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Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
Micro Turbine Senior Micro Turbine Senior DesignDesign
PDR – May 20PDR – May 20thth, 2004, 2004
Project Project 0401304013
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Meet The TeamMeet The Team
Donald Slate (ISE) Lucas Lessa (ISE) Ream Kidane (EE)
Simien Lin (ME) – Project ManagerSimien Lin (ME) – Project Manager
Chuck Daze (ME) – Lead EngineerChuck Daze (ME) – Lead Engineer
Matthew Davis (ME) Meg LaRochelle (ME) Thomas Cague (ME)
Dr. Kozak – Faculty AdvisorDr. Kozak – Faculty Advisor
Dr. Hensel – Faculty CoordinatorDr. Hensel – Faculty Coordinator
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Presentation Presentation LayoutLayout
Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
OVERVIEWOVERVIEW
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
PurposePurpose Micro Air Vehicle
Surveillance purpose Approx. 90 grams.
Use of batteries for electrical power.
Search for lighter power source.
Courtesy of Dan Holt
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
BackgroundBackground Micro Turbine Project Overall Scope
Replace BatteriesMount onto MAV
Last year’s design – Proof of concept was successful18 watts of power100 grams
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Design ObjectivesDesign Objectives
Refine Micro Turbine More feasible for
MAV applications 18 watts down to 5 100 grams down to 40
Courtesy of www.symetrics.com
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
Turbine Turbine DesignDesign
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Concept Concept DevelopmentDevelopment
Pel
ton
Impu
lse
Axi
al I
mp
ulse
Rad
ial O
ut-
Flo
w
Rad
ial I
n-F
low
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Turbine FeasibilityTurbine Feasibility
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Final Turbine Final Turbine DesignDesign
8 Blades
Overall Dia. – 5/16”
Pitch Dia. – 0.27”
Blade Height – 0.05”
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Turbine Design Turbine Design ValidationValidation
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
Housing Housing DesignDesign
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing Design Housing Design ConceptsConcepts
Con
cep
t 2
Con
cep
t 3
Con
cep
t 1
Con
cep
t 4
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing – Pugh’s Housing – Pugh’s WeightedWeighted
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Final Housing Final Housing DesignDesign
1.75”1.75”
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing Design Housing Design DetailsDetails Attributes
LightweightEqually Split Flow ChannelMinimized Flow Restriction Two inlets, Two ExitsImproved Alignment
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Lightweight Lightweight MaterialMaterial Objective: To create housing from the
lightest material that will meet specifications.
Solution: MDS-Filled Cast NylonProperties
Tensile Strength 11,000 psi Good Manufacturability (ductility) Enhanced Pressure/Velocity Capabilities
Resulting Weight Total System weight < 44 grams
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Flow ChannelsFlow Channels Objective: To direct airflow to turbine with
minimum pressure loss.
Solution: Curved channel, cylindrical shellProperties
Reduced sharp turns/losses Equivalent flow channels/velocities
Calculated Head Loss Total Head Loss = 9.1%
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
ComponentsComponents
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing Assembly Housing Assembly
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing Housing ComponentsComponents Screw Selection
Resulting force calculatedScrew selected provides a F.O.S over 4
SealsStepped design provides for gasket
compression. Alignment
Cap/Shell design provides accurate alignment
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Shaft to Shaft Shaft to Shaft CouplingCoupling
Previous CouplingDuct Tape
Belgian Group CouplingShrink Tubing~1% Power Loss
Original ConceptSingle Piece CouplingPurchased Coupling
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Coupling Coupling CompaniesCompanies Manufactured Micro Couplings
NBKRelianceBellows
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Coupling SelectedCoupling Selected Final Concept
Rigid Shrink Tubing InexpensiveLightweightSimple Assembly, Disassembly
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Turbine ShaftTurbine Shaft Original Concept
Stainless Steel Micro Shaft0.059 in diameter, .8064” in length
14200
14400
14600
14800
12000 13000 14000 15000
Rad/Sec
Str
ess
(psi
)
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
BearingsBearings Previous Design Problems Possible Solutions
Air BearingsMagnetic BearingsSealed Bearings
Selected Bearings
Courtesy of NMB Minebea Co.
