Multidisciplinary Engineering Senior Design Project Micro Turbine III 2005 Critical Design Review May 13, 2001 Project Sponsor: Mechanical Engineering Department Team Members: Cliff CummingsAllison Studley Joe CalkinsMark Fazzio Team Mentor: Dr. Jeff Kozak Acknowledgements: Jon Ross, Dr. Fuller, John Bonzo, Borce Gorevski, Dave Hathaway Kate Gleason College of Engineering Rochester Institute of Technology

Background Current battery technology causes the battery to be up to half of the weight of the MAV. Research into lighter weight power generation methods led to micro-turbine generators. Third generation RIT Senior Design project Micro Turbine III Senior Design

Mission Statement We will design and build a microturbine generator that can be integrated onto a micro air vehicle airframe and power the vehicle’s accessories. The microturbine will be a continuation of the previous team’s project with the application of their design to be used for MAV power production Micro Turbine III Senior Design

Primary Objectives Produce a minimum constant 5 watts of power Minimum flight time of 3 minutes Overall weight of less than 45 grams Integrated onto the MAV airframe Micro Turbine III Senior Design

Research Methods Preliminary Research Review of last year’s design Additional Research Micro Turbine III Senior Design

Feasibility Assessment 2 Options – Direct Comparison >2 Options – Weighted Comparison Micro Turbine III Senior Design

Feasibility Assessment Considerations Ability to meet the objectives Overall Size Total Weight Availability of procured items Ease of Manufacture Cost of procurement/manufacture Micro Turbine III Senior Design

Efficiencies and Costs 2-D Pelton Wheel –Typically 15% efficient –Approx. $100 3-D Pelton Wheel –Approx. 80% efficient –Estimated above $1,000 Axial Impulse (Katholieke University, Belgium) –Approx. 20% (for mechanical, 10% total) –Over $1,000 Francis (large scale turbine) –80-90% Micro Turbine III Senior Design

Turbine Feasibility Micro Turbine III Senior Design

Housing Concept Cross flow design 2 Inlets – 2 Outlets Tight tolerances to prevent flow from going around the turbine. 30% Fiberglass reinforced Nylon material Overall Size: 1.25” OD 0.6” Depth Micro Turbine III Senior Design

Housing Design Cross flow design at 45 o 2 Inlets – 2 Outlets 0.005” – 0.010” tolerances on all critical diameters. 30% Fiberglass reinforced Nylon material Overall Size: 1.25” OD 0.75” Depth Micro Turbine III Senior Design

Housing Feasibility Smaller OD ( 1.25” vs ” ) Lighter weight ( 15g vs. 30g ) O-Ring seal vs. Gasket seal Inlet/Outlet redesign Designed for manufacturability Micro Turbine III Senior Design

Housing Analysis Micro Turbine III Senior Design Load: 300 psi Maximum Stress: psi Safety Factor: 10.49

Housing Analysis Micro Turbine III Senior Design Load: 300 psi Maximum Stress: psi Safety Factor: 4.88

Propellant System Feasibility Fuel Compressed CO 2 Cartridges Compressed N 2 Cartridges Compressed Air Tanks Tubing Flexible Nylon lines Rigid metal lines Regulator Bellows regulator to decrease the inlet pressure Micro nozzle to maintain a choked flow Pressure Regulator Piercing device Micro Turbine III Senior Design

Other Design Concepts/Considerations Bearings: Sealed Air Shielded Magnetic Seals: Neoprene O-Ring at 40% compression Paper / Cork Gasket Micro Turbine III Senior Design

Safety Precautions “Safety Box” for protection during preliminary testing Mount for fuel canister during prototype testing –(picture) Micro Turbine III Senior Design

Prototype Financial Analysis Micro Turbine III Senior Design PartPriceperQtyLine Price Turbine$ Housing Material$5.78foot0.08$0.48 Shaft$ O - Ring$ $0.17 Bearings$5.0012$10.00 Tape$ $0.24 Housing Connections$ Flow Split$ $36.88 Tubing$ Nozzlefree11$0.00 Fuel$ Puncture Device$ Fuel Connections (Puncture device to Regulator)$ Regulator$ Overall Cost$427.32

