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Multidisciplinary Engineering Senior Design
Project 05002 Micro Turbine III2005 Critical Design Review
May 13, 2001
Project Sponsor:Mechanical Engineering Department
Team Members:Cliff Cummings Allison StudleyJoe Calkins Mark Fazzio
Team Mentor:Dr. Jeff Kozak
Acknowledgements:Jon Ross, Dr. Fuller, John Bonzo, Borce Gorevski, Dave
Hathaway
Kate Gleason College of EngineeringRochester Institute of Technology
Background
• Current battery technology causes the battery to be up to half of the weight of the MAV.
• Research into lighter weight power generation methods led to micro-turbine generators.
• Third generation RIT Senior Design project
05002 Micro Turbine III Senior Design
Mission Statement
We will design and build a microturbine generator that can be integrated onto a micro air vehicle airframe and power the vehicle’s accessories. The microturbine will be a continuation of the previous team’s project with the application of their design to be used for MAV power production.
05002 Micro Turbine III Senior Design
Primary Objectives
• Produce a minimum constant 5 watts of power• Minimum flight time of 3 minutes• Overall weight of less than 45 grams• Integrated onto the MAV airframe
05002 Micro Turbine III Senior Design
Research Methods
• Preliminary Research
• Review of last year’s design
• Additional Research
05002 Micro Turbine III Senior Design
Feasibility Assessment
Last Year's Design 2 Inlet 2 Outlet ConceptCost 3 2Size 3 2Weight 3 3Availability 3 3Manufacturability 3 2
Average 3.00 2.40Normalized Average 1.00 0.80
• 2 Options – Direct Comparison
• >2 Options – Weighted ComparisonWeighting Air Bearings Magnetic Bearings Axial Bearings Radial Bearings
Cost 0.2 4 4 3 2Size 0.1 5 5 2 2Weight 0 3 3 3 3Availability 0.35 5 5 2 2RPM Rating 0.35 2 2 3 3
Weighted Average 3.75 3.75 2.55 2.35Normalized Average 1.25 1.25 0.85 0.78
05002 Micro Turbine III Senior Design
Feasibility Assessment
Considerations• Ability to meet the objectives• Overall Size• Total Weight• Availability of procured items• Ease of Manufacture• Cost of procurement/manufacture
05002 Micro Turbine III Senior Design
Efficiencies and Costs• 2-D Pelton Wheel
– Typically 15% efficient – Approx. $100
• 3-D Pelton Wheel– Approx. 80% efficient– Estimated above $1,000
• Axial Impulse (Katholieke University, Belgium)– Approx. 20% (for mechanical, 10% total)– Over $1,000
• Francis (large scale turbine)– 80-90%
05002 Micro Turbine III Senior Design
Turbine Feasibility
05002 Micro Turbine III Senior Design
Housing Concept• Cross flow design• 2 Inlets – 2 Outlets• Tight tolerances to prevent
flow from going around the turbine.
