Micro Turbine III PDR

8/9/2019 Micro Turbine III PDR

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Microturbine III Senior Design 05002

Micro Turbine III

Senior Design Project 05002

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Preliminary Design Report

Design Team:

Lincoln Cummings

osep! Cal"ins

Mar" #a$$io

%llison Stu&ley

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reducing the drag on the plane were either newly designed or modified from last year-s

design

The design of the Micro Turbine III was done through the use of the ngineering

Design 3rocess which consists of twel"e different facets nly si of the facets were

used in the de"elopment of the preliminary design and are discussed throughout this

document ach of these facets is contained in its own chapter( which discusses the facet

in detail

Through the use of the ngineering Design 3rocess( a new Micro Turbine design

was de"eloped that allows the system to be implemented into the M$% airframe .y

using aspects of the pre"ious designs along with some newly de"eloped concepts( the

system was not only made more compact( but may also possibly decrease the drag on the

M$% These designs and concepts must now be "alidated through the de"elopment of

prototype systems which can be tested and analytically compared to the theory

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Table of Contents

Executive Summary:*10 +ecogni#e and 4uantify the eeds611 Mission Statement12 3ro!ect Description1* Scope 7imitations1) Stakeholders15 8ey .usiness 9oals1: Top 7e"el /ritical ;inancial 3arameters16 ;inancial $nalysis1< 3reliminary Market1= Secondary Market

110 rder 4ualifiers111 rder >inners112 Inno"ation pportunities11* .ackground +esearch11) ;ormal Statement of >ork115 rgani#ational /hart

20 /oncept De"elopment21 Subgroups

211 ?ousing Team212 Turbine Team21* ;uel System Team

22 ?ousing /oncepts221 .earings

2* Turbine /oncepts2) ;uel System /oncepts

2)1 ;uel2)2 Tubing @ /onnectors2)* ;low +egulation

25 9enerator *0 ;easibility

*1 Turbine ;easibility*2 ?ousing ;easibility** .earing ;easibility*) ;uel System ;easibility

*)1 ;uel ;easibility*)2 Tubing ;easibility*)* ;low +egulation ;easibility

)0 b!ecti"es and Specifications)1 b!ecti"es)2 3erformance Specifications)* Design 3ractices)) Safety Issues

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50 Design $nalysis @ Synthesis51 Turbine $nalysis @ Synthesis52 ?ousing $nalysis @ Synthesis

521 ?ousing ;$ $nalysis522 Shaft Selection @ $nalysis

52* .earing Selection52) /oupling Selection5* ;uel System Selection @ $nalysis

5*1 ;uel Selection5*2 Tubing @ /onnectors Selection5** ;low +egulation5*) ;uel System $nalysis

:0 ;uture 3lans :1 Test Setup:2 Schedule :* .udget

60 /onclusion $ $ppendi $ A Turbine 3erformance 9raphs. $ppendi . A Turbine 3erformance Data/ $ppendi / A Mass ;low /alculation D $ppendi D A ;inite lement

$nalysis n ?ousing B /apD $ppendi D A ;inite lement $nalysis n ?ousing B /ap $ppendi A Turbine 3erformance Data

Figures, Tables, and EquationsPage Title

13 Fig 1-1: Capstone Micro Turbine14 Fig 1-2: MIT's Micro Turbine & Test Stand

17 Fig 1-3: Organiationa! C"art

1# Fig 2-1: $ousing Concept

2% Fig 2-2: 3- e!ton ("ee! Turbine

33 Fig )-1: *!ade

33 Fig )-2: Turbine esign

3) Fig )-3: Cap F+,

3 Fig )-4: $ousing F+,

42 Fig -1: Sc"edu!e

43 Fig -2: *udget

2) Tab!e 3-1: $ousing Feasibi!it.2 Tab!e 3-2: *earing Feasibi!it.

33 +/n )-1: *!ade Ca!cu!ation

34 +/n )-2: Tor/ue

34 +/n )-3: +00icienc.

4% +/n )-4: ensit.

4% +/n )-): e!ocit.

