Actuated Electromagnetic System for Ice Removal

Transcription

1 University of Colorado at Boulder Actuated Electromagnetic System for Ice Removal Customers Ellis Langford, Ed Wen Advisor Joe Tanner 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 1

2 Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 2

3 Problem Statement & Objectives Design, build, and test a small-scale prototype of a deicing system for the Orion UAV. Functional Requirements Orion UAV FR.1 - The full-scale system shall be integrable with the Orion UAV. FR.2 - The prototype shall remove ice. FR.3 - The full-scale system shall use less than 4kW-hr to deice the wing section. 2/4/16 Schedule Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 3

4 Design Overview Electromagnetic Deicing Mechanism Ice Target Disk Magnetic Field 6kΩ Resistor Deicing Mechanism = Baseline design used for all levels of success Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 4

5 Level 1 Success Design & Conops Purpose of Level 1: Proof of Concept of circuit and electromagnetic theory Solenoid Force Model verification Switch Position for Capacitor Discharge Charging Circuit Target Disk 15.8 in Solenoid (behind target disk) OFFON Trigger to fire mechanism 2.7 V Power Supply Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 5

6 Level 2 Success Design & Conops Purpose of Level 2: Testing for ice breaking capabilities on a carbon fiber test article Top View 16 in Carbon fiber plate Supports Electric Leaf Blower (2) 20 in 24 in Ice Testing Occurs in Freezer ( 11 o F) 38 in Solenoid in housing Test cage with viewing window Screws Safety covers over circuitry Ice casting Broken Ice apparatus Ice Switch Position for Capacitor 12Charging 1 Circuit Freezing Time OFF~5 ONhrs Switch Position for Capacitor Discharge Circuit OFF Trigger to fire mechanism Carbon fiber plate Trigger to fire mechanism Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 6

7 Level 3 Success Design & Conops Purpose of Level 3: Integration into wing structure like Orion UAV Testing in flight like wing section and conditions Ice Testing Occurs in Freezer ( 11 o F) DAE11 Wing DAE11 Wing Section Section SolenoidIce Casting Apparatus Electric Leaf Blower (2) Broken 3/8 th In Ice thick ice Test cage with viewing window Freezing Time ~5 hrs Deicing Circuit Deicing Circuit OFF ON Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 7

8 Functional Block Diagram Electrical System Legend Operator (person) Knife Switch Charging Circuit Discharging Circuit 1000 V Power Supply Mechanism Electrical Operation 2.7 V Power Supply Trigger Switch Solenoid Target Disk Deicing Mechanism Low Voltage Line High Voltage Line Force Interaction Operator Control 2/4/16 Schedule Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 8

9 Critical Project Elements Wing Section Test Setup Deicing Mechanism Test Section Sensors Ice Casting Assembly Housing Unit & Support Structure Wind Speed & Test Cage 2/4/16 Schedule Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 9

10 Schedule 2/4/16 Overview Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 10

11 Current Schedule Spring 2016 Week 1 Week 5 Week 10 Week 15 = Test Setup = Wing Section = = Testing = Spring Break = Margin = Milestone Critical Path Wind tunnel does not achieve DR off-ramp Currently obtaining off-ramp equipment Foam took longer than = New anticipated Level 1 to arrive Wing section not required until end of phase 2 2/4/16 Overview Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 11

12 Manufacturing Wing Section Test Setup Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 12

13 Description = Deicing Mechanism + Assembly Completed Thyristor 500μF Capacitor Bank 16AWG Wire Solenoid Housing Block Solenoid in housing block * All circuit components rated for 1000V 12AWG Wire Diodes Knife Switch Power Supply Attachment Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 13

14 Proof of Concept = Deicing Mechanism + Assembly Completed Proof-of-Concept Test* (50V) Assembly* Arm Target Disk Solenoid Assembly Solenoid * Deicing mechanism not shown Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 14

15 - Overview = Deicing Mechanism + Assembly In Progress Assembly * All components built in-house Aluminum Brace Aluminum Pillow Bearing Aluminum Pivot Rod Acrylic Arm Aluminum Target Disk Leveling Screw Pillow Bearing Leveling Screw Front View Side View Accelerometer *All materials received except acrylic 2/2 Wood Solenoid Block Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 15