• 30% Fiberglass reinforced Nylon material
• Overall Size: 1.25” OD
0.6” Depth
05002 Micro Turbine III Senior Design
Housing Design• Cross flow design at 45o
• 2 Inlets – 2 Outlets• 0.005” – 0.010” tolerances on
all critical diameters.• 30% Fiberglass reinforced
Nylon material• Overall Size: 1.25” OD
0.75” Depth
05002 Micro Turbine III Senior Design
Housing Feasibility• Smaller OD ( 1.25” vs. 1.875” )
• Lighter weight ( 15g vs. 30g )
• O-Ring seal vs. Gasket seal
• Inlet/Outlet redesign
• Designed for manufacturability
05002 Micro Turbine III Senior Design
Housing Analysis
05002 Micro Turbine III Senior Design
Load: 300 psi
Maximum Stress: 1921.75 psi
Safety Factor: 10.49
Housing Analysis
05002 Micro Turbine III Senior Design
Load: 300 psi
Maximum Stress: 4130.67 psi
Safety Factor: 4.88
Propellant System Feasibility
Fuel• Compressed CO2 Cartridges• Compressed N2 Cartridges• Compressed Air TanksTubing• Flexible Nylon lines• Rigid metal linesRegulator• Bellows regulator to decrease
the inlet pressure• Micro nozzle to maintain a
choked flow• Pressure Regulator• Piercing device
05002 Micro Turbine III Senior Design
Other Design Concepts/Considerations
• Bearings: Sealed Air Shielded Magnetic
• Seals: Neoprene O-Ring at 40% compression Paper / Cork Gasket
05002 Micro Turbine III Senior Design
Safety Precautions
• “Safety Box” for protection during preliminary testing
• Mount for fuel canister during prototype testing– (picture)
05002 Micro Turbine III Senior Design
Prototype Financial Analysis
05002 Micro Turbine III Senior Design
Part Price per Qty Line Price
Turbine $96.00 1 1 $96.00
Housing Material $5.78 foot 0.08 $0.48
Shaft $4.64 1 1 $4.64
O - Ring $8.25 50 1 $0.17
Bearings $5.00 1 2 $10.00
Tape $0.97 1 0.25 $0.24
Housing Connections $24.15 1 1 $24.15
Flow Split $18.44 1 2 $36.88
Tubing $0.71 1 1 $0.71
Nozzle free 1 1 $0.00
Fuel $18.15 1 1 $18.15
Puncture Device $22.15 1 1 $22.15
Fuel Connections (Puncture device to Regulator) $6.20 1 1 $6.20
Regulator $207.55 1 1 $207.55
Overall Cost $427.32
Overall Financial Analysis
05002 Micro Turbine III Senior Design
Schedule
05002 Micro Turbine III Senior Design
Testing• Three main phases of testing:
– Phase 1 (shop air)• Preliminary static testing
– No computer or nozzles
• Preliminary dynamic testing– No nozzles– LabView and DAQ system
– Phase 2 (shop air)• Dynamic testing with nozzles
– Phase 3 (fuel canisters)• Calibrate regulator• Repeat tests on best nozzles
05002 Micro Turbine III Senior Design
Test Setup (Phase 1 & 2)
• Test initially using
laboratory supplied
compressed air to prove feasibility of design (without nozzles)
• Determine which nozzle produces optimal power
• Provide data for mass flow calculations
Incoming Air
Plenum
Turbine System
Flo
w M
eter
Pressure Meter
Thermocouple
Thermocouple
Thermocouple
Oscilloscope
05002 Micro Turbine III Senior Design
Test Setup (Phase 3)
Turbine SystemFuel Canister
Thermocouple
ThermocoupleRegulator
Oscilloscope
• Replace shop air with compressed Nitrogen fuel canisters
• Duplicate test results from preliminary testing
• Prove feasibility of prototype
05002 Micro Turbine III Senior Design
Final Design
05002 Micro Turbine III Senior Design
Final Design
05002 Micro Turbine III Senior Design
Final Design
05002 Micro Turbine III Senior Design
Design Limitations
• Propellant cartridge & piercing device are 250g and 192g respectively
• Pressure regulator is an inefficient way of reducing the pressure from the canisters to the housing
• Miniature sealed bearings were unavailable at the required size
• Shrink tube coupling loses adhesion after extended use at 25,000+ rpm
05002 Micro Turbine III Senior Design
Major Design Issues
• Lead times – Machining of housing and cap– Delivery of turbine and regulator
• Production in a small quantity• Weight of fuel system components
– Canister, piercing device, regulator all greater than 190g each
• Compared to last year, fewer team members and more aggressive goals
05002 Micro Turbine III Senior Design
Analysis of Design• Outlet channels angled 45o to accommodate inlet/outlet
fittings
• Housing components tested using FEA and found to have a minimum SF of 4.88 using Nylon 6/6
• Cap contains the highest stress of the components at 4130 psi under a 300 psi load.
