P14651: Drop Tower for Microgravity Simulation Adam Hertzlin Dustin Bordonaro Jake Gray Santiago Murcia Yoem Clara Agenda List of experiments Engineering Requirements Concept Design Subsystem / System Analysis Data Analysis Software Files Risk Assessment Test Plan MSD II Schedule Bill of Materials List of Experiments 1. Vacuum vs. Atmosphere Time – Fall 4. Undergraduate Level (Fluids / Numod) Middle School Level (Science) Requires Complete System Requires Vacuum Chamber Start and End Time Required No Calculations Needed 2. Calculate Drag Coefficient High School Level (Physics) Decreasing Object Acceleration (Air Resistance) Requires Complete System Undergraduate Level (Fluids) Start and End Time Required Requires Release / Laser System Gravity in Vacuum Conditions 5. Multiple Data Points Required 3. Gravity in Atmospheric Conditions Undergraduate Level (Physics) Requires Release / Laser System Start and End Time Required 6. Extra Vacuum Experiments Middle School Level (Science) Requires Vacuum Chamber No Data Required Engineering Requirements Rqmt. # SR1 SR2 SR3 SR4 SR5 SR6 SR7 SR8 SR9 SR10 SR11 SR12 SR13 SR14 SR15 SR16 SR17 I 9 9 9 9 9 9 9 9 9 3 3 3 3 3 3 3 3 Unit of Measure Marginal Value Ideal Value ft sec psi min psi / sec Yes / No in FOS millisecond ft in 0-15 0-2 0-14.7 1-10 mins 0-? Yes 0-? 0-5 0-? 10-15 6-8 >Tower Height Pump Flow Rate ft3/min 2-10 10 Impact Energy Dissipation Method Joule 0-(mmaxvfinal2/2) (mmaxvfinal2/2) ft3/min % error Yes / No 0-? 0 - 1% Yes ? 0% Yes in (0.50*ID)-(0.99*ID) (0.99*ID) Engr. Requirement (metric) Measure Relative Object Position Measure Relative Object Drop Time Measure Pressure Cycle Run Time Pressure Leak Rate Minimized Aesthetic Structure with Supports No Horizontal Motion Tube Collapse Pressure Timing difference of object release Tower Height Tower Cross - Section (Diameter) Air Intake - Tower Pressure Change Rate Minimal Error in Calculations Aesthetic Data Display Platform for Stationary Experiments 0 - 14.7 1 min 0 Yes 0 5 0 15 8 Drop Tower Design Tower Height Distribution Total Height of Tower 11’ 1.30” 3.385 m Drop Distance 8’ 3.77” 2.535 m Total Height Available 11’ 7” 3.53 m Results Total available height: 3.53 m (11ft 7in) Total used height: 3.385 m (11ft 1.3in) Total clearance: 0.145m (5.7 in) Total drop distance: 2.535m (8ft 3.77in) In Vacuum: Total drop time with standard gravity is .719s Speed at impact is 7.052 m/s Full System Analysis Release Mechanism Analysis Solid Model Section View Motor Type w/ Specifications Speed at 6V 0.12 sec/60° 0.04 sec/60° 0.24 m/s Torque 61 oz-in 3.81 in-lb 0.43 Nm Weight 43g Max Applied Force Gear Ratio 3 Length of the door 1.5 in (0.038 m) Micro-Controller Future Use Compatibility • The tower that will be built will have the capabilities of hosting a continuous lift system within the pipe. All the other subsystems