4% +/n )-: Mass F!o

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'(0 Recogni$e an& )uanti*y t!e +ee&s

1.1 Mission Statement

The purpose of the 05002 Senior Design team is to design and build a working

prototype of a micro,turbine generator that can be integrated into a M$% airframe and

power the "ehicles electrical accessories The micro,turbine design is to be a

continuation and impro"ement upon the pre"ious design team-s pro!ect through the use of

much of the pre"ious research and design along with new research and design to create a

baseline for integration into the M$% airframe

1. !ro"ect #escri$tion

The current +IT M$% "ehicle-s motor and electronics are powered by a hea"y

and epensi"e 7ithium Ion battery $lthough these batteries supply the proper electrical

capabilities( it has been pro"en through pre"ious research and senior design teams that a

more lightweight and compact power supply is feasible The scope of the current pro!ect

is to impro"e upon the pre"ious year-s designs and to implement the design into the M$%

airframe( which has not been done by pre"ious teams

$s a result of last year-s senior design team( there is an eisting 3elton wheel

turbine design which can be used in this years design ther turbine designs( as well as

other 3elton wheel designs will be in"estigated and their feasibility will be determined

compared to the current design 7ast year-s design produced the necessary power

reCuirements( howe"er was much too large to be implemented into the M$% airframe

This year-s team will research different turbine designs( propellants( and other

components and e"aluate their feasibility and ad"antagesBdisad"antages o"er the current

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design ne of the ma!or goals is to make a smaller housing which will be able to fit into

the M$% airframe as well as be lightweight( robust( and fulfill the reCuired power and

flight reCuirements The M$% reCuires a minimum of 5 watts of power for use by the

onboard electronics In order to achie"e these power reCuirements( the turbine must

rotate at high speeds( which last year-s team determined to be around 100(000 rpm

>hile designing the new system( the o"erall weight goal of )5 grams must be considered

1.% Sco$e &imitations

Through pre"ious senior design research( it has been determined that a minimum

of 5 watts of power is needed in the flight of the +IT M$% This reCuirement sets a

limitation on the micro turbine to produce a minimum of 5 watts of power for sustainable

flight $s mentioned pre"iously( the weight of the system is also an issue to impro"e

upon the current battery power $ goal of an o"erall weight including propellant tanks is

a reasonable )5 grams

Many of the limitations to research and design parameters are due to the limited

amount of time as well as a pro!ect budget of 1000 , 1500 The budget is to be

supplied by the 8ate 9leason /ollege of ngineering

1.' Sta(e)olders

The primary stakeholders in this design pro!ect are the members of the design

team In addition to these persons is the faculty of +IT-s Mechanical ngineering

Department Dr Eeff 8o#ak( the teams ad"isor and contact( is the dominate member of

the faculty who will benefit from this year-s pro!ect in ad"ancing the design onto future

micro turbine design teams along with M$% teams


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Secondary stakeholders include the outside "enders sought for the manufacture of

intricate parts $lso on this list are faculty and staff of other +IT departments including

the Microelectronics Department and those in the .rinkman 7aboratory Stakeholders

etend onto member of other current and future M$% design teams at +IT and other

schools in"ol"ed in micro turbine research

1.* +ey usiness -oals

$ successful pro!ect will be defined by the e"idence of a working micro turbine

prototype producing fi"e watts of power( weighing less than )5 grams( and si#ed to be

implemented onto a M$% If the design team is capable of completing the task( then

much will ha"e been accomplished ot only will the core ob!ecti"e of the pro!ect be

achie"ed( the students on the team will ha"e also gained a "aluable eperience in working

with a multidisciplinary team The results of this pro!ect will ser"e as a stepping stone

for further de"elopment in this field Success of this pro!ect will bring future research a

step closer to replacing the power source on M$%s( which is the ultimate goal

1. To$ &evel Critical Financial !arameters

$lmost all of the budget will be used for purchasing of raw materials or sub,

assemblies The goal is to ha"e the micro,turbine design be within a reasonable amount

of a battery powered system The prototype will use nitrogen gas in large canisters( the

goal for future micro,turbine teams is to shrink the weight and si#e of the nitrogen

canisters and piercing components so that they can be incorporated onto an M$%

airframe

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1./ Financial 0nalysis

The pro!ect has a tentati"e budget of 1000 from the Mechanical ngineering

department at +IT This will be used to fund purchases of all the components listed in the