• Mass flow calculations were used to determine a nominal nozzle diameter of 100m
05002 Micro Turbine III Senior Design
Testing Results
• Phase 1– Static (maximum)
• 4.42 watts at about 100 psi and 25,000 rpm
– Dynamic (maximum)• 9.08 watts at 120 psi and 26,300 rpm (5 resistance)• 7.26 watts at 130 psi and 43,000 rpm (8 resistance)
• Phase 2– 100 micron nozzles
• Pending
• Phase 3• Pending
05002 Micro Turbine III Senior Design
Desired Outcomes• Produce 5 watts of power
• Weigh less than 45 g
• 3 minute run time (on N2 canisters)
• Integrate onto MAV airframe
Actual Outcomes• Produced a maximum of
9.08 watts of power
• System weight 48.9 g
• Run time pending final test
• Sized to fit onto MAV (without canisters and regulator)
05002 Micro Turbine III Senior Design
Actual Results• Weight
– 48.9g• Max Power
– 9.08 watts• Run Time
– Pending final test• Cost (for prototype)
– $
Alternative Fuel Sources• Batteries
– Cost ($30 - 50)– Power (10 – 20 watts)– Run time (10 – 30 min)– Weight (30 – 90 g)
• MIT Gas Turbine– Cost ($15 mil budget)– 30+ Faculty– Power (10-50 watts)– Run time (approx. 3 second)– Weight 85g
• Stanford Turbine (still in development)– Cost (?)– Power (designed for 100 watts
at 800,000 rpm, reached 420,000)
– Runtime (designed for 100 hours, reached ?)
– Weight (50 g)
05002 Micro Turbine III Senior Design
Conclusions
05002 Micro Turbine III Senior Design
Future Recommendations
05002 Micro Turbine III Senior Design
Questions?
05002 Micro Turbine III Senior Design
Backup Slides and References
05002 Micro Turbine III Senior Design
Data Acquisition GUI
05002 Micro Turbine III Senior Design
Data Acquisition Set-up
05002 Micro Turbine III Senior Design
FEA Analysis
05002 Micro Turbine III Senior Design
FEA Analysis
05002 Micro Turbine III Senior Design
FEA Analysis
05002 Micro Turbine III Senior Design
Flow Calculations
RTMVexit
RT
Pflowflow
05002 Micro Turbine III Senior Design
Nozzle Exit Velocity:
Flow Density:
Mass Flow: 22 nozzleexitflow AVm
Test Results (Phase 1)
05002 Micro Turbine III Senior Design
Power Output vs. Plenum Pressure
0
1
2
3
4
5
6
7
8
9
10
60 70 80 90 100 110 120 130 140
Plenum Pressure (psi)
Po
wer
(W)
1 ohm
5 ohm
8 ohm
100 ohm
Housing Post-Machining
• Main Housing– Had to machine inlet and outlet holes separately– Deburr housing after CNC machining– Bearing holes were too small due to limited tooling– Turbine seat was not concentric due to CNC tooling
path
05002 Micro Turbine III Senior Design
Preliminary Budget05002 Micro-Turbine III Project
Component Description Price per Qty Line PriceHousing Turbine $96.00 1 2 $192.00
Nylon rod $5.97 foot 1 $5.97machining $10.00 1 1 $10.00fittings $1.00 1 4 $4.00bearings $40.00 10 10 $40.00coupling $14.09 10 10 $14.09Mini Stainless Steel Shaft $3.93 1 1 $3.93O-Ring $4.00 100 100 $4.00Nylon cheese head screw $5.60 100 100 $5.60black nylon 6/6 nut $10.00 100 10 $1.00
Fuel Systems Ni Canisters $20.00 1 2 $40.00Connector $0.62 1 2 $1.24O-Ring $7.50 1 2 $15.00Puncture components $20.00 1 2 $40.00Jets $100.00 50 50 $100.00
Electrical Generator $200.00 1 1 $200.00
Overall Cost $676.83
Final Budget
05002 Micro Turbine III Senior Design
Previous Design
Back
05002 Micro Turbine III Senior Design
Previous Turbine DesignSenior Design Team 04013
05002 Micro Turbine III Senior Design