16 Manufacturing Status Task Status Estimated Man-Hours Remaining Completion Date Build Deicing Circuit & Test Proof of Concept Complete --- 1/18 Build Circuit Safety Cage Complete --- 1/31 Obtain Materials Complete --- 2/1 Machine Pillow Bearings In Progress 4 2/8 70% Complete (Man-Hours) Machine Acrylic Arm In Progress 3 2/8 Machine Aluminum Pivot Rod In Progress 2 2/8 Machine Aluminum Brace In Progress 1 2/8 Total Man-Hours Remaining for Manufacturing : 10 hrs Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 16

17 Overall Status Task Circuit & POC Testing Design Manufacturing Component Assembly Completion Date 1/18 1/31 2/7 2/8 = Up-to-Date Progress = On-Schedule Marker STATUS: On Schedule Manufacturing for level 1 success completed by: 2/8 25% margin in days Overview Schedule Wing Section Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 17

18 Wing Section DAE 11 Layup Overview Wing Section = DAE11 Wing Layup + Housing Unit & Support Structure Machine Foam Molds Prepreg Carbon Fiber Layup Vacuum Bag Cure (3 hrs, 250 o F) In Progress Upper Surface Mold Lower Surface Mold Future Work Machine Foam Molds (CNC) Upper & Lower Surfaces Allow for 14% margin in span during layup Negative layup with upper and lower surfaces attached DAE11 Layup with Wooden Spar Includes rib on one end (dragon plate with epoxy) * All materials are received with excess foam and prepreg Overview Schedule Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 18

19 Wing Section Housing Unit & Support Structure Overview Wing Section = DAE11 Wing Layup + Housing Unit & Support Structure Future Work Top Plate (Polyethylene) Housing Unit Epoxy + Dado Joint Support Structure Base Plate (Polyethylene) L-Brackets & Through Holes Solenoid Housing Unit Countersink screw Top Plate with Dimensions [in] Carbon fiber (foam core) support structures (Dragon Plate) laser cut (1 support structure = 2 laser cut dragon plates) Front View of 1 Support Structure *All materials are received Overview Schedule Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 19

20 Wing Section Manufacturing Status Task Status Estimated Man-Hours Remaining Completion Date Wing Section Obtain All Wing Section Materials Complete --- 1/24 Machine Foam Molds In Progress 10 2/8 Layup DAE11 & Flat Plate Future Work 6 2/19 Machine Housing Unit Future Work 5 3/3 10% Complete (Man-Hours) Cut Support Structure & Rib Future Work 6 3/3 Wing Section Integration Future Work 4 3/8 Total Man-Hours Remaining for Manufacturing Wing Section: 31 hrs Overview Schedule Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 20

21 Wing Section Overall Status Task Manufacture Foam Molds Layup Wing Section & Flat Plate Manufacture Housing Unit, Support Structure, & Rib Integrate Wing Section Completion Date 2/7 2/19 3/3 3/8 = Up-to-Date Progress = On-Schedule Marker * Foam delivered late Schedule allowed for adjustment in layup STATUS: On Schedule * completion date Manufacturing for level 2 wing section completed by: 2/19 20% margin in days Manufacturing for level 3 wing section completed by: 3/8 30% margin in days Overview Schedule Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 21

22 Test Setup Sensors Description Test Setup = Sensors + Wind Source + Ice Casting Sensor Goal Verify force model and ANSYS model with force calculation Methods to Calculate Force Accelerometer (acceleration) High Speed Camera (height of pendulum arm) Laser (deflection) (Level 1) Carbon Fiber (Levels 2 & 3) Completed Accelerometer Software Development: Force Calculation Function Accelerometer Power Unit Oscilloscope Read in Accelerometer Data (CSV file) Convert V to g s Calculate acceleration from g s Find max acceleration F = ma Return force Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 22