.ill of Materials &see appendi FFF' The ma!or components that will be ordered are

the followingG

?ousing material

;uel canisters

3uncture system for the fuel canisters

Turbine

Internal componentsG shaft( bearings( couplings

Machining costsG housing

1. !reliminary Mar(et

The pro!ect team two years ago conducted a proof of concept pro!ect( while last

year-s team designed a functioning prototype That pro!ect initiated a host of long,term

research pro!ects Therefore( the work being done is still set in the research realm while

concern for actual implementation onto an M$% is under hea"y scrutiny The primary

customer for this year-s pro!ect remains academia "entually these efforts and research

will de"elop into a feasible energy source that the +IT M$% team can utili#e for efficient

flight

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1.2 Secondary Mar(et

Through added time and research( this design could be de"eloped into a reliable

source of lightweight energy production There are numerous applications for such

products The Department of Defense &DoD' and the ;orest Ser"ice are currently

interested in utili#ing M$%s for their particular needs The DoD is interested in using

M$%s in military conflicts for ground personnel to utili#e as scouts or forward obser"ers

The ;orest Ser"ice would like M$%s to fly into and around forest fires and monitor their

status to help better direct fire fighting efforts ?owe"er( the product is not limited to

M$%s This lightweight energy production is open to a host of other applications Micro

robots that could be made lighter and smaller using micro turbines are a good eample of

this The micro turbine is open to numerous applications in the future

1.13 4rder 5ualifiers

The purpose of this research design is to impro"e upon the technology that has

already been produced at +IT Therefore( the senior design team must produce a

prototype micro turbineBgenerator system that is si#ed to be more suitable for M$%

application than last year-s design in addition to including the fuel system into the design

To be more useful( the power produced shall be reduced from 1< > to 5 > This is the

power reCuired by a M$% flight production The weight must also be held to less than )5

grams This will make the product more feasible for M$% application

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1.11 4rder 6inners

If time and money permit the team will work to complete the following goalsG

Implement the fuel system into the design

ptimi#e turbine efficiency

Maintain the ease of assembly and disassembly of the turbineBgenerator system

Impro"e bearing setup and design

Impro"e the housing design to better fit an M$%

.e safe to users and en"ironment

%alidate data using /omputational ;luid Dynamics modeling

Design and test all components for form and function

1.1 7nnovation 4$$ortunities

In this day and age( persons in all industries are looking to maimi#e efficiency

while minimi#ing the materials reCuired Micro turbines stri"e to achie"e the same goal

in pro"iding an alternate power source Since e"erything is on the micro scale( the

complete package will be light in weight and compact in si#ed +esearch in these

turbines will aid any electrical reCuired applications limited by space and weight

1.1% ac(ground 8esearc)

The term micro turbine has become undefined as its definition changes from field

to field It can be used to describe a stand,alone unit producing hundreds of kilowatts in

industry to a Micro lectrical Mechanical System &MMS' producing milliwatts of

power in academic institutions $ wide range of applications in industry see the potential

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;ig 1,1G /apstone Micro Turbine


for micro turbine generators for electricity The primary use for micro turbines is in the

growing Hnmanned $erial %ehicle &H$%' and model airplane markets Institutions

throughout the country are currently designing micro turbines on the micrometer scale

The high efficiency of micro turbines has led

industry to scale down power producing turbines from

thousands of megawatts to tens of kilowatts /apstone

Turbine /orporation remains the world leader in the

micro turbine market since introducing their products in

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;ig 1,2G MIT-s Micro Turbine @ Test Stand


MIT is leading the micro turbine research market due to their hea"y funding

pro"ided by the Defense $d"anced +esearch 3ro!ects &D$+3$' along with other defense

agencies Due to this fact( much of their work remains unpublished while it is in the

de"elopment stages ;igure 1,* represents the radial flow reacti"e compressor(

combustor and turbine system being de"eloped by MIT The greatest difficulty with this

design is in the bearings( which are unable to withstand the high rotations per minute

The goal of this pro!ect is to produce approimately ten to twenty watts of power based

on liCuid hydrogen fuel $lternati"e fuels such as hydrocarbons could produce up to a

hundred watts of power

Stanford and Simon ;raser Hni"ersity are focusing their work on new

manufacturing techniCues to be used to produce highly speciali#ed turbines Stanford is

de"eloping a Mold Shape Deposition Manufacturing &Mold SDM' process to produce

comple silicon nitride parts >hile they ha"e not testing a compressor and turbine

system( compressed gas testing has pro"en the turbine to be successful up to )5:(000

