Hyperloop Final Design Review 2016 -- Working Slides

Comments How to think about arranging slides:

Answer the question of how were addressing each design problem Show what work weve done to realize that solution

Need measurements to be consistent -- USE METRIC Reuse what we can! Check the previous FDR and 195C presentation to

make sure youre not reinventing the (back-up) wheel

With a lot of the information, I think itll suffice to say that its a work in progress, but make it obvious that were actively considering the issue

I think the way SpaceX has organized their bullet points is odd, but its what theyll be looking for. Would be happy to hear any suggestions about rearrangement

Dont worry about formatting, but PLEASE INCLUDE LINKS TO PICTURES. Copying them from Google Slides into Powerpoint degrades their quality

Useful Links

Slide designations (https://docs.google.com/document/d/1zikggXN1aQbpYssF8_PHopi6FRMU7Qo8zDGj6sDLL7I/edit?usp=sharing)

FDR Requirements on page 6 of Competition Rules (https://drive.google.com/file/d/0B23GQLtvn4pbYUNJVVg3Rm9YaGM/view?usp=sharing)

Hyperloop v1 FDR (https://drive.google.com/file/d/0B23GQLtvn4pbcXYxME5BR2lsTm8/view?usp=sharing)

Hyperloop ECE 195C Presentation (https://docs.google.com/presentation/d/1Q9Pv0Sg1-zIhsf4HOt0Ml72ivW4l2y-dlod0iILpNzQ/edit?usp=sharing)

https://docs.google.com/document/d/1zikggXN1aQbpYssF8_PHopi6FRMU7Qo8zDGj6sDLL7I/edit?usp=sharinghttps://docs.google.com/document/d/1zikggXN1aQbpYssF8_PHopi6FRMU7Qo8zDGj6sDLL7I/edit?usp=sharinghttps://docs.google.com/document/d/1zikggXN1aQbpYssF8_PHopi6FRMU7Qo8zDGj6sDLL7I/edit?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbYUNJVVg3Rm9YaGM/view?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbcXYxME5BR2lsTm8/view?usp=sharinghttps://docs.google.com/presentation/d/1Q9Pv0Sg1-zIhsf4HOt0Ml72ivW4l2y-dlod0iILpNzQ/edit?usp=sharinghttps://docs.google.com/presentation/d/1Q9Pv0Sg1-zIhsf4HOt0Ml72ivW4l2y-dlod0iILpNzQ/edit?usp=sharinghttps://docs.google.com/presentation/d/1Q9Pv0Sg1-zIhsf4HOt0Ml72ivW4l2y-dlod0iILpNzQ/edit?usp=sharing

Rolling ResistanceR = 0.005*Estimated Pod Mass = 150kgFD = (150kg) (9.8m/s

2) (0.005)FD = 7.4N

Magnetic DragNeed Data From Zach!!!!

*R = 0.002-0.005 for Low Resistance Tubeless Tires-engineeringtoolbox.com

BEFORE: 64 MPa at corner AFTER: 12 MPa at corner

Maglev Mounted to Payload Chassis with angled brackets

Will use PVC vibration damping pads and rubber grommets between the bolted connections to dampen motor vibrations

Motor Speed is approximately 33Hz. If we tighten the bolts such that the

brackets are held on with 105 psi, the vibration pads will provide 18% transmissibility

Figure: Bode Plot for Vibration Pad

Spindle mounted front drag race wheel system Dimensions: 22.5/4.5-15 Selection of spindle mount based on lightweight mounting on midget sprint cars All bearing/hub components rated >5000rpm Wheels rated to 350mph

89.75

26.5

22.5

Component Material

Cart and Payload Chassis Aluminum 6061-T6 tubes

Drag Wheels Aluminum Racing Wheels with Rubber Tires

Shell Dacron Fiber With Wooden Frame

Brakes Aluminum Housing with Polymatrix Q Brakepads

Stability Wheels Polyurethane

Levitation Magnets NdFeB Magnets

Motor Controllers and Motors (4)

http://www.digikey.com/product-search/en?keywords=Z3732-NDhttp://www.digikey.com/product-search/en?keywords=Z3732-NDhttp://www.adafruit.com/product/1604http://www.adafruit.com/product/1604http://nullhttp://nullhttp://www.digikey.com/product-detail/en/GP2Y0A51SK0F/425-2854-ND/4103863http://www.digikey.com/product-detail/en/GP2Y0A51SK0F/425-2854-ND/4103863http://www.digikey.com/product-detail/en/LPC4088FBD208,551/568-9835-ND/3635124http://www.digikey.com/product-detail/en/LPC4088FBD208,551/568-9835-ND/3635124https://www.arduino.cc/en/Main/ArduinoBoardUnohttps://www.arduino.cc/en/Main/ArduinoBoardUnohttp://www.digikey.com/product-search/en?keywords=1278-1015-NDhttp://www.digikey.com/product-search/en?keywords=1278-1015-ND

http://www.farnell.com/datasheets/1691322.pdfhttps://www.fairchildsemi.com/datasheets/QR/QRD1113.pdfhttp://www.st.com/web/en/resource/technical/document/datasheet/DM00027543.pdf