would be able to work as regular with the moving system. • The only thing that would have to be address would be the modification of the software so it can monitor the displacement of the platform. Displacement Platform This platform would be the one responsible to catch the objects at the bottom of the tower and to bring them to be pick up by the release mechanism. Object Positioning Assembly This assembly will allow the object to be picked up by the release mechanism doors. A stopper in the release mechanism fixture will activate the motion upwards, and gravity would do the work to bring it back to a regular position. Object Positioning Assembly Frame Analysis Tube Deflection Assumes a worst case, where the entire structure is laying horizontally, 10ft (~3m) tower. The tube is fixed at the riser clamps pictured above, and is analyzed with two or three riser clamps, at either 8 or 4ft (2.44 to 1.22m) apart. With 2, ymax is -.058in (-1.5mm) With 3, ymax is -.0037in (-.093mm) So, three riser clamps will be used as deflection is decreased dramatically Riser Clamp Connections Critical Tipping Scenario Tower Supports Frame Subsystem Analysis Subcomponent Selection Rotation joints at top (for laser adjustment): From McMaster-Carr ¼” binding post ¼” bolt Wheels and axels: Wheels from McMaster-Carr, each supports 250 lbs. Axels from McMaster-Carr, analysis follows. Height adjustment/leveling: • From McMaster-Carr, 6 required, each supports 250 lbs Axel Calculations I= 1.27698E-09 m^4 a=.0381m F2 (fixed) fy=0: F1+W-F2=0 b=.026m M(wheel)=0: -F1(.0381+.026)+F2(.026)=0 F1=522.2N; F2=1287.4N x Singularity Functions: F1 (fixed) Reaction at Wheel (weight) (free) Deflection M(x)=F1x-F2<x-a>^1 0.060 EI(d2y/dx2)=F1x-F2<x-a>^1 0.050 EIY=(1/6)F1x^3-(1/6)F2<x-a>^3+c1x+c2 @x=0,y=0: c2=0 @x=a,y=0: c1=-(1/6)F1a^2 deflection-mm EI(dy/dx)=.5F1x^2-.5F2<x-a>^2+c1 0.040 0.030 0.020 Deflection 0.010 0.000 so, y=(1/EI)*((1/6)F1x^3-(1/6)F2<x-a>^3-(1/6)F1xa^2) Also, shearing of axels: τ= 6.69E+06 Pa FOS= 55 -0.010 -0.020 0 10 20 30 40 x-mm 50 60 70 80 Laser & DAQ Analysis Specifications & Setup Micro-Epsilon ILR 1030-8/LC1 10ms response time -- over ~2.6m (8.5 ft) this is ~ 70 data points (fall time .727 seconds in a vacuum) +/- 2.5mm accuracy 4-20 mA output related to distance fallen, and must be calibrated. So 4mA=0m and 20mA=2.6m Voltage will be created from mA output via a 249 ohm resistor, for DAQ purposes; DAQ will be NI USB-6008 Can see though polycarbonate, as long as it passes through before start of data collection (data collection starts at 0.2m (7.9in) and angle of entry +/5° from perpendicular to surface Laser is visible dot (important for alignment and calibration) M12 connector for power and interface, requires 10-30 VDC M12 cable has pigtail bare lead ends Mounted via M5 through holes Frame Mounting Components