23 Test Setup Wind Source Description Test Setup = Sensors + Wind Source + Ice Casting Test Cage Wind Source Completed Side View of Test Cage Front View of Test Cage In Progress Original Source: Wind Tunnel Cannot achieve wind speed requirement - Off Ramp - 2 Leaf Blowers Currently achieving 25% lower than required average wind speed through simulation Cross-Section 25 in x 16 in * Currently in possession of 1 leaf blower, in process of obtaining 2nd Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 23

24 Test Setup Ice Casting Apparatus Description Test Setup = Sensors + Wind Source + Ice Casting Future Work Ice Casting Apparatus Beeswax Anti- Leak Coating Acrylic Molds Polyethylene Base Sheet Aluminum End Caps Casting Base Support Note: end caps held in place with clamp * Currently in possession of all materials for ice casting apparatus Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 24

25 Test Setup Manufacturing Status Task Obtain all materials for test cage & ice casting, build test cage Status Estimated Man-Hours Remaining Completion Date Complete --- 1/18 Preliminary Laser Test Complete --- 1/22 Accelerometer Code & Preliminary Test Complete --- 1/23 20% Complete (Man-Hours) Obtain Second Leaf Blower In Progress 1 2/19 Machine Aluminum End Caps Future Work 7 3/3 Cut Acrylic Molds Future Work 5 3/3 Ice Casting Integration Future Work 3 3/8 Total Man-Hours Remaining for Manufacturing Wing Section: 16 hrs Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 25

26 Test Section Overall Status Task Build Test Cage Preliminary Sensor Testing & Prep Test Wind Source Manufacture Ice Casting Apparatus Ice Casting Trials Completion Date 1/14 1/24 2/7 2/21 3/6 = Up-to-Date Progress = On-Schedule Marker STATUS: On Schedule Manufacturing for level 3 test section complete by: 3/6 33% margin in days Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 26

27 Budget 2/4/16 Overview Schedule Wing Section Test Setup University of Colorado Boulder Aerospace Engineering Sciences 27

28 Dollars ($) Budget Status $ Budget Distribution Potential Uses of Margin Additional Thyristors Capacitor Leaf blower(s) Improvement of electronic set up 1000 $991 $ $ $13 Electronics Test Section Test Setup Management Margin 2/4/16 Overview Schedule Wing Section Test Setup University of Colorado Boulder Aerospace Engineering Sciences 28

29 Questions? 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 29

30 Previous Work Plan (CDR) Spring 2016 Week 1 Week 5 Week 10 Week 14 = Test Setup = Wing Section = Circuit/Electrical = Testing = Spring Break = Margin = Milestone Critical Path 2/4/16 Overview Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 30

31 Current Work Plan Backup Spring 2016 Week 1 Week 5 Week 10 Week 15 = Test Setup = Wing Section = = Testing = Spring Break = Margin = Milestone Critical Path 2/4/16 Overview Wing Section Test Setup Budget University of Colorado Boulder Aerospace Engineering Sciences 31

32 Full-span Backup Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 32

33 Full-span Weight Budget Item Weight (lb) Solenoids + Target Plates (76) 38.3 Housings (76) 69.3 Capacitors + Mounting (10) 27.2 Wire + Mounting 30.7 Voltage Converters 55.0 Total 221 lb Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 33

34 Sensors Backup D d= D 2 tan Θ θ 2 d Θ Laser Overview Schedule Test Setup Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 34

35 Wing Section Backup Housing Unit Housing Unit SolidWorks Designs * All units in inches Tolerance = 0.01 inches Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 35

36 Wing Section Backup Support Structure Support Structure SolidWorks Designs * All units in inches Tolerance = 0.01 inches Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 36

37 Test Cage Backup Test Cage (all units in inches) Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 37

38 Wing Section Rib Backup Dragon Plate Rib (Carbon Fiber plates with foam core) Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 38

39 Test Setup Backup Leaf Blower Simulation Two Leaf blowers simulated in test cage with exit velocity = 250 knots Overview Schedule Wing Section Budget 2/4/16 University of Colorado Boulder Aerospace Engineering Sciences 39