 2 @ $0 8 @ $0

Brass n/a

Learning Factory robotshop.com

17 @ $0 $39

aluminum

Learning Factory

$15

aluminum wood

Learning Factory Learning Factory

12 @ $0 $0 $315.64

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Table 25. Radial Drive Bill of Materials Item Electric Conduit Electric Box Thread Rod Conduit Coupler Stepper Motor Journal Bearing Motor Coupler PVC tee Table Drive Table Screws Thrust Bearing Nuts Bolts Set Screws GRAND TOTAL Description Steel, 0.5in diameter Steel, 1 Gang 1/2"-13, 6' Length Steel Bipolar,10V, 500mA Alum, 0.7"x0.75" diam Alum, 0.7"x0.75" diam 0.5in diam Alum, 0.5" x 0.5" x 1.5" Wood, 0.5" x 4" x 6" Metal 1/2" ID, 15/16" OD Steel, Hex, Assorted Steel, Hex, Assorted Metal Vendor Lowes Lowes McMaster Carr Lowes Pololu Robotics Learning Fact. Learning Fact. Home Depot Learning Fact. Learning Fact. Lowes McMaster Carr Home Depot Learning Fact. Learning Fact. $1.12 $4.37 $2.72 $0.88 $0.96 2@$0.10 $47.11 Unit Cost 2@$3.30 2@$1.64 $4.89 $2.28 $12.95 $2.63 $2.63 4@$0.40

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Table 26. Vertical Lift Bill Of Materials Item Aluminum stock Aluminum stock Aluminum stock Threaded rod Stepper Motor Machine screws Machine screws GRAND TOTAL Description 12" x 24" x 1/4" plate 1/2" square x 4' 1/2 round x 4' 5/16" x 24", 18 TPI, steel Bipolar, 4V, 1200mA #8-32 x 1" (8 pieces) #8-32 x 1.5" (4 pieces) Vendor OnlineMetals.com OnlineMetals.com OnlineMetals.com Home Depot Pololu Robotics Home Depot Home Depot Unit Cost $55.12 $4.70 $2.47 $1.76 $19.95 2@$1.18 $1.18 $87.54

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Table 27. Controls Bill of Materials Item Silicone Tubing Pitot Probe Pressu. Transducer Pin Header Motor Driver Carrier Capacitors Copper Circuit Board Female Housing Female Crimp Pins GRAND TOTAL Description 12in diydrones hobby grade MPXV7002DP 0.100", Male, 1x40 pin Allegro A4988 100uF, 50V capacitor PC Board 4.5 x 6in 1x4 pin, 0.1" Housings 100 pack, for 0.1" Vendor DIY Drones DIY Drones DIY Drones Mouser Elect. Pololu Robotics Mouser Elect. Mouser Elect. Mouser Elect. Mouser Elect. Price $1.95 $8.95 $19.95 3@$0.99 3@$9.95 2@$0.25 $4.65 3@$0.59 $5.95 $76.79

Table 28. Software Bill of Materials Item Arduino Arduino Box GRAND TOTAL Description Arduino MEGA 2560 Injection Molded Enclosure Vendor SainSmart Amazon Price $30.99 $11.01 $42.00

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