Bending of Links Assumptions: -Treat multiple distributed loads as a point load on the end -Treat as a solid beam 250mm to mass application apllication Total weight of all components is ~5N Applying twice this at 250mm: I= (1/12)*b*h^3 I= 4.06E-10 m^4 Beam dimensions: l= b= h= 250 mm 19.05 mm 6.35 mm E= 2.05E+11 Pa y= y= y= -0.000625 m -0.63 mm -0.024608 in Pipe Analysis CAD Drawing Critical Negative Pressure Critical Pressure Calculations for Clear PVC P 14.7 psi v 0.37 E 429000 psi Formula PCrit=(2*E/(1-v^2))*(1/((OD/t)-1)^3) SCH 40 Pipe Maximum Pressure Size (in) OD (in) Thickness (in) Max Pressure (psi) Factor of Safety 6 6.625 0.28 85.43 5.81 Desired Factor of Safety = 3-4 Max Pressure Rating of Schedule 40 PVC*, from HARVEL Size (in) 6 Max Pressure (psi) 90 *Specifications for white PVC Pipe Dimensions Courtesy of Engineeringtoolbox.com Factor of Safety 6.12 Energy Dissipation Analysis Material Selection Polystyrene Beads (Bean Bag) Critical Dimensions of Impact Absorption material Critical Dimensions of Impact Absorption material 𝑚𝑎 𝑚𝑏= 𝐶𝑅 • Assuming a Object 1 mass of 1kg. • Assuming a Coefficient of Restitution of 0.712 • Assuming a Ball Radius of 0.0508 m (2 in) . Height of energy absorbing material = 0.16 m ̴ 16 cm (6.30 in) Volume =Mass / density Area= Pi x Radius^2 Height = Volume / Area Pump Analysis Specifications Free Air Displacement – 6.25 CFM @ 60Hz Horse Power – 1/2 HP RPM – 3440 @ 60Hz Ultimate Vacuum – 15 microns (2 Pa) Intake Ports (male flare) – 1/4", 3/8" SAE Male & 1/2" ACME Male Oil Capacity – 15 oz./450 ml Dimensions – 13.7'' x 5.6'' x 10.4'' Shipping Weight – 25.4lb/11.5kg Evacuation Time Equivalent Length, Le, based on pipe losses Effective Pump Speed based on pipe geometry and flow regime Evacuation Time based on Volume, Pump Speed and flow regime Main Pipe Secondary Pipe Combination of Pipes Evacuation Time Total Le (ft.) 60.0 3.9 Conductance (cfm) Viscous Transitional Molecular 4268347.2 315.4 49.0 16135.4 2.4 1.5 Sp (cfm) 6.25 Effective Pump Speed (cfm) Viscous Transitional Molecular 6.25 1.70 1.17 4.74 1.38 Total Evacuation Time (no leaks): 6.12 mins N/A Connection Port Analysis Cable Feed Through • • • • • • By recommendation of Dr. Robert Pearson and a price vs. effectiveness research. The use of potting compound is preferable for our application Apiezon Sealing compound Q is an economic option to seal a leak in a vacuum system. It is sufficiently firm at room temperature to remain in position, yet soft enough to be molded by hand and is readily removed Some Properties: temperature range, °C: -10 to + 30 Vapor pressure @ 20°C, in torr: 1x10-4 Packaging: 1 kg Cable Polycarbonate Plate Shrink Tubing Sealing Compound Pipe Connection - Bottom Connection allows for vacuum hose to be Brewer’s Hardware - P/N WLFM12F12 -Weldless Bulkhead - 1/2" MPT X 1/2" FPT connected