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
HousingHousingFinite Element Finite Element
AnalysisAnalysis
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Finite Element Finite Element AnalysisAnalysis
Modeled with Worst Case Scenario Loads Used a Minimum of Stability Points Results
Sufficient Margin of Safety
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing – Top viewHousing – Top view2.46E+2
2.21E+2
9.83E+1
7.36E+1
2.93E+1
2.47E+1
2.46E+2E-1
1.23E+2
1.47E+2
1.72E+2
1.96E+2
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing – Housing – Side/Inlet viewSide/Inlet view
Max Stress: 286 psi
2.46E+2
2.21E+2
1.96E+2
1.72E+2
1.47E+2
1.23E+2
9.83E+1
7.36E+1
2.93E+1
2.47E+1
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
DeflectionDeflection2.46E+2
2.21E+2
9.83E+1
7.36E+1
2.93E+1
2.47E+1
2.46E+2E-1
1.23E+2
1.47E+2
1.72E+2
1.96E+2
Max Deflection: 1.66E-4”
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
System System DesignDesign
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
MotorMotor Motor Selection
ConsiderationsSpecs
Min/Max RPM Output Power
Direct driveThree-Phase Brushless PM DC
Motor/Generator
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Motor Simulation - Motor Simulation - SimulinkSimulink
Matlab Parameters Easily modified
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Measurements/Measurements/TestingTesting Initial design
Closed loop feedback controlFeasibility
Final DesignOpen loopMeasurements
LabviewData Acquisition
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Data AcquisitionData Acquisition Inputs
Temperature Pressure Flow Current Voltage
Output Efficiency Power
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Testing SetupTesting Setup
Servo Valve
Generator
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
Closing Closing RemarksRemarks
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Proposed ScheduleProposed Schedule
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
BudgetBudgetComponent Description Price per Qty Line Price
Mini Stainless Steel Shaft 3.93$ 2m 1 3.93$
Vegetable Fiber Gasketing 9.64$ 5' 1 9.64$
Female Threaded Hex Standoff 1.27$ each 4 5.08$
Black Nylon 6/6 Nut 5.15$ 50 1 5.15$
Nylon Cheese Head Screw 5.39$ 100 1 5.39$
Polyolefin Adhesive Lined Shrink Tubing 5.03$ 4' 1 5.03$
Turbine 120.00$ 1 120.00$
Housing Fabrication 320.00$ 1 320.00$
General Purpose High Strength PVC Tubing 0.20$ 1' 25 5.00$
Male Compression Fitting 0.81$ each 2 1.62$
Female Compression Fitting 1.22$ each 2 2.44$
Turbine 120.00$ each 1 120.00$
Motor Bolt (Zinc-plated steel M1.6x6) 4.96$ 100 1 4.96$
Pressure Transducer 149.00$ each 1 149.00$
Flow Sensor 200.00$ each 1 200.00$
Servo Valve 1,000.00$ each 1 1,000.00$
Housing
Tubing
Electrical
Overall Cost = $1,957.24
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
SummarySummary Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary
Micro Turbine Senior Micro Turbine Senior DesignDesign 0401304013
Thank You AllThank You All QUESTIONS?QUESTIONS?
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Cap – Side ViewCap – Side View
0401304013Micro Turbine Senior Micro Turbine Senior DesignDesign
Housing CapHousing Cap1.13E+3
7.89E+2
1.01E+3
9.02E+2
6.76E+2
5.64E+2
4.51E+2
3.38E+2
2.26E+2
1.13E+2
2.83E-1
Max Deflection = 3.89E-6