The final phase of MSD I, where the entire prototype design should be finalized. After this phase plans should be set for next semester, so building and testing can commence. This phase includes the fine details of the work being done on the design, such as the test plans, exploded views, and etc.
Team Vision for Detailed Design PhaseGoals
- Purchase pieces for prototype designs: DC Motor
- Begin coding
- Assembly of the entire system
- Update risks and Engineering Requirements
- Update BOM
- Drawings of designs
- Electrical designs, procedures, and diagrams
- Flow charts updated
- Complete the Test Plans
- All the goals set in the team vision were accomplished. Problems did occur, mainly in the flow simulation, which did not give out the expected results and did not work properly.
Prototyping, Engineering Analysis, Simulation
Initial Conditions, Boundaries, & Initial Predicted Results for Tests
- Test in air
- Wind speed variable (for this case 5 m/s)
- Density of air: 1.225 kg/m^3
- Motor/Propeller RPM: 842 rev/min
- Rotational Velocity: 5.47 m/s
- Mass flow rate dependent on velocities and speeds: 0.074 kg/s
- Exit Velocity of the air dependent on the initial wind speed (for this case 12.01 m/s)
- Expected thrust of the propeller with these conditions: 0.88 N
- The expected outcomes are extremely different compared to results from a water test
- Enclosure for magnets
- 3D printers on campus are available for creating propeller and enclosure
- Choosing the propeller design was based off of the Pugh chart for the propeller and the DC motor that was purchased. Below is the chart describing the best choices.
Drawings, Schematics, Flow Charts, Simulations
Mechanical System DesignPreliminary Assembly
A 3D PDF of the complete assembly can be found here. (Save link if it is not showing up in web PDF viewer)
- DC motor
- Rare Earth magnets (various sizes and shapes)
- Enclosure for propeller
- Enclosure for entire system
- Micro-controller (Beagle-bone)
Solenoid Controller Schematic V1.01
Actual Board Design V1.01
Solenoid Controller Schematic V2.0
Routed Board Design V2.0
Sensor Board V1.0
Routed Sensor Board V1.0
Wiring Block Diagram
Full System Circuitry Diagram
- Using a basic set of equations, found on the Excel sheet below, the required number of turns, along with other solenoid requirements can be calculated.
- For our specific design we need at least 0.03N
- This would require a minimum of 137 turns using the dimensions of the selected bobbin
- To help create a buffer and ensure that we will have extra headroom, we will be using 250 turns, generating 0.1N of force.
Bill of Material (BOM)
- Motor Construction
- Purchase motor
- Purchase motor
- New Budget
- $4,000 for “allowed” spending
- $1,818.67 allocated
- Funds spent to date: $128.99
- Magnets: Stabilization (lateral, axial) of the magnets and the entire system, preventing the system from falling apart. This will also include a mock build.
- Propeller: Flow simulation in SolidWorks will allow us to understand how the water or air will flow through the propeller and in what areas it will be disrupted or experience turbulence.
- Motor: Use an encoder to measure RPM; hook up and see if it the motor spins.
- Solenoids: Helmholtz coils will show if power runs through the solenoid.
- Enclosure: A leakage test will show if the propeller is enclosed properly & see if the motor fits.
- Coding: Check values, troubleshoot, and emulate the program to see if any errors occur or if the code runs.
- Temperature: Use thermo-couples to see get temperature values.
- Solenoid Controller: Verifying proper voltage output via multimeter, based on different inputs.
- Power Supply: Verifying the proper voltage is being output.
- Note: At this moment the test plans for the entire system as one have not been entirely planned. Therefore the full plan with both subsystem and the entire system plans will be complete in the Detailed Design page.
- The test plans seem to cover all Engineering Requirements, but due to the overall system plans not being completed at this moment it's not necessarily prepared to account for leakage and the backup safe mode.