though the bottom polycarbonate cap Seals against each side via gasket Allows for pipe to be screwed on inside drop tower to pass by polystyrene beam bag Pipe Fitting Analysis Pipe End Cap Fittings Top Bottom Tower Fittings Pressure Gauge Analysis Digital Vacuum Gauge Specifications Range Atmospheric to 0 microns Max Working pressure 400 PSIG Acurracy +/- 10% Powered By 9V Battery Operating Temp. Range 32° - 120° F (Compensated) -22° - 158° F (Non-Compensated) Mechanical Connection Standard 1/4” female SAE refrigerant hose type with core depressor Labview / Matlab Code Vacuum Conditions Calculating Gravity within a vacuum Base chamber pressure will be considered as the optimal vacuum condition (Goal = 2Pa or 15 microns) 𝑔 𝛥𝑔 𝜕𝑔 ∗ 𝛥𝑥 𝜕𝑥 2𝑥 𝑡2 2 𝜕𝑔 + ∗ 𝛥𝑡 𝜕𝑡 Note: Pressure threshold between Vacuum and Non-vacuum will be determined through tested 2 Model Sensitivity - Vacuum Which measurement is the most critical? Assume Δ# is 1% of # (for each variable) 𝛥𝑔 𝜕𝑔 𝜕𝑥 ∗ 𝛥𝑥 2 + 𝜕𝑔 𝜕𝑡 ∗ 𝛥𝑡 2 Use position (x) component of 𝛥𝑔 as datum Compare other variables relative to position 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑡 𝜕𝑡 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 100% (𝐷𝑎𝑡𝑢𝑚) 200% In other words, the time measurement is 2x more critical than the position measurement. Atmospheric Condition Calculating Gravity with Drag Pressure range: Atmospheric Pressure –Vacuum Pressure Threshold 𝑚𝑎 𝑑𝑉 𝑑𝑡 𝑔 𝛥𝑔 𝜕𝑔 ∗ 𝛥𝑥 𝜕𝑥 2 𝐹𝐷 𝑚𝑔 𝜌𝐶𝐷 𝑉 2 𝐴 2𝑚 𝑔 𝑥𝜌𝐶𝐷 𝐴 2𝑚 2𝑚 ∗ 𝑖𝑛𝑣𝑐𝑜𝑠ℎ 𝑒 2 𝜌𝐶𝐷 𝐴𝑡 𝜕𝑔 + ∗ 𝛥𝑡 𝜕𝑡 2 𝜕𝑔 + ∗ 𝛥𝑚 𝜕𝑚 2 𝜕𝑔 + ∗ 𝛥𝐴 𝜕𝐴 2 2 𝜕𝑔 + ∗ 𝛥𝜌 𝜕𝜌 2 𝜕𝑔 + ∗ 𝛥𝐶𝐷 𝜕𝐶𝐷 2 Model Sensitivity - Atmospheric 𝛥𝑔 𝜕𝑔 ∗ 𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑡 𝜕𝑡 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 𝜕𝑔 ∗𝛥𝑚 𝜕𝑚 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 2 𝜕𝑔 + ∗ 𝛥𝑡 𝜕𝑡 2 𝜕𝑔 + ∗ 𝛥𝑚 𝜕𝑚 100% 𝐷𝑎𝑡𝑢𝑚 200% 0.213% 2 𝜕𝑔 + ∗ 𝛥𝐴 𝜕𝐴 2 𝜕𝑔 + ∗ 𝛥𝜌 𝜕𝜌 2 𝜕𝑔 + ∗ 𝛥𝐶𝐷 𝜕𝐶𝐷 𝜕𝑔 ∗𝛥𝐴 𝜕𝐴 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 0.213% 𝜕𝑔 ∗𝛥ρ 𝜕ρ 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 0.213% 𝜕𝑔 ∗𝛥𝐶𝐷 𝜕𝐶𝐷 𝜕𝑔 ∗𝛥𝑥 𝜕𝑥 0.213% 2 Example: 𝛥𝑔 𝜕𝑔 ∗ 𝛥𝑥 𝜕𝑥 2 𝑔 𝜕𝑔 + ∗ 𝛥𝑡 𝜕𝑡 2 2𝑚 𝜌𝐶𝐷 𝐴𝑡 2 ∗ 𝑖𝑛𝑣𝑐𝑜𝑠ℎ 𝑒 𝜕𝑔 + ∗ 𝛥𝑚 𝜕𝑚 2 𝑥𝜌𝐶𝐷 𝐴 𝜕𝑔 + ∗ 𝛥𝐴 𝜕𝐴 2 2 2𝑚 𝜕𝑔 + ∗ 𝛥𝜌 𝜕𝜌 2 𝜕𝑔 + ∗ 𝛥𝐶𝐷 𝜕𝐶𝐷 2 Gravity = g +/- Δg Given Variables: m= 0.067278 kg t= 0.782895 sec ρ= 1.2041 kg/m^3 x= 3.0 m A= 0.0005067075 m^2 Cd= 0.47 Scenario #1 Scenario #2 Scenario #3 +/- 1% for all variables +/- 10% for Cd +/- 1% for all other variables +/- 10% for t +/- 1% for all other variables g= 9.81 +/- 0.2195 m/s^2 (2.24% Error) g= 9.81 +/- 0.2195 m/s^2 (2.24% Error) g= 9.81 +/- 1.9645 m/s^2 (20.03% Error) Labview Front Panel Matlab Code Drag Coefficient, 𝐶𝐷 Cannot solve directly for 𝐶𝐷 𝑔 𝑥𝜌𝐶𝐷 𝐴 2𝑚 2𝑚 ∗ 𝑖𝑛𝑣𝑐𝑜𝑠ℎ 𝑒 𝜌𝐶𝐷 𝐴𝑡 2 2 Use root finding method to solve for 𝐶𝐷 Secant Method (or other) Must assume value for gravity (9.81 m/s^2) Import Position and