Direction of motion

Total mass on Cart 18kg

Total mass on Payload

5kg

Power consumption (static, full load, x4)

90W

Max Braking Force 8.91kN

Temperature rating 90% efficient at < 600

Total Price $1755.75

Stroke length 50mm

Load in push 6kN

Load in pull 4kN

Static safety factor 2.5

Voltage 12V DC

Current 7.4A http://img.directindustry.com/images_di/photo-g/7052-8255886.jpg

Linak LA35 Small Electric Linear Actuator Integrated Control Steel backing Positioning Options

Chosen Pad is the Wilwood Polymatrix Q material

Per manufacturer spec this pad is designed to be used with aluminum rotors

A brinell hardness test will be performed to confirm

Very low dust and noise ratings Capable of performing under high

temperature conditions Coefficient of friction: .35 - .47 Low wear rate Smooth engagement with a flat

torque curve

Aluminum housing to encase brake pads, rubber pads, and metal shims

Metal shims used to correct larger errors

Rubber used to correct smaller/remaining variances

Metal ShimsFabrication Error

Brake Pad Back Plate

Aluminum Housing Bottom PlateBrake Pad

Aluminum Housing Top Plate Silicone Rubber

Brake pads have been selected to achieve an optimal COF over a low temperature range

To maintain optimum braking force, the maximum allowable pad temperature is 500

Matlab and COMSOL analysis are being completed to simulate pad temperature rise

Thermal testing will be completed to verify thermal properties

Estimated Pad Thermal Properties

Brinell hardness testing to determine if pad is softer than the Al 6061-T6 I-beam (95 Bhn)

SpaceX requires pad to not damage the surface of the I-beam Wear testing using a grinder to determine wear rate and debris from wear

The I-beam can not have residue left behind from brake pad Thermal testing to determine heat transfer from surface of the pad to the

back of the pad This will show how heat is spread from the surface of the pad to the

housing and rubber padding

Item Date

Build Plan 2/03/17

Complete purchase orders 2/10/17

Complete sensor calibration 2/10/17

Complete machining 3/17/17

Complete testing 3/31/17

Y

Z

X

YAW

ROLL

PITCH

Limits:60

6080

Staging, Pod Moves into Tube & Tube Depressurization

Tube Dynamic Run at Low Speed

Battery and Speed Controller Thermal Management BoxBlack = Mag Lev BatteryBrown = PCM Wax

Figure: Vibration Damping Mount

Competition Pod Full Scale Pod

Mass (kg) 137 1000

Number of Arx Pax Engines

4 12

Production Cost ($) 25,000 70,000

Maintenance Cost Per Year ($)

0 3,500

Payload Capability (lb) 225 850

Number of Passengers 1 5

a. Full descriptions of all functional tests (see Sections 10 and 12)b. Full description of Ready-to-Launch checklist/state (e.g. Loop Computer in Launch Mode

and sending telemetry, Pod hovering at 0.25 inches).c. Full description of Ready-to-Remove checklist/state (e.g. Wheels locked, Power Off).d. Description of how Pod is moved from Staging Area to Hyperloope. Description of how Pod is moved from Hyperloop to Exit Area

https://drive.google.com/file/d/0B23GQLtvn4pbRmxnOEVIbTBDV1E/view?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbRmxnOEVIbTBDV1E/view?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbRmxnOEVIbTBDV1E/view?usp=sharing

https://drive.google.com/file/d/0B23GQLtvn4pbdHBXcW5GRjFxSVU/view?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbdHBXcW5GRjFxSVU/view?usp=sharinghttps://drive.google.com/file/d/0B23GQLtvn4pbdHBXcW5GRjFxSVU/view?usp=sharing

Functional Test A Transport pod to Staging Area.Power on pod and establish connection with web app.

Confirm power consumption data. Conduct basic photoelectric sensor test (wave reflective tape over sensor). Conduct basic contact sensor test (push contact sensor).

Functional Test B Use the service propulsion motors to move the pod into the Hyperloop. Confirm wheel tachometers data.

Connect the pod to the Mechanical Propulsion Interface.Power up the maglev engines.

Confirm engines are spinning and engine tachometer data. Confirm power consumption data. Confirm temperature data (engines, batteries). Confirm short-ranging sensor data (height, offset from I-beam).

Power down the maglev engines.

Functional Test C Gate 1 is closed.Demonstrate a continuous communications link

Monitor all pod sensor data.

Functional Test D Hyperloop is depressurized.Power up the maglev engines.

Monitor all pod sensor data, esp. temperature data. Confirm brake actuation is functional.

Power down the maglev engines.

Jonathan Siegel