MECH486 Project Summary – 2009/2010€¦ · MECH486 Project Summary – 2009/2010 ... The 2010...

ME Senior PracticumProjects Overview - 2008- 09/10

MECH486 Project Summary – 2009/2010

• Formula Hybrid Competition (1) P. Fitzhorn• Shape Memory Composites (2) D. Radford• Unmanned Aerial Vehicle (3) T. Bradley

V. Manivannan• Woodward Turbine Control Unit (4) J. Gessaman• Hydraulic Hybrid Driveline (5) G. Babbitt

C. Turner• Human Powered Vehicle Competition (6) S. Schaeffer • InteGrid Photovoltaic Simulator (7) D. Zimmerle• John Deere Straight Vegetable Oil D. Olsen

Engine Development (8)


MECH486 Project Summary – 2009/2010• RocketSat Fiberoptic Mass Gauging A. Yalin

System (9)• SAE Aero Competition (10) H. Sakurai• Neonatal Transport Medical Unit (11) S. James

B. Woods• SCAMP – Cryogenic Firefighter (12) T. Bradley• Afghanistan Solar Water Purifier (13) W. Duff• Formula SAE Racecar Competition (14) P. Fitzhorn• Bamboo Bicycle Structural Testing (15) Jacob Pastillo

Bill Reeves• Composite Engine Valves (16) D. Radford• Novel Water Purification System (17) V. Manivannan


Formula Hybrid Competition (1) Formula Hybrid is a collegiate challenge to students to design, build and race

high performance hybrid vehicles. The competition is sponsored by SAE and will be held May 3-6, 2010, in

Loudon, NH. 30 teams from 5 countries are registered to compete. The 2010 CSU Formula Hybrid Race Car a modified 2004 FSAE chassis

powered by a 49 horsepower electric motor and Yamaha YZ-250F four-stroke internal combustion engine

The accumulator system is made up of NiMh battery modules donated by Denver based battery manufacturer Nilar at a total pack voltage of 144 v.

ME Senior PracticumProjects Overview - 2008 4

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ME Senior PracticumProjects Overview - 09/10

Shape Memory Composites (2)•Shape Memory Polymers (SMPs) have the ability to ‘freeze’ an applied strain. This strain can be recovered upon heating above the transition temperature and in some instances can provide very high deformation and recovery.

•SMP Linear Actuators are advantageous to use over mechanical/electrical actuators in aerospace applications due to decreased power requirements and decreased mass; combination with carbon fiber results in a high strength to mass ratio.

•The goal of the project is to develop a model for linear actuators which looks at the holding force, deployment force, maximum overall strain, and strain energy, as well as manufacture and test samples.


Unmanned Aerial Vehicle (3)Motivation Unmanned aerial vehicles (UAVs) are in

high demand for surveillance applications in remote and hostile environments.

The design space for long endurance, hand launched, man packable UAVs is largely unexplored and a validated design tool is needed.

Project Scope The Colorado State MPUAV team has constructed a computational tool to

aid the decision making process of small scale, long endurance UAVs. An aircraft was constructed to validate the design choices made using the

computational tool. On display at E-Days: Validation aircraft, summary of computational

design tool, manufacturing summary, testing documentation.


Woodward Turbine Control Unit (4)

Cartridge Isolation Valve

Manifold Mounted Isolation Valve

Manifold

Project Objectives• In the event of a CPC-II failure, the slave CPC-II can seamlessly take control of master hydraulic pressure line.• Reliable operation at ISO 20/18 cleanliness level.•CPC-II replaceable while system is operating•Validate system with a hydraulic relay valve load simulator and contamination testing•Design, analysis, construction and validation of switching mechanism and manifold.

Project Details•Visual confirmation of master pressure line.•Four valves to allow isolation of pressure lines to replace a failed CPC-II .•Contamination test to run 150 hours.•Total mechanical operation of switching element• Pressure drop to be less than 1.5 Bar•Load cylinder to have less than 0.225 bar total hysteresis.

CPC-II


Hydraulic Hybrid Driveline (5)Refuse(trash) companies can spend as much as $40 million a month

on fuel because the vehicles can get as little as 2 miles per gallon.

