Presentation 3 - Senior Design
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Connecticut Corsair Senior Design Simulator Refurbishment EE Design Team 194 Connecticut Corsair Senior Design Problem Statement Summary In interdisciplinary team of mechanical, computer and electrical engineering students are reengineering the base of an outdated flight simulator to have movements characteristics akin to that of a Corsair F4U-4 aircraft. 2 Connecticut Corsair Senior Design Previous Work Pros/Cons of Induction vs. Servo Motors SERVO MOTORS INDUCTION MOTORS Small Large Integrated Encoder Encoder Separate Low Run Temperature High Run Temperature Easier to Prototype Hard to Develop Prototype Efficient Less Efficient Expensive Cheaper Servo drives are expensive VFDs are less expensive Arduino compatible Arduino compatible 3/15 Connecticut Corsair Senior Design Previous Work Ideal Motor Specifications OLD SPECIFICATIONS NEW SPECIFCATIONS RPM: 26 RPM: 65 Torque Out: 1212 in-lbs Torque Out: 3484.1 in-lbs Gear Ratio: 63:1 Gear Ratio: 21:1 πππ‘ππ π ππππ = 120 ∗ πππππ’ππππ¦ 60 = 120 ∗ = 1800 π ππ πππππ 4 πΌπππ’π‘ πππππ 1800 πΊπππ π ππ‘ππ = = = 21.1 ππ’π‘ππ’π‘ πππππ 85 πΌπππ’π‘ πππππ’π = πππππ’π ππ’π‘ πΊπππ π ππ‘ππ = 3484 21.1 = 164.5 in-lb =13.7 ft-lb π ππ 1800 π»πππ ππππ€ππ = πΌπππ’π‘ πππππ’π ∗ 5252 = 13.7 ∗ 5252 = 4.7 π»π** **4.7hp non-standard. 5hp required.** 4/15 Connecticut Corsair Senior Design Current Work: Second Design Semester Motor Purchase and Installation - Induction motors mounted, relays built - Existing VFDs wired to motors - Servo purchased and being shipped Electronics Interfacing Components include... - Motor, - Arduino - VFDs - Protective circuitry, i.e: relays - Computer - Joystick inputs Arduino Sketch development - Function documentation and specifications 5/15 Connecticut Corsair Senior Design Current Work: Existing Motor Rebuild and Servo Integration - Initial Design: three servo motors - Redesign: single servo, two induction! - More compliant with budget - Small simulator load makes this possible - Induction motor damage update - Motor stator housings replaced Connecticut Corsair Senior Design Current Work: Second Design Semester 7/15 Connecticut Corsair Senior Design Current Work: Rewire VFDs Given the previous design team’s wiring… • Wiring modifications were made • Parts of existing setup cut out • New wiring allows for variable frequency input • Old schematics didn’t provide Arduino pin numbers Connecticut Corsair Senior Design Current Work: Wire Schematics Connecticut Corsair Senior Design Current Work: Arduino Sketch Development Thus Far • Reads Joystick(Pots) inputs to move motors at variable speeds using PWM. • Easy to write analog output with simple math. • Only at half capacity, will be solved with circuit elements. • Encoder code is being developed for the AS25 Gurley Absolute Encoder. Connecticut Corsair Senior Design Current Work What’s Next? • Interfacing with Servo drive • shipment estimated between 3/14 and 3/22 • Actual position controlled induction motors. Connecticut Corsair Senior Design Current Work Absolute Encoder • Provides absolute position information to Arduino controller • 16 bit resolution - very accurate • Synchronous serial data communication between encoders and Arduino • High speed: ~1 microsecond response time Connecticut Corsair Senior Design Current Work Simulation Software: Prepar3D • Lockheed Martin’s Prepar3D Academic v 1.4.4747.0 • Used for both entertainment and training • Immersive cockpit with real-life airports and environments • Mission Design, capable of entertainment and training purposes • SimConnect Developer SDK • Add-ons can be written in C, C++, C#.net or VB.net • Add gauge processing, replace events processing, record/monitor flights, create custom missions, weather manipulation, enable hardware with Prepar3D, control additional views and/or AI aircraft • F4U-4 Corsair Plane Model Import via A2A • A2A is a software add-on company • “Aircraft Factory” Line • Fine distinction: use software to control machine • Future application: 3D immersive LCD screen Connecticut Corsair Senior Design Timeline 2/24/2014 3/3/2014 3/10/2014 3/17/2014 3/24/2014 3/31/2014 Zach Mosch Run VFD's Absolute and Induction encoder motors with feedback Joystick Position controlled Induction Motors David Tartaglino Complete VFD and Induction motor wiring Finalize wirings and mount to simulator. Unpack and Make new start working Complete wiring See previous on servo servo and diagrams and motor drive wiring schematics installation Amanda Sweat Contact Lockheed customer support for installation issues Corsair model Outline how Create imported encoder Purchase A2A logfiles of using client feedback simulation positions server. Model inputs are Corsair model from joystick imported into Prepar3D control software Randy Bertrand Find usable code for Prepar3d outputs Absolute encoder feedback Link motors to Prepar3d position outputs See previous Servo's hopefully? See previous Servo motors 4/7/2014 4/14/2014 Transfer Arduino code See previous Testing to servo drive 4/21/2014 Testing Make servo wiring Testing diagrams and schematics Testing Integrate logfiles with existing Arduino code Answer: Can environment outputs be processed to affect flight simulator? Manipulate machine and software for simulation Help with servo setup Incorporate servo position info with encoder Testing feedback from other motors Write up on machine + Prepar3d integration. Computer wired. Testing Connecticut Corsair Senior Design High Level Joystick Motor Diagram = Arduino Sketch Connecticut Corsair Senior Design ME Contributions • Drive motor Analysis and Replacement • Free body Diagrams • Torque Requirements and Comparison • Nonlinear Linkages Analysis • Scissor Arm Analysis and Redesign • Determined failure scenarios • ANSYS analysis • CAD models • Motor Mount Redesign • Gearbox designs • ANSYS analysis • CAD models Connecticut Corsair Senior Design Questions? 17