Time Data from Labview Experiment will require numerical methods and physics knowledge Test Plan # Main Component Description Status 1 Catching System Dissipate Objects Energy from Falling Open 2 Release Mechanism Quick Release w/ No Horizontal Motion Open 3 Tower Frame Test Tower Stability During Operation Open 4 Laser Sensor Best Position to Track Objects Fall Open 5 DAQ Device Appropriate Signal is Programmed and Functional Open 6 Labview Program Compare Results to Analytical Predictions Open 7 Pressure Gauge Calibrate and Test Entire Pressure Range Open 8 Vacuum Pump Vacuum Tube & Fittings Stationary Platform & Objects Attach Pressure Gauge Directly to Pump Open Test Ultimate Pressure Open Observe Behavior of Objects in Vacuum Open 9 10 High Leak Rate Importance 1 Risk Item Severity ID Likelihood Risk Assessment – High Risk Items 3 2 6 • Improper sensor alignment • Sensor range inadequate • Power loss 2 3 6 Effect • • • Loss of Vacuum Noisy Increased depressurize time Cause • • • Bad Sealant Gaps in o-rings Surface impurities 2 Laser Sensor Looses • Loss of data Item (position and time) 3 Unsuccessful Release of Objects • • • Items does not fall Horizontal motion occurs Unsynchronized release • • • Mechanism doesn’t open Release timing off Loss of power 2 2 4 4 Pipe Implodes • • Safety Hazard Project ruined • • Pipe wall thickness Material 1 3 3 Tower Falls Over • • • Safety Hazard Damages to Surroundings Project Ruined • • • Poorly supported Earthquake Weak structure 1 3 3 5 MSD II Schedule Bill of Materials Tower Pricing: 6in Diameter-10ft Tall NOTES: * Sale Price. Item Pipe Union Fitting Polycarbonate Sheet Polycarbonate Sheet Size (in) 6in 6"slip x 6"slip 1/4" 1/2" THK Item Range 0 micron - atm; 1/4 SAE F CPS Vacuum Gauge Laser Distance Sensor 0.2m - 15m DAQ 8 Analog inputs Arduino Uno Arduino Motor Controller (SAINSMART) Item Length 10 ft n/a 12" x 24" 15 Microns Item Brass Connector: SAE x NPT Brass Adapter: SAE x NPT Pipe Hose Hex Nipple Adapter Ball Valve Brass Cross NPT Pipe Feed Through Fitting Dimensions 1/4" SAE M - 1/2" MPT 1/2" SAE F - 1/2" MPT 2" 1/2"ID - 5/8"OD 1/2" MPT x 1/2" MPT 1/2" FPT 1/2" FPT Polycarbonate Gages, Sensors, & DAQ Vendor Part # / Size Century Tool VG200 Micro-Epsilon ILR-1030 National Instruments Amazon Amazon Rating 2 Stage Rotary Pump ** Price and vendor could change based on pipe clarity Tower Pipes & Fittings & Gaskets Material Rating Vendor Part # Clear PVC SCH40 clearpvcpipe 1395-061 white PVC SCH40 mc master 4880K311 Voltage Pump Flow Rate 110-120V / 220V 50/60Hz 6.25 CFM Length n/a n/a 10 ft 25 ft 1.81" 2 5/16" n/a n/a mc master Price for 1 $146.45 $545.00 $149.00 $17.50 $10.88 Power Supply 8574K45 Price for 1 $410.40 $88.44 $54.22 Quantity 1 2 1 1 Subtotal: Price per Qty $410.40 $176.88 $0.00 $0.00 $587.28 Quantity Price per Qty Quantity Price per Qty 