04013 Micro Turbine Senior Design Micro Turbine Senior Design PDR – May 20 th, 2004 Project 04013

04013 Micro Turbine Senior Design Meet The Team Donald Slate (ISE) Lucas Lessa (ISE) Ream Kidane (EE) Simien Lin (ME) – Project Manager Chuck Daze (ME) – Lead Engineer Matthew Davis (ME) Meg LaRochelle (ME) Thomas Cague (ME) Dr. Kozak – Faculty Advisor Dr. Hensel – Faculty Coordinator

04013 Micro Turbine Senior Design Presentation Layout Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary

04013 Micro Turbine Senior Design OVERVIEW

04013 Micro Turbine Senior Design Purpose Micro Air Vehicle  Surveillance purpose  Approx. 90 grams. Use of batteries for electrical power. Search for lighter power source. Courtesy of Dan Holt

04013 Micro Turbine Senior Design Background Micro Turbine Project Overall Scope  Replace Batteries  Mount onto MAV Last year’s design – Proof of concept was successful  18 watts of power  100 grams

04013 Micro Turbine Senior Design Design Objectives Refine Micro Turbine More feasible for MAV applications  18 watts down to 5  100 grams down to 40 Courtesy of

04013 Micro Turbine Senior Design Turbine Design

04013 Micro Turbine Senior Design Concept Development Pelton ImpulseAxial Impulse Radial Out-Flow Radial In-Flow

04013 Micro Turbine Senior Design Turbine Feasibility

04013 Micro Turbine Senior Design Final Turbine Design 8 Blades Overall Dia. – 5/16” Pitch Dia. – 0.27” Blade Height – 0.05”

04013 Micro Turbine Senior Design Turbine Design Validation

04013 Micro Turbine Senior Design Housing Design

04013 Micro Turbine Senior Design Housing Design Concepts Concept 2 Concept 3Concept 1 Concept 4

04013 Micro Turbine Senior Design Housing – Pugh’s Weighted

04013 Micro Turbine Senior Design Final Housing Design 1.75”

04013 Micro Turbine Senior Design Housing Design Details Attributes  Lightweight  Equally Split Flow Channel  Minimized Flow Restriction  Two inlets, Two Exits  Improved Alignment

04013 Micro Turbine Senior Design Lightweight Material Objective: To create housing from the lightest material that will meet specifications. Solution: MDS-Filled Cast Nylon  Properties Tensile Strength 11,000 psi Good Manufacturability (ductility) Enhanced Pressure/Velocity Capabilities  Resulting Weight Total System weight < 44 grams

04013 Micro Turbine Senior Design Flow Channels Objective: To direct airflow to turbine with minimum pressure loss. Solution: Curved channel, cylindrical shell  Properties Reduced sharp turns/losses Equivalent flow channels/velocities  Calculated Head Loss Total Head Loss = 9.1%

04013 Micro Turbine Senior Design Components

04013 Micro Turbine Senior Design Housing Assembly

04013 Micro Turbine Senior Design Housing Components Screw Selection  Resulting force calculated  Screw selected provides a F.O.S over 4 Seals  Stepped design provides for gasket compression. Alignment  Cap/Shell design provides accurate alignment

04013 Micro Turbine Senior Design Shaft to Shaft Coupling Previous Coupling  Duct Tape Belgian Group Coupling  Shrink Tubing  ~1% Power Loss Original Concept  Single Piece Coupling  Purchased Coupling

04013 Micro Turbine Senior Design Coupling Companies Manufactured Micro Couplings  NBK  Reliance  Bellows

04013 Micro Turbine Senior Design Coupling Selected Final Concept  Rigid Shrink Tubing  Inexpensive  Lightweight  Simple Assembly, Disassembly

04013 Micro Turbine Senior Design Turbine Shaft Original Concept  Stainless Steel Micro Shaft  in diameter,.8064” in length

04013 Micro Turbine Senior Design Bearings Previous Design Problems Possible Solutions  Air Bearings  Magnetic Bearings  Sealed Bearings Selected Bearings Courtesy of NMB Minebea Co.

04013 Micro Turbine Senior Design Housing Finite Element Analysis

04013 Micro Turbine Senior Design Finite Element Analysis Modeled with Worst Case Scenario Loads Used a Minimum of Stability Points Results  Sufficient Margin of Safety

04013 Micro Turbine Senior Design Housing – Top view 2.46E E E E E E E+2E E E E E+2

04013 Micro Turbine Senior Design Housing – Side/Inlet view Max Stress: 286 psi 2.46E E E E E E E E E E+1

04013 Micro Turbine Senior Design Deflection 2.46E E E E E E E+2E E E E E+2 Max Deflection: 1.66E-4”

04013 Micro Turbine Senior Design System Design

04013 Micro Turbine Senior Design Motor Motor Selection  Considerations  Specs Min/Max RPM Output Power  Direct drive  Three-Phase Brushless PM DC Motor/Generator

04013 Micro Turbine Senior Design Motor Simulation - Simulink Matlab  Parameters  Easily modified

04013 Micro Turbine Senior Design Measurements/Testing Initial design  Closed loop feedback control  Feasibility Final Design  Open loop  Measurements Labview  Data Acquisition

04013 Micro Turbine Senior Design Data Acquisition Inputs  Temperature  Pressure  Flow  Current  Voltage Output  Efficiency  Power

04013 Micro Turbine Senior Design Testing Setup Servo Valve Generator

04013 Micro Turbine Senior Design Closing Remarks

04013 Micro Turbine Senior Design Proposed Schedule

04013 Micro Turbine Senior Design Budget

04013 Micro Turbine Senior Design Summary Overview Turbine Design Housing Design & Components Housing Finite Element Analysis System Design Summary

04013 Micro Turbine Senior Design Thank You All QUESTIONS?

04013 Micro Turbine Senior Design Cap – Side View

04013 Micro Turbine Senior Design Housing Cap 1.13E E E E E E E E E E E-1 Max Deflection = 3.89E-6