1. Senior Design I Project – P08454 Anthony Squaire – Team Leader - Industrial and Systems Engineering Alan Mattice – Lead Engineer - Mechanical Engineer Cody Ture - Mechanical Engineer Brian Bullen – Mechanical Engineer Charles Trumble – Mechanical Engineer Aron Khan – Electrical Engineer Jeff Cowan – Electrical Engineer Andre Mc Rucker – Computer Engineer

2. BLWRPG17 Brushless DC Motor Planetary Gear Ratio: 4.9 to 1 Torque: 24.07 oz-in @4200 rpm (Un-geared) 117.943 oz-in @857 rpm (Geared) Power: 25W Weight: 1.37 lbs Dimensions: 2.36 in (Motor), 1.39 in (Gearbox), 1.654 in (Diameter) Figure 1: Motor Picture from Anaheim Automation Figure 2: Motor dimensions from Anaheim Automation

3. Choosing a Motor The only two feasible motors of this list are the first two: IG42GM and BLWRPG170S. Both of those motors run at 24V, while the second BLWRPG motor runs at 36V and the Tecnadyne motor runs at 150V. From the assertion that the motor needs adequate power with a decent amount of revolutions to spin the impeller, motor two is really the only choice as its meets the torque of the current motor used by the land vehicles but has roughly 2.5 times the revolutions per minute. (Current)(Proposed) (Tecnadyne) Motor Type:IG42GMBLWRPG170S-24V-4200BLWRPG111S-24V-10000RBE(H)-00712 Torque (oz-in)7.915824.075.66463.3 Speed (rpm)590042001000012000 Gear Ratio174.9146 Power (W)34.72541.88124 Voltage (V)24 36150 Run Current (A)1.4458333331.0416666671.1633333330.826666667 Geared Torque (oz-in)112.4878315117.94379.296379.8 Geared Speed (rpm)325857.1428571714.28571432000 Efficiency1053.5603814043.761352.435536125.806452

4. Magnetic Coupling Mag-Link Max Torque: 144.44 oz-in Effective Gap: 0.187 in Bore: 0.318 in (Min), 0.748 in (Max) Length/ Diameter: 1.73 in/ 2.4 in Mass: 0.661x10 -3 lbs Rimtec MSV1 Max Torque: 141.6 oz-in Effective Gap: 0.098 in Bore (Max): 0.6299 in (Outer), 0.315 in (Inner) Length/ Diameter: 1.77 in/ 1.33 in Figure 3: Proposed magnetic coupling picture and section view Figure 4: Proposed magnetic coupling section view

5. Impeller Muffin Fan Impeller Comes in an assembly in which most parts are not needed Curved ends allow for best curve fit along shroud inner diameter to reduce tip vortices Hard plastic resistant to corrosion and deformation Fan Impeller Very cheap and easy to make: cut and bent out of a sheet of stainless steel The thin stainless steel is more likely to corrode or deform over the life of the thruster Flat edges allow large tip vortices Figure 5: Solidworks model drawn by Cody of a proposed impeller Figure 6: Solidworks model drawn by Cody of a proposed impeller

6. CFD of Impeller (Muffin Fan) Figure 7: Velocity of the flow field over the impeller to identify tip vortices

7. CFD of Impeller (Muffin Fan) cont… Figure 8: Velocity of the flow perpendicular to the axis of rotation

8. Early Analysis from CFD The muffin fan pushes a very high volume and will most definitely overload any motor for our application Tip vortices are reduced because the curve on the tips of the blades matches the curve of the ideal shroud From Here: Run CFD for stainless steel impeller with modified blade tips to make a circle around the center hub to reduce tip vortices. Also, run CFD on the shown 3- blade “boat” style impeller Change the two “fan” impeller designs so that both only have two, three, and four blades and run a CFD of those designs to see how much performance is reduced when the work of the motor is reduced to find an optimal design Figure 9: Solidworks model found of proposed impeller design

9. Housing/ Full View Magnetic Coupling Motor/ Gearbox Space for Microcontroller Impeller Bearings and housing extension to hold coupling Housing Shell Electrical Access (Drawing does not include: impeller shroud, nose cone of impeller, or electrical wiring) Figure 10: Solidworks model of thruster Figure 11: Section view in Solidworks of the thruster design thruster