This is our retrofit system mounted into a class 6 truck for testing

•Hydraulic hybrid vehicles use regenerative braking to capture and store the vehicle’s kinetic energy with hydraulics and reuse that energy to accelerate the vehicle

•The system was designed for retrofit applications with adaptability in mind, targeting being able to install on most class 6-8 trucks in service

•The scope of this project included the analysis, design, and manufacturing and testing of a robust system

•The vehicle will be driven to e-days and will be on displaysponsored by


Human Powered Vehicle Competition (6)• ASME Sponsored design competition of innovative human powered

vehicles for everyday use• Drag reduction device in the form of a clear plastic fairing• Customized removable storage compartment• Ergonomic design for riders of any age and heights between 5’4” and 6’2”• Light weight aluminum frame with an iridized finish for oxidation

prevention and appearance• Direct steering mechanism for smooth turning at high and low speeds• Lighting system that includes headlights and turning signals• Full roll protection system including a 5 point seat harness


InteGrid Photovoltaic Simulator (7)Power generation from grid-tied photovoltaic systems is variable and unpredictable. When there is high density of PV grid-tied systems the grid will be affected by the variable power generation. Our PV Simulator allows InteGrid Lab to easily test these effects in the lab without the cooperation of the weather.

The InteGrid team has done the following:• Built a PV simulator that can output power in

the range of 2–50kW• Designed it to be adaptable for grid-tied

inverters whose outputs are either 208VAC 3-phase, 240VAC 1-phase, or 480VAC 3-phase

• Incorporated data acquisition devices on both the DC input and AC output of the inverter

• Designed safety features in the form of breakers, disconnects, E-stops on the AC and DC sides

• Designed LabVIEW software to simulate PV arrays given prerecorded irradiance data provided by Sandia Labs

• Tested the system and its subsystems and generated valid output data

• Generated Safety Manual and Electrical Schematic for the system


John Deere SVO Engine Development (8)

“Evaluate the performance and emissions characteristics of a John Deere, common rail, CI engine while operating on straight vegetable oil.”

Problem Statement:

•Fuel System Redesign•8-Mode Emissions & Baseline Performance•Injection Timing Probe•Timing Sweeps•Final 8-Mode Emissions & Performance Testing

Project Tasks


RocketSAT Fiberoptic Mass Gauging System (9)• No current, acceptable solution exists to determine liquid

volume in a tank exposed to microgravity, without some form of stratification, tank stirring or spacecraft acceleration

• The amount of space occupied by a fluid inside a tank is determined by measuring the index of refraction of a gas within the system. This is done by using an interferometer which operates by analyzing the interference pattern generated by two or more optical signals.

• Two tanks w/ different volumes of liquid are independently exposed to Gas Cell. The amount of liquid in each will be measured, this will represent fuel/fluid levels at different periods during a mission.

The 2009-2010 senior design team is responsible for developing a sensor using an existing measurement technique to accurately determine the liquid volume in a tank in any gravitational environment. Also

to demonstrate its accuracy and reliability on board a sounding rocket mission.

Mach-Zehnder Interferometer

Fiber based MZ Interferometer


SAE Aero Competition (10)“The Mission of Regular Class is to design an aircraft that can lift as much weight as possible while

observing the available power and aircraft’s length, width, and height requirements. Accuratelypredicting the lifting capacity of the aircraft is an important part of the exercise as it oftendetermines difference in placement between competing teams.”

Competition Constraints:• Takeoff within 200 feet• Complete one 360 degree circle• Land within 400 feet• Maximum combined length, width and height of 200 in.• Capable of carrying an enclosed rectangular block

measuring 5” x 5” x 10”• Must be powered by a single, unmodified OS 0.61FX

with E-4010 Muffler• Utilize a common grade, 10% nitro methane fuel• Fiber reinforced plastics prohibited

Competiton Details:• Aero Design East in Fort Worth• April 30-May 2, 2010• 65 teams from seven countries


Neonatal Transport Medical Unit (11)

•Transport Incubators are complex devices that are used to transport newborn or pre-term babies. The main aim of the transport team is to redesign these devices for newly industrialized countries (NIC).

•The unit must be light weight, agile, and easy to use, given that the user may not be well-trained. Most importantly, it must provide a safe environment for the neonate. The unit must shelter the neonate from heavy vibrations, noise, and extreme temperatures, while remaining maneuverable and unobtrusive to rescue workers.

