1. Multidisciplinary Engineering Senior Design Project 06445 Alternator Test Stand Preliminary Design Review 02/24/06

2. Sponsor/Mentors/Members Project Sponsor Center for Integrated Manufacturing Systems Team Members Aaron Wright - Project Manager Dan Guerand - Mechanical Engineer Kevin Lloyd – Mechanical Engineer Tim Marvin - Mechanical/Electrical Engineer Dave Schuele - Mechanical Engineer Team Mentors Mike Thurston Omar Anbari Cyril Gaillard Abhijit Mukherjee

3. Alternator Test Stand Background CIMS development of Reliability Centered Maintenance RCM focuses on predicting failure CIMS would like to predict the failure of military and domestic alternators Prediction of failure in alternators allows preventative maintenance to save time, money, life, and equipment. Project Overview

4. Test Stand Requirements Apply a load capable of failing an alternator Failure must occur in an accelerated time frame Acquire valuable data for life of alternator Flexible system design Test stand must be safe to operate Self-sustaining for life of alternator

5. Breakdown of Team Process 1.Project sponsor meetings determined needs 2.Assessed member interests 3.Task list compiled 4.Members assigned to tasks based on interests 5.Concepts for each component categorized by task 6.Gantt chart compiled to provide time requirements for tasks 7.Component feasibility determined by budget and physical constraints

6. Needs Assessment 100% load must be applied to 14 or 28 volt alternator continuously for life of alternator Load must be capable of battery configurations of 12 or 24 volts Data collection must be available for life of alternator System components must provide maximum safety ATS must be easily set up by one person ATS must be self-governing for duration of testing

7. Project Tasks Systems Integration - Aaron Frame/Safety – Kevin Drive motor – predetermined by CIMS Battery Bank – predetermined by CIMS Alternator & Mounting – Dave Load Bank / Cooling – Dan Data Acquisition – Tim

8. Alternator and Battery Load System The alternator is loaded using 6 banks of low resistance, high power, helical wound resistors. All resistors are placed in parallel so as to decrease the total amount of resistance with each bank step. Each bank steps up the amount of current drawn from the alternator or battery. Resistors will dissipate at most 85% of their rated load.

9. Load Stepping BANK RESISTANCE RATED POWER MAX POWER USE 14V % LOAD CURRENT STEP 1 2.8 560 78 14 5 2 2.8 560 78 14 10 3 0.45 2280 485 21 41 4 0.45 2280 485 21 72 5 0.375 3750 580 16 110 6 0.6 1710 360 21 133 BANK RESISTANCE RATED POWER MAX POWER USE 28V % LOAD CURRENT STEP 1 2.8 560 280 56 10 2 2.8 560 280 56 20 3 0.45 2280 1740 85 82 4 0.45 2280 1740 85 145 5 0.375 3750 2090 62 220 6 0.6 1710 1305 85 265 * Resistors have a +/- 10% tolerance on resistance values

10. Thermal System The thermal system uses forced convection to dissipate the heat produced by the resistors. Advantages  Allows for heat transfer rates that are much higher than those for natural convection.  Maintains the ambient temperature of the air surrounding the resistor bank to levels that the resistors can operate within. Disadvantages  Use of fans requires more power to operate the test stand.  Mounting and space constraints within the frame.

11. Varying the Parameters Staggered array Air velocity Number of rows of resistors Transverse pitch

12. Heat Rate versus Velocity

13. Varying the Number of Resistor Rows

14. Varying the Transverse Pitch

15. Amount of Power Dissipation Maximum power that must be dissipated from resistors is 7.5 kilowatts. Theoretical maximum power that can be dissipated through the bank of tubes is 150 kilowatts per meter.

16. Thermal System Final Design

17. Safety Prevention of Burns ASTM E1509 used as a guideline  Load Bank & Ambient Exhaust Prevention of Pinch & Crush Points 4 Fans (Sever Points)  Steel Fan Guards 2 Belts (Crush Points & Belt Break Concern)  Belt Guards – 16 gauge Steel Internal Frame Concerns Automatic Soft-Stop (Software Shuts Down)  Overheat (Load, Batteries, Electronic Components)  Doors, Access Panels, Safety Guards In-Place Manual Hard Stop (Complete Power Disconnect)  Emergency Stop On Side Visual Monitoring of Frame Internals  Transparent Front and Top

18. Safety Battery Ventilation & Spill  Minimal Hydrogen Out Gassing  Vent Through Wire Access Slots – Frame Fans  Spill Protection – Sulfuric Acid  Polypropylene Lining Identification of Hazards

19. Aesthetics Professional Appearance Specified Placement for Subassemblies Electronic Components Board Bundle & Harness Wires Conceal Rough Edges Visually Appealing to CIMS Vendors & Customers Display Components  Transparent Front & Top

20. Frame Design Key Aspects Given Angle-Iron Frame, Motor, and Motor Controller Place Sub-Assemblies To:  Maximize Performance  Maximize Efficiency  Meet Safety Specifications  Meet Aesthetics Requirements Subassemblies Battery Unit  Stock Cabinet  Transparent Doors  Sulfuric Acid Resistant  Easy Access

21. Frame Design Subassemblies Electronic Components Board  Electronic Insulator - Polypropylene  Accessible  Position Adjustable Rear Door Track System  Accessibility  Low Cost  Removable Front Panels  Transparent  Easy & Quick Access  Low Cost

22. Frame Design Other Frame Components Top  Transparent  Sealed Sides  Moderately Rigid Placement Limited Option:  Battery Unit – Front Left  Load Bank – Horizontal Other Components  Based on Requirements (Previously Mentioned)

23. Frame Design

24. Alternator Drive System Requirements Ability to turn alternator at maximum RPM  Intermediate Shaft Allow for proper belt tensioning Accept wide range of alternators  Physical Mounting  Drive Type  Electrical Interface

25. Alternator Drive System Intermediate Pulley Assembly From Front of Case From Rear of Case

26. Alternator Drive System Alternator Mounting

27. System ComponentCost Alternator Fixture$938.15 Data Acquisition$1024.77 Frame & Safety$1074.84 Intermediate Pulley$443.62 Load & Load Cooling$3494.67 Grand Total$6976.05 Financial Investment

28. Questions

29. Backup Slides and References