1. CDR October 9, 2008 Mike Oertli Jonathan Karnuth Jason Rancier

2. Division of Labor Mike O. Program MCU Matlab interface Jonathan K. Construct rails Assist in control system design and coding Jason R. Construct capacitor array Design voltage sensors

3. Block Diagram MSP430F169 Power Supply Keypad LCD Railgun Capacitor Array Kill Switch LEDs Inductor Voltage Sensor Pneumatic Starter System Encoder

5. Budget ItemQty. NeededCost PerTotal for item Brass Rails (36")258.68117.36 Garolite G-10 (39")192.16 Teflon (12")69.2155.26 Aluminum (12")217.4134.82 Capacitors50Donated0.00 PCB233.0066.00 Microcontroller20.00 Air compressor156.10 Air tank162.00 Solenoid Valve1170.00 Pressure Regulator135.00 Transformer1100.00 Plastic housing150.00 Sensors/Miscellaneous200.00 Grand Total1,038.70

6. Safety Features Voltage sensors on rails, cap bank, & source Kill power if out of expected range Plexiglas casing o Keep user isolated from high voltages and short circuited rails Pressure Regulator o Added ability to safely release tank pressure

7. Power System Diagram

8. Capacitor Battery 50x 450V 3.7mF Capacitor Donated by CDE Array of 3 banks of 16 in parallel Overall: 1350V ~ 20mF

9. Capacitor Battery

10. Basic Charger

11. Power Parts 2x 200KOmh @ 3W 1x 800Omh @.25 W 50x 100kOmh @ 3 W 3x 22KOmh @ 50 W 1x 120V 15 Amp AC switch 1x Fuse Holder 120VAC 1x 1600v Power Diode 2x High Voltage Switch(1000V) 1x Microwave Transformer 1x Variac Variable Transformer Copper Plate Plexiglass Box

12. Cylindrical Rail Design Design Difficulties Material Tolerances Material Loss Toxic materials Difficult to machine at desired barrel length Efficient Design method Maintain physical contact despite material disintegration

13. Machined & Fabricated Parts

15. Compressed Air Injector Adapter

16. Injector Adapter Drawing

17. Brass Rails Composite: ~70% Copper, ~.07% Lead, ~.05% Iron, Remainder Zinc Electrical Conductivity: 28% IACS Electrical Resistance: 6.2µΩ/cm Friction: Very low with Most metals Melting Point: 910 o C Inner/Outer Diameter: 0.87”/1”

18. Projectile Metal: Aluminum Composite: 2011 Temper: T3 Part #: 88615K411 Melting point: 540 o C Electrical Conductivity: 45% IACS Electrical Resistivity: 3.8µΩ/cm Diameter: 7/8” Length: ~1”

19. Pneumatic Kick-start Avoids spot welding projectile Added kinetic energy Eliminates static friction coefficients Compressed Air system Activated by Microcontroller post safety checks Additional safety with inclusion of Pressure Regulator

20. Injection System

21. Complete System Compressed Air Tank Compressor Solenoid Valve Ball Valve Pressure Regulator Manufactured Parts Railgun Adapter Tank Adapter Compressor Adapter

22. Electromagnetic Solenoid Valve

23. Pressure Regulator Features High Pressure capabilities Very Low Flow 1/150 Flow of the Solenoid (.06 Cv) Adjustable Pressure Range Low leakage Value 3600 Psi Capabilities

24. Chassis Specs Inner SupportOuter Sheath CompositeTeflon PTFEGrade G-10/FR4 Crosswise Tensile Strength 3,900 PSI35,000 PSI Melting Point 335 o C ~384 o C Max Temp Dielectric Strength19.7MV/m15.7MV/m Inner/Outer Diameter.875”/1”1”/1.375” Cost$9.21 per 12”$92.16 for 39” Part #8547K298668K49

25. Parts List- Control System Voltage Sensor MM74C922 16 key encoder Keypad, 3-line LCD Master kill switch “Hot” switch

26. Parts List- MCU MSP430F169 2 ADC 1 RS232 Voltage regulator LEDs

27. Interfaces MSP430F169Matlab RS232 Key EncoderKeypadMSP430F169 Wire-wrap/Solder MSP430F169 P6 I/O (ADC) Voltage Sensor 3-Line LCDMSP430F169 Wire-wrap/Solder

28. Keypad Pin Layout 1234567 141312111098

29. Key Encoder MM74C922 16 Key Debounce Continuous row scan

30. Keypad & Encoder Schematic

31. Keypad Demo

32. Software- MCU Language: C++ Inputs: Keypad (via encoder chip on P1), voltage sensors (1 on ADC on P6, 2 nd via off board ADC), power (6V) Outputs: 3-line LCD (P2), Matlab (RS232), capacitor charging control (switch based on sensors), safety/kill switch

33. MCU Logic

34. Software- Matlab Plot time domain analysis of sensor readings Keep test-run information Inputs: Data from MSP Outputs: GUI showing data Interface: RS232

35. Questions?