Overall Financial Analysis Micro Turbine III Senior Design

Schedule Micro Turbine III Senior Design

Testing Three main phases of testing: –Phase 1 (shop air) Preliminary static testing –No computer or nozzles Preliminary dynamic testing –No nozzles –LabView and DAQ system –Phase 2 (shop air) Dynamic testing with nozzles –Phase 3 (fuel canisters) Calibrate regulator Repeat tests on best nozzles Micro Turbine III Senior Design

Test Setup (Phase 1 & 2) Test initially using laboratory supplied compressed air to prove feasibility of design (without nozzles) Determine which nozzle produces optimal power Provide data for mass flow calculations Incoming Air Plenum Turbine System Flow Meter Pressure Meter Thermocouple Oscilloscope Micro Turbine III Senior Design

Test Setup ( Phase 3 ) Turbine System Fuel Canister Thermocouple Regulator Oscilloscope Replace shop air with compressed Nitrogen fuel canisters Duplicate test results from preliminary testing Prove feasibility of prototype Micro Turbine III Senior Design

Final Design Micro Turbine III Senior Design

Final Design Micro Turbine III Senior Design

Final Design Micro Turbine III Senior Design

Design Limitations Propellant cartridge & piercing device are 250g and 192g respectively Pressure regulator is an inefficient way of reducing the pressure from the canisters to the housing Miniature sealed bearings were unavailable at the required size Shrink tube coupling loses adhesion after extended use at 25,000+ rpm Micro Turbine III Senior Design

Major Design Issues Lead times –Machining of housing and cap –Delivery of turbine and regulator Production in a small quantity Weight of fuel system components –Canister, piercing device, regulator all greater than 190g each Compared to last year, fewer team members and more aggressive goals Micro Turbine III Senior Design

Analysis of Design Outlet channels angled 45 o to accommodate inlet/outlet fittings Housing components tested using FEA and found to have a minimum SF of 4.88 using Nylon 6/6 Cap contains the highest stress of the components at 4130 psi under a 300 psi load. Mass flow calculations were used to determine a nominal nozzle diameter of 100  m Micro Turbine III Senior Design

Testing Results Phase 1 –Static (maximum) 4.42 watts at about 100 psi and 25,000 rpm –Dynamic (maximum) 9.08 watts at 120 psi and 26,300 rpm (5  resistance) 7.26 watts at 130 psi and 43,000 rpm (8  resistance) Phase 2 –100 micron nozzles Pending Phase 3 Pending Micro Turbine III Senior Design

Desired Outcomes Produce 5 watts of power Weigh less than 45 g 3 minute run time (on N 2 canisters) Integrate onto MAV airframe Actual Outcomes Produced a maximum of 9.08 watts of power System weight 48.9 g Run time pending final test Sized to fit onto MAV (without canisters and regulator) Micro Turbine III Senior Design

Actual Results Weight –48.9g Max Power –9.08 watts Run Time –Pending final test Cost (for prototype) –$ Alternative Fuel Sources Batteries –Cost ($ ) –Power (10 – 20 watts) –Run time (10 – 30 min) –Weight (30 – 90 g) MIT Gas Turbine –Cost ($15 mil budget) –30+ Faculty –Power (10-50 watts) –Run time (approx. 3 second) –Weight 85g Stanford Turbine (still in development) –Cost (?) –Power (designed for 100 watts at 800,000 rpm, reached 420,000) –Runtime (designed for 100 hours, reached ?) –Weight (50 g) Micro Turbine III Senior Design

Conclusions Micro Turbine III Senior Design

Future Recommendations Micro Turbine III Senior Design

Questions? Micro Turbine III Senior Design

Backup Slides and References Micro Turbine III Senior Design

Data Acquisition GUI Micro Turbine III Senior Design

Data Acquisition Set-up Micro Turbine III Senior Design

FEA Analysis Micro Turbine III Senior Design

FEA Analysis Micro Turbine III Senior Design

FEA Analysis Micro Turbine III Senior Design

Flow Calculations Micro Turbine III Senior Design Nozzle Exit Velocity: Flow Density: Mass Flow:

Test Results (Phase 1) Micro Turbine III Senior Design

Housing Post-Machining Main Housing –Had to machine inlet and outlet holes separately –Deburr housing after CNC machining –Bearing holes were too small due to limited tooling –Turbine seat was not concentric due to CNC tooling path Micro Turbine III Senior Design

Preliminary Budget Final Budget Micro Turbine III Senior Design

Previous Design Back Micro Turbine III Senior Design

Previous Turbine Design Senior Design Team Micro Turbine III Senior Design