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rpm ;igure 1,) shows an eample of some of the Stanford-s designs Simon ;raser

Hni"ersity is using a design already tested in nuclear magnetic resonance &M+'

spectroscopy of solid samples Hsing this technology( impulse radial inflow turbines

were produced in si#es ranging from 10,22 millimeters in diameter Samples of these

spun by compressed nitrogen ha"e shown to function up to 1(000(000 rpm

The research and de"elopment at +IT began !ust three years ago with a proof of

concept senior design pro!ect During this pro!ect( headed by Dan ?olt( a dentist drill

was used to spin a generator ?olt continued the pro!ect on with his master-s thesis( in

which he epanded into the realm of using a compressed gas to dri"e a turbine which in

turn spins the generator 7ast year-s design team continued the efforts of ?olt by

designing and producing a functioning micro turbine generator This design was a great

achie"ement for +IT in de"eloping a usable design for Micro $ir %ehicle &M$%'

applications ?owe"er( the prototype from last year remained too large and hea"y for use

on a M$% In addition( the fuel system was not included in the design The current

pro!ect described within this report aims to reduce the si#e and weight of the system( as

well as implementing the fuel storage and deli"ery system into the o"erall design

1.1' Formal Statement of 6or(

The Micro Turbine III Design Team shall produce a micro turbineBgenerator

system fitted for implementation onto a M$% This system will be centered on a micro

turbine and self contained fuel source The micro turbine will be attached to a rotor that is

coupled to a generator The design must also be contained in a housing that supports the

turbine and necessary flow paths

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The generator of this system shall output a minimum of 5 >atts of power To be

useful in the application of M$% power production( the system must output at least 5

>atts of power for onboard electrical eCuipment In addition( if necessary( addition

power produced could be used for propulsion

The micro turbine system shall weigh less than )5 grams The prototype designed

and built by the pre"ious senior design team was within this weight limit( howe"er did

not include the fuel system and remained relati"ely large in si#e for M$% uses To get

closer to the goal of M$% application( the system must undergo weight and si#e

reductions( along with design of the fuel system This is why the design must undergo a

drastic redesign of many components( time permitting The micro turbine system

includes the turbine( shaft( bearings( housing( seals( couple( fuel canisters( fuel deli"ery(

choked flow no##le and all hardware reCuired for the housing to remain closed It does

not include the controls sensors( power con"erters( signal modifiers( and the generator

/urrently the si#es of the components not included are due to the test set,up( our limited

budget( and a"ailable resources within the team ;or a practical application on M$%s(

the generator must be incorporated as part of the turbineBhousing This would reCuire

tremendous research and is outside the scope of this pro!ect

The design should maintain ease of assembly and disassembly of the

fuelBturbineBgenerator system In thinking of e"entual application( the system must be

"ersatile and simple $ssembly and alignment should be Cuick and sure 3arts should

also be easily replaceable in case of part malfunction

The Design Team should design the onboard fuel system 7ast years design used

an unlimited source of fuel for the turbine power This year-s team shall design and

produce a fuel system suited to fit our needs

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The generator selection should be optimi#ed for our application 3re"ious

generators were selected primarily because of si#e This created a loss of efficiencies at

certain power le"els and operating speeds The generator should be chosen to best fit all

of our design parameters

1.1* 4rgani9ational C)art

2(0 Concept De,elopment

This chapter will co"er the different concepts the team in"estigated and redsigned

The first few sections discuss the break down of the team Since there are se"eral

different aspects to the pro!ect( the team of four engineers broke up into subgroups