10. Thermal and Magnetic Concerns Thermal The motor, microcontroller, and H-bridge will generate heat that needs to be dissipated out into the surroundings. May need to use a dissipative fluid (oil) or large heat sink to help remove this heat as the most sensitive component ( microcontroller) needs a temperature less than 194 o F (90 o C) Downside to oil: need to seal off compartment for microcontroller Downside to heat sink: takes up space in housing Magnetic Shielding May need to block strong magnetic field generated by the motor to protect the microcontrollers circuitry Need a partition or separate compartment for the microcontroller Needs: Using the heat generated from the motor and the microcontroller, a heat transfer analysis needs to be completed to see if a convective fluid is needed to better dissipate the heat so that the motor and microcontroller will operate within acceptable temperature parameters Determine if the magnetic field of the motor is strong enough to affect the circuitry of the microcontroller If it is, design a barrier or contained space in which the microcontroller can function without being affected by the magnetic field

11. 3-Phase Brushless DC Motor Driver Figure 12: ST Microelectronics L6235 motor driver

12. Integrated Hall Effect sensor for the accurate feedback of ω r and direction of rotation Rated Current: 5.6 A Rated Voltage: 52 V Over Current Detection Circuitry sense the current in each high side. Built in braking option - Motor braking is achieved through the shoring the windings. Tachometer for easy implementation of speed control loop Figure 13: The Hall Effect Principle

13. FPGA vs. Microcontroller

14. Microcontroller Pugh Matrix

15. Microcontroller Comparison SpecificationsdsPIC30f2010ATMega168 Number of Instructions83131 CompilerCC Maximum Processor Speed30 MIPS20 MIPS I/O Pins2023 Flash Memory12K16K PWM Channels66 Operational Voltage2.5-5.5V2.7-5.5V Built-In EncoderquadratureAVR443 (Hall) Serial I/OUART, I2C, CAN, SPII2C, SPI, USART

16. Figure Sources Figure 1: Anaheim Automation: http://anaheimautomation.com/blwrpg17_brushless_dc_planetary_gearmotors.aspx http://anaheimautomation.com/blwrpg17_brushless_dc_planetary_gearmotors.aspx Figure 2: Anaheim Automation: http://anaheimautomation.com/blwrpg17_brushless_dc_planetary_gearmotors.aspx http://anaheimautomation.com/blwrpg17_brushless_dc_planetary_gearmotors.aspx Figure 3: Huco Dynatork: http://www.huco.com/products.asp?p=true&cat=506http://www.huco.com/products.asp?p=true&cat=506 Figure 4: Rimtec Corporation: http://www.rimteccorporation.com/products/magnetic/pdf/msv.pdfhttp://www.rimteccorporation.com/products/magnetic/pdf/msv.pdf Figure 9: 3D Content Central: http://www.3dcontentcentral.com/3DContentCentral/Download- Model.aspx?catalogid=171&id=517http://www.3dcontentcentral.com/3DContentCentral/Download- Model.aspx?catalogid=171&id=517 Figure 12: ST Microelectronics: http://www.st.com/stonline/products/literature/an/9214.pdfhttp://www.st.com/stonline/products/literature/an/9214.pdf Figure 13: Wikipedia: http://en.wikipedia.org/wiki/Hall_effecthttp://en.wikipedia.org/wiki/Hall_effect Information Sources Anaheim Automation: http://www.anaheimautomation.comhttp://www.anaheimautomation.com Shayang Ye: http://www.allproducts.com/ee/shayye/http://www.allproducts.com/ee/shayye/ Danaher Motion: http://kmtg.kollmorgen.com/products/motors/http://kmtg.kollmorgen.com/products/motors/ Huco Dynatork: http://www.huco.comhttp://www.huco.com Rimtec Corporation: http://www.rimteccorporation.comhttp://www.rimteccorporation.com ST Microelectronics: http://www.st.comhttp://www.st.com Microchip: http://www.microchip.comhttp://www.microchip.com Atmel Corporation: http://www.atmel.comhttp://www.atmel.com