•The goal of the 2009-2010 Senior Design team was to incorporate the work done by last year’s group while focusing on maneuverability, modularity, safety, and affordability for the NIC demographic. This will include redesigning existing units to make them more feasible in our target market while adhering to the regulations.


SCAMP – Cryogenic Firefighter (12)To create a PAPR (Powered-Air Purifying Respirator) that can be used as a modular unit as well as be integrated into a SCBA (Self-

Contained Breathing Apparatus)•The PAPR will provide purified air based on the user demand to maintain positive pressure in the mask.•This air will be mixed with 5 liters per minute of SCBA air unless the oxygen concentration is too low. •The oxygen content of the air will be sampled, to ensure the continuous safety of the HAZMAT personnel.

• When connected to the SCBA, visual indicators on the mask will allow for the user to be informed of tank life, battery life, and if he/she is on full SCBA.

• If there is any change in the environment, the user will be alerted with visual and audible alarms.• An expected 3.5 hours of user life, for the PAPR, with a half an hour on the SCBA to total 4 hours.


Afghanistan Solar Water Purifier (13)Goal: Design of a passive solar powered water purification system that is: low cost, can withstand adverse environmental conditions, ability to be

cleaned and user friendly proven to meet the EPA (Environmental Protection Agency) standard

of 99.9% pathogen reduction by holding water at a high temperature for an appropriate time

Accomplishments: Designed and manufactured 2 heat exchangers Various tests

• 42 days of temperature tests using thermocouples at 12-15 locations throughout the system• 6 tests using EPA Contaminant Level testing kit; Passed (6/6)• Completed Environmental Health Service E. coli test•Heat exchanger efficiency tests •Wind tunnel testing• Solar collector tube failure testing

Designed for easy assembly • Students from Fort Collins High school built the system from a kit in 45 minutes


Formula SAE Racecar Competition (14)Team Goals for the 2010 Ram Racing Team:1. Compete in the ‘10 FSAE West competition and improve our performance in

all events over last year’s benchmark2. Leave a legacy of knowledge with underclassmen to develop future teams

All car components are designed, manufactured, and assembled by students using tools such as

Solidworks/Cosmos, Fluent, vertical mills, lathes, CNC machinery, welding equipment, and

hand tools. This year, our car has four systems: chassis, powertrain/drivetrain, suspension, and

composites.

The team consists of M.E. Seniors, M.E. Underclassmen, and other CSU students.


Bamboo Bicycle Structural Testing (15)• Design an affordable and marketable 56 cm bamboo bicycle• Meet ASTM bicycle frame performance standards• Focus on:

• Lug design• Manufacturing • Epoxy

Replication of ASTM test at

CSU Biomedical Engineering Lab

sponsored by

E-day Expectations:• Fully functional bicycle with bamboo/steel frame• Frames used in testing (BME lab and Microbac (ASTM test facility))• Material property and frame test results• Lug redesign documentation


Composite Engine Valves (16)• Racing Applications:

• reduced engine mass • increase in max. engine speed• improved fuel economy.

• Manufacturing: Resin Transfer molding PETI-RTM / PETI-RP46 polymer to produce engine intake valves. Composite vs. Steel Resin Transfer Molding

Heat simulationDynamometer Testing

• Quality: Using coordinate measuring machine (CMM) and valve head stiffness analysis to evaluate valve dimensions.

•Dynamometer: Testing intake valves in racing engine environment for durability.


Novel Water Purification System (17)Problem Statement: Utilize recent advancements in materials science to improve upon current methods of point-source water purification.

• Utilize the photocatalyst TiON to deactivate bacteria contamination in drinking water through exposure to sunlight and ambient light. • Demonstrate the application of carbon nanotubes in membranes for nanofiltration of water. • Design a water purification system to overcome the disadvantages of currently available commercial systems;

• Entirely gravity-driven; no external power supply• No chemical disinfectants leading to possible byproducts• Simplistic user interface to indicate the need for filter replacement• Comparable performance and cost to the consumer.

• Testing to show the functioning and safety of the system and all components.

E. coli testingFilter components

Purification system

TiON-coated glass plates

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