;rom the subgroups( ideas were generated and brought together to aid in concept

de"elopment on housing( turbine( and fuel system designs

16

05002 Micro,Turbine 3ro!ect7eader A /liff /ummingsMentor A 3rof Eeff 8o#ak

;uel Systems7ead A Mark

/liff

3D+B/D+

3aper7ead A Mark

3resentation7ead , Eoe

Turbine and ?ousing7ead A Eoe

$llison

;ig 1,*G rgani#ational /hart


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.1 Subgrou$s

>e found it necessary to split the design pro!ect into smaller subgroups headed up

by indi"idual members of the design team The small group of four team members led to

o"erlapping of members in"ol"ed in each subgroup The purpose of the subgroups is to

in"estigate( research( and design concepts to be brought forth and implemented into the

o"erall design The subgroups created areHousing( Turbine( andFuel System

.1.1 ousing Team

The housing subgroup-s main task was to reduce the si#e and weight of the

turbine and flow housing This subgroup was headed by Eoe /alkins( with the assistance

of $llison Studley The main focus of their research was on scaling down the outer

dimensions of the housing to be more appropriate for M$% applications ;urther thought

was placed on the bearing and seals to be used within the design and the flow path at both

the inlet and outlet

.1. Turbine Team

$llison Studley led the research into alternati"e turbine designs >ith the support

of Eoe /alkins( the subgroup in"estigated numerous pro"en high efficiency turbine

designs and their possible inclusion into our concept The limited source of persons

a"ailable pre"ented a full redesign of the turbine

.1.% Fuel System Team

The fuel system reCuired the primary initial attention as it had to be completely

designed with no current benchmark ?eading up this subgroup was Mark ;a##io with

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the assistance of 7incoln /ummings The main focus of research and design was placed

on the fuel canisters to be used $dditional attention was spent on the fuel deli"ery to the

turbine including tubing( connectors( and no##les

. ousing Conce$ts

$ ma!or reCuirement of this year-s housing design is the implementation of the

housing into the current M$% airframe In order to meet this reCuirement( the new

housing must be more compact than the pre"ious design $fter a session of housing

concept brainstorming( it was determined

that the circular design was the most

compact( durable( and easily manufactured

design

ne impro"ement made upon last

year-s design was the implementation of two

separate inlet ports( which was able to

eliminate the large inlet channel The

remo"al of this inlet channel allowed the diameter of the housing to be shrunk from

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the high pressure blowing the grease out of the shielded bearings ;rom this( it was

determined that sealed bearings were necessary ther bearings were in"estigated(

including air and magnetic bearings( but no bearings of a small enough si#e were found

.% Turbine Conce$ts

The aial impulse and ;rancis turbines are impulse turbines that pro"ide high

efficiency They are * dimensional designs and are "ery costly to produce The aial

impulse uses aial flow and the ;rancis uses a combination of radial and aial flow

The 3elton wheel is a design that de"eloped in the 1heel Turbine


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Methods in which this could be done were contri"ed as a group Stemming from

the single inlet housing of the pre"ious design would lead to the use of a single canister to

hold the compressed gas This method became obsolete as a single canister would not fit

along the center of the M$%( and placing the canister to one side would cause se"ere

imbalance of the M$%

The design would thus incorporate two canisters of fuel to be placed eCually on

either side of the fuselage and be ducted into a duel inlet housing design 3lacement of

the canisters then had two options The first was to place the canisters along side the

fuselage( while the second was to incorporate them along the leading edges of wings of

the M$%

.'.1 Fuel

The options for the fuel to be used were kept to those which are most easily

a"ailable .rainstorming let to a choice between compressed air( itrogen( and /arbon

Dioide Due to weight being a key issue in the design parameters( itrogen was chosen

as the optimal gas to be used to propelling the turbine $ second ad"antage for the use of

itrogen is that it acts as an ideal gas under our conditions

The reCuired amount of fuel needed to operate the generator for a time of three

minutes would be determined in order to find the necessary Cuantity of itrogen to be

stored This calculation would be performed based on the properties of the itrogen( and

characteristics of the flow nce this Cuantity is known( a supplier of customi#ed

compressed gas canisters will be used for purchasing the fuel

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.'. Tubing ; Connectors

Transporting the fuel from the canisters to the housing was the net step in the

fuel system design Tubing to duct the fuel would be used( and two options presented

themsel"es Tubing to be used could be made of plastic( such as surgical tubing( or

metal( either aluminum or copper The positi"e aspects of surgical tubing being light,

weight and fleible led to this as the optimal choice ?owe"er( once the gas pressure to

be used within the tubing was determined( it was concluded that metal tubing would ha"e

to be used to withstand the pressures

nce this choice had been made( thoughts turned to the connections at the

canisters as well as at the housing Se"eral options were brainstormed including threaded

fittings( epoy( and compression fittings $s each of these were researched and analy#ed(

an alternati"e to the tubingBconnector component presented itself

The e"entual supplier of the compressed gas also pro"ides puncturing de"ices to

be used to pierce the canister and duct the gas out through a threaded hole $ male,to,

male brass coupler could then be threaded into the puncture de"ice and the housing

