1. Multidisciplinary Engineering Senior Design Project 05002 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

2. 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 05002 Micro Turbine III Senior Design

3. 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. 05002 Micro Turbine III Senior Design

4. 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 05002 Micro Turbine III Senior Design

5. Research Methods Preliminary Research Review of last year’s design Additional Research 05002 Micro Turbine III Senior Design

6. Feasibility Assessment 2 Options – Direct Comparison >2 Options – Weighted Comparison 05002 Micro Turbine III Senior Design

7. Feasibility Assessment Considerations Ability to meet the objectives Overall Size Total Weight Availability of procured items Ease of Manufacture Cost of procurement/manufacture 05002 Micro Turbine III Senior Design

8. 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% 05002 Micro Turbine III Senior Design

9. Turbine Feasibility 05002 Micro Turbine III Senior Design

10. 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 05002 Micro Turbine III Senior Design

11. 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 05002 Micro Turbine III Senior Design

12. Housing Feasibility Smaller OD ( 1.25” vs. 1.875” ) Lighter weight ( 15g vs. 30g ) O-Ring seal vs. Gasket seal Inlet/Outlet redesign Designed for manufacturability 05002 Micro Turbine III Senior Design

13. Housing Analysis 05002 Micro Turbine III Senior Design Load: 300 psi Maximum Stress: 1921.75 psi Safety Factor: 10.49

14. Housing Analysis 05002 Micro Turbine III Senior Design Load: 300 psi Maximum Stress: 4130.67 psi Safety Factor: 4.88

15. 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 05002 Micro Turbine III Senior Design

16. Other Design Concepts/Considerations Bearings: Sealed Air Shielded Magnetic Seals: Neoprene O-Ring at 40% compression Paper / Cork Gasket 05002 Micro Turbine III Senior Design

17. Safety Precautions “Safety Box” for protection during preliminary testing Mount for fuel canister during prototype testing –(picture) 05002 Micro Turbine III Senior Design

18. Prototype Financial Analysis 05002 Micro Turbine III Senior Design PartPriceperQtyLine Price Turbine$96.0011 Housing Material$5.78foot0.08$0.48 Shaft$4.6411 O - Ring$8.25501$0.17 Bearings$5.0012$10.00 Tape$0.9710.25$0.24 Housing Connections$24.1511 Flow Split$18.4412$36.88 Tubing$0.7111 Nozzlefree11$0.00 Fuel$18.1511 Puncture Device$22.1511 Fuel Connections (Puncture device to Regulator)$6.2011 Regulator$207.5511 Overall Cost$427.32

19. Overall Financial Analysis 05002 Micro Turbine III Senior Design

20. Schedule 05002 Micro Turbine III Senior Design

21. 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 05002 Micro Turbine III Senior Design

22. 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 05002 Micro Turbine III Senior Design

23. 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 05002 Micro Turbine III Senior Design

24. Final Design 05002 Micro Turbine III Senior Design

25. Final Design 05002 Micro Turbine III Senior Design

26. Final Design 05002 Micro Turbine III Senior Design

27. 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 05002 Micro Turbine III Senior Design

28. 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 05002 Micro Turbine III Senior Design

29. 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 05002 Micro Turbine III Senior Design

30. 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 05002 Micro Turbine III Senior Design

31. 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) 05002 Micro Turbine III Senior Design

32. Actual Results Weight –48.9g Max Power –9.08 watts Run Time –Pending final test Cost (for prototype) –$ Alternative Fuel Sources Batteries –Cost ($30 - 50) –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) 05002 Micro Turbine III Senior Design

33. Conclusions 05002 Micro Turbine III Senior Design

34. Future Recommendations 05002 Micro Turbine III Senior Design

35. Questions? 05002 Micro Turbine III Senior Design

36. Backup Slides and References 05002 Micro Turbine III Senior Design

37. Data Acquisition GUI 05002 Micro Turbine III Senior Design

38. Data Acquisition Set-up 05002 Micro Turbine III Senior Design

39. FEA Analysis 05002 Micro Turbine III Senior Design

40. FEA Analysis 05002 Micro Turbine III Senior Design

41. FEA Analysis 05002 Micro Turbine III Senior Design

42. Flow Calculations 05002 Micro Turbine III Senior Design Nozzle Exit Velocity: Flow Density: Mass Flow:

43. Test Results (Phase 1) 05002 Micro Turbine III Senior Design

44. 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 05002 Micro Turbine III Senior Design

45. Preliminary Budget Final Budget 05002 Micro Turbine III Senior Design

46. Previous Design Back 05002 Micro Turbine III Senior Design

47. Previous Turbine Design Senior Design Team 04013 05002 Micro Turbine III Senior Design