1 $146.45 1 $545.00 1 $149.00 1 $17.50 1 $10.88 Subtotal: $840.45 Vendor Part # / Size Price for 1 120V rms @ 60Hz CPS products VP6D $268.92 Pump Piping, Fittings, and Hose Rating Vendor n/a fastenal n/a fastenal SCH40 lowes 29.9"Hg Vacuum mc master 1200PSI fastenal 29.9"Hg Vacuum mc master 1200PSI fastenal Material brass brass White PVC Polyethlene brass brass brass Part # / Size Price for 1 69535 $3.69 440292-131280 $4.61 23832 $6.97 50375K51 $8.00 440049-131280 $5.33 47865K23 $9.84 440095-131280 $19.09 $25.00 1 Subtotal: $268.92 $268.92 Quantity 1 1 1 1 2 2 1 1 Subtotal: Price per Qty $3.69 $4.61 $6.97 $8.00 $10.66 $19.68 $19.09 $25.00 $97.70 Bill of Materials Item Square Metal Tubing 3/16" Sheet Plug Caps for Aesthetics Riser Clamp (Includes Bolts) Wheels Axels Bolts, washers, nuts M5 bolts M5 nuts Bolts Barrel screw Washers Nuts Thumb screw Wing nut Height Adjustors Size (in) 1-1/2 X 1-1/2 x .12thk x 12ft 30" x 30" 1-1/2 x 1-1/2 6" 4" 4" 1/2-13 x 2.5" 40 mm M5 1/4-20 x 2.5in 1/4-20 x .5in 1/4-20 1/4-20 6-32 6-32 M6 Frame Components Vendor Part # / Size Klein Klein mc master (50 pk) 9565K29 Fastenal $49,140.00 mc master 2319T11 mc master 23595T45 RIT Lowes (4 pk) 91280A240 Lowes (4 pk) $138,357.00 mc master (25 pk) 91309A552 mc master 92463A403 RIT RIT mc master 94567A270 Lowes (3 pk) $58,091.00 mc master 62805k49 Dimension 7.487"x .103" 48DP, 60Tooth 48DP, 20Tooth 3/16" x 5" 50ft #4-40 x.5" #8-32 x 1.75" n/a 3001HB Release Mechanism Vendor Material Rubberstore servocity plastic servocity plastic servocity Steel servocity RIT RIT amazon n/a pololu Price for 1 $22.14 $40.00 $9.32 $25.37 $14.31 $6.24 $0.00 $0.80 $0.68 $3.78 $2.72 $0.00 $0.00 $1.47 $1.18 $2.36 Quantity 4 1 1 3 2 2 1 1 1 1 1 1 6 Shipping Price per Qty $20.00 $108.56 $0.00 $40.00 $0.00 $9.32 $0.00 $76.11 $0.00 $28.62 $0.00 $12.48 $0.00 $0.00 $0.00 $0.80 $0.00 $0.68 $0.00 $3.78 $0.00 $2.72 $0.00 $0.00 $0.00 $0.00 $0.00 $1.47 $0.00 $1.18 $0.00 $14.16 Subtotal: Item O-ring (AS568-169) Servo Pinon Gear Shaft Servo wires Cap Head Bolt Cap Head Bolt on/off Switch (for release mech.)* Servo Part # / Size RSA48-2FS-60 SPBD48-23-20 634122 n/a Price for 1 $1.00 $5.60 $1.56 $0.79 $12.95 $0.00 $0.00 $6.73 $9.95 Quantity 2 2 2 2 2 18 8 1 2 Subtotal: $299.88 Price per Qty $2.00 $11.20 $3.12 $1.58 $25.90 $0.00 $0.00 $6.73 $19.90 $70.43 Bill of Materials Misc. Item Polystyrene Beads Computer Ladder PTFE Pipe tape Clear Cement/Glue Vacuum Sealant Final Total: Dimension 3 ft3 n/a 6ft 50ft roll 1 quart n/a Vendor Material Hayneedle Polystyrene n/a n/a RIT aluminum mc master PTFE pvcfittingsdirect Clear Cement Ideal Vacuum products thermal-plastic Part # / Size HN-CT110 n/a n/a 4591K13 n/a n/a Price for 1 $29.99 $0.00 $0.00 $3.05 $38.02 $49.75 Quantity 1 1 1 1 1 1 Subtotal: Price per Qty $29.99 $0.00 $0.00 $3.05 $38.02 $49.75 $120.81 $2,285.47 Questions?