Thus no additional tubing or connectors are needed

.'.% Flo< 8egulation

Due to the concept of a high pressure gas canister to be used for storage of the

fuel onboard the M$%( the flow out of the regulator and into the housing must be

regulated to an efficient and effecti"e pressure Since a redesign of the turbine would not

be performed( the pressure "alues from last year-s data would be used to determine an

inlet pressure to the turbine

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.ased on this information( se"eral concepts of regulation were brainstormed The

use of a spring regulator is commonplace for such flow regulation The si#e and weight

of this( howe"er( would be too large for our needs $ bellows spring had potential as it is

generally lighter and smaller than a standard spring regulator >hile this appeared to be a

feasible option( it was still larger than we would prefer

The final concept would be the simplest of the three .y choking the flow of the

gas and thus achie"ing a flow speed of Mach 1( by fluid dynamics this would pro"ide a

constant mass flow nce this method was determined( options presented themsel"es on

how this could be done $n inline small diameter throat could be placed in the tubing

between the canister and housing This option would merely add components to the

system as well as additional connections which ser"e as a greater number of leakage

points

The other concept for choking the flow is to incorporate the narrow diameter

throat with the no##le within the housing To achie"e the reCuired mass flow( a simple

standard no##le would be insufficient The use of a micro,no##le a"ailable from the +IT

Microelectonic ngineering department would be optimal for the reCuirements

.* -enerator

>ithout any pre"ious electrical engineering background( Dr 8o#ak suggested to

us to speak with Dr 7yshe"ski of the electrical engineering department >e know we

need a *,phase motor that will generate a target speed of 100(000 +3M and 5> of power

The si#e needs to be a 15mm diameter shaft( about 1 total diameter( and ob"iously as

light as possible

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In speaking with Dr 7yshe"ski( he informed us that it needs to be a brushless dc

motor and pointed us to two companies online that we may be able to find what we need

In researching these companies( it was found that the highest speed for this si#e motor is

about :5(000 +3M This may be able to be used( howe"er we would like something

faster 7ast year-s electrical engineer( +eam 8idane( will try to be contacted in order to

see where their motor was from

-(0 #easibility

Two different assessment methods were used to decide on the actual designs for

fabrication The feasibility of all concepts centered on the o"erall ob!ecti"es and goals of

the pro!ect The key aspects which were considered in the assessments were weight( si#e(

cost( a"ailability( and manufacturability ;or concepts which in"ol"ed only two options(

a direct comparison was used( while a weighted 3ugh-s comparison was used on

components with more than two concepts ;easibility assessments were performed on

the housing( turbine( bearings( fuel system( tubing( and flow regulation $ brief

discussion and procedure of the assessment are found in the following sections ;inal

decisions and selections will be discussed in the conclusion segment of this chapter

%.1 Turbine Feasibility

The feasibility attributes considered in the turbine selection are cost and

a"ailability( cost being the more weighted of the two ;rancis and aial impulse are "ery

difficult to manufacture To do this would cost a lot and take a long time These designs

are not practical for our application

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f the 3elton wheel designs( the *,dimensional is more costly due to the added

machining( howe"er may not be out of possibility ;or time and cost considerations( the

2,dimensional design was chosen >e will be using the same design from last year This

will ob"iously not add to efficiency but this was chosen as the best option so we could

focus on other aspects If there is time( we may ha"e a *,dimensional design option

a"ailable for Cuoting

%. ousing Feasibility

Through our process of housing concept de"elopment( we determined that

the most appropriate concept was similar to last year-s design The new design would

ha"e 2 inlets and 2 outlets( as opposed to last year-s 1 inlet 2 outlet design The

feasibility of this concept is shown below as compared to last year-s design Through this

feasibility test( it was determined that the new concept is more feasible than last year-s

design and will be used as the baseline for further design

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Cost

Size

We

igh

t

Availa

bility

Manuf

ac

tura

bility

RowT

otal

To

tals

We

igh

ting

Cost \ | \ | 1 1 !1

Size \ " \ # #!$ !#$

Weight " \ 1!$ % !%

Availability | !$ !$

Manufacturability % !%

Colu&n Total !$ 1!$ !$ %

We

ighting

'as

t(ear)s

*es

ign

#+nlet#,u

tle

tConce-

t

Cost !1 % #

Size !#$ % #

Weight !% % %

Availability !$ % %

Manufacturability !% % #

Weighte. Average %! #!%$

/or&alize. Average 1! !0

2ousing 3easibility

%.% earing Feasibility

Through our research of a"ailable bearings( our findings were "ery similar to last

year-s bearings There are no air or magnetic bearings small enough for our application

This causes them to be unfeasible This lea"es the aial and radial bearings Due to the

low loads and thrust on the bearings( the radial bearings are the most feasible bearings for

our application They are of lower cost( similar +3M rating and a"ailability to the aial

thrust bearings

2:

Table *1G ?ousing ;easibility


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Cos

t

Size

We

ight

Ava

ila

bility

RPMRa

ting

Row

To

tal

To

tals

We

ighting

Cost " " | | # # !#

Size " | | 1 1 !1

Weight | |

Availability \ !$ %!$ !%$

RPM Rating %!$ !%$

Colu&n Total % %!$

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ighting

Air4earin

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Magne

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4earings

A5

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rings

Ra

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Cost !# 6 6 % #

Size !1 $ $ # #

Weight % % % %

Availability !%$ $ $ # #

RPM Rating !%$ # # % %

Weighte. Average %!6 %!6 #!0 #!7

/or&alize. Average 1!1% 1!1% !8 !0

4earing 3easibility

%.' Fuel System Feasibility

The fuel system is composed to three components( the fuel canister( tubing( and

flow regulator ach of these were assessed from a feasibility standpoint separately( as

outlined below Since each is a direct comparison( a 3ugh-s comparison was not needed

The critical features of each were the weight( si#e( and a"ailability of the components

$s a collecti"e group( determining the layout of the fuel system itself pro"ided

se"eral concepts The three main concepts wereG

Single fuel tank with a split flow duct

26

Table *2G .earing ;easibility


28/64


Duel fuel tanks positioned within the leading edge of the M$%

Duel fuel tanks positioned along the fuselage of the M$%

It was Cuickly decided that a single fuel tank would be a poor option as it could

not be centered properly on the M$%( thus disrupting the stability and control of the

aircraft The positioning of the duel fuel tanks was not of real concern until the si#e of

the tanks was known nce we calculated the amount of nitrogen reCuired and pressure

in which it must be stored( it became infeasible to place the canisters within the leading

edge This decision was supported by the design of the M$% in which the leading edge is

not straight off of the fuselage The final decision was made to align the fuel canisters

along side of the turbine and generator within the fuselage

%.'.1 Fuel Feasibility

The nature of the pro!ect kept the fuel options to a minimum The use of a

compressed gas to be used to dri"e a turbine was already knownJ therefore the selection

of gases to be used was left Due to a"ailability( cost( and en"ironmental issues( the list

was Cuickly condensed down to compressed air( nitrogen( and carbon dioide The

weight became the separating characteristic of the choices itrogen was chosen due to

its "ery low density( and high compressibility In addition to these properties( the flow

characteristics pro"ed to be fa"orable as nitrogen would act as an ideal gas within our

system

%.'. Tubing Feasibility

The net step in the fuel system is the deli"ery from the fuel canisters to the

housing To do this( two choices presented themsel"es( plastic or metal tubing The

2


29/64


plastic tubing would likely be surgical tubing which is easily a"ailable $luminum or

copper would be used in the instances of metal tubing

Due to the high pressures the tubing would be eperiencing( surgical tubing was

determined to be infeasible as a result of connection issues The choice was made for use

of metal tubing and connectors ?owe"er( as the design began to come together it was

reali#ed that a male,to,male threaded elbow coupler would reduce the number of

connections and act as the tubing directly from the puncture de"ice to the housing

%.'.% Flo< 8egulation Feasibility

Since the fuel will be stored at a high pressure( the mass flow must be regulated

In order to do this( and maintain a light weight compact design( two concepts were made

The first was the use of a spring operated regulator( likely using a bellows spring The

bellows regulator would reCuire additional connections to tubing as well as using more

space in the fuselage The second is to choke the flow using a mirco,no##le( thus

pro"iding a constant mass flow The micro,no##le was chosen on the basis that it is

lighter in weight( smaller( and can be an added piece to the housing

.(0 /bjecti,es an& Speci*ications

'.1 4b"ectives

The ob!ecti"es of the Microturbine 9enerator Senior Design pro!ect were

presented prior to work being performed The ob!ecti"es were laid out by the +IT

Mechanical ngineering department in collaboration with M$% pro!ect teams and goals

The key ob!ecti"es are listed as follows

Design a micro,turbine system

2=


30/64


.uild the micro,turbine system

3roduce 5 watts of power

"erall system weight less than )5 grams

Integrate into a M$% airframe

/omplete pro!ect by May 2005

Dri"e the propeller

'. !erformance S$ecifications

The ob!ecti"es we are set out to achie"e are established based on pre"ious work

performed( and the goal of producing a lighter and battery power alternati"e During this

design process( we are likely to encounter a number of issues which may not ha"e been

foreseen >hile e"ery attempt to work through these obstacles will be made( limiting

factors due to time and budget will inhibit us to do so .y understanding the performance

specifications( the team will be guided toward the appropriate tasks intended to be

achie"ed by the conclusion of the pro!ect >ith this thorough understanding of the

performance specifications( the team will be able to !ustify those issues that must be dealt

with and those which can be left for future design teams

The key ob!ecti"e of the pro!ect is to scale down the current micro turbine

generator design as well as include the fuel system into the design The specifications

established were to produce 5 watts of continuous power( si#e the system to fit within the

M$%( and keep the weight of the system less than )5 grams Since the turbine has been

pro"en to produce sufficient power( hea"y consideration this year was on the si#e and

weight of the o"erall system

*0


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'.% #esign !ractices

To help the team achie"e the ob!ecti"es and specifications that was established( a

list of design practices were kept in mind when team members were de"eloping designs

$ list of these practices is as followsG

1' Design for Manufacturability A ne achie"ement in the new design of the housing is

a more simplified flow path This design has basic geometric shapes which can be

easily manufactured at +IT This impro"ement will sa"e both money and time in

manufacturing as opposed to seeking an outside "endor

2' Design for $ssembly A The initial design is intended to be assembled and

disassembled with ease This allows for streamlined testing as little time will be

reCuired between tests for maintenance In addition( should certain aspects of the

design reCuire modificationJ any piece can be remo"ed and interchanged with

simplicity

'.' Safety 7ssues

To ensure the safety of all members on the team( a set of safety precautions were

established Since the testing of the design will undergo high pressures and components

will be spinning at high speeds( it is imperati"e that the members of the team follow these

guidelines

1' To a"oid any flying ob!ects from hurting the engineers and whoe"er may come in

contact with it( all testing will be conducted in a contained area The container will

be made out of pleiglass The pleiglass is transparent so the engineers can see the

process( and it is strong enough to compensate for any accidents in"ol"ing the design

*1


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2' ngineers must wear goggles while testing Despite the fact that there is a layer of

pleiglass between the engineer and the micro turbine( there is always room for the

unepected .y wearing goggles( this will preser"e the well being of the engineer

*' If team members are to machine any parts in the machine shop( the machine shop

safety guidelines must be followed strictly

)' The team ought to be careful when working with the electronics There is a chance of

minor electrical shocks caused by the generation of electrical power by the turbine

5' Due to the high speed the components of the turbine will be spinning at( there may be

a slight raise in temperature >hen handling the turbine after testing( team members

must be careful and make sure all parts are at handling temperature

5(0 Design %nalysis Synt!esis

*.1 Turbine 0nalysis ; Synt)esis

Initial research into turbine designs led the team to use last year-s turbine design

This was done because of two ma!or factors( first the amount of resources and time that

would be reCuired to design a new turbine( as well as the lack of technological

ad"ancements in the last year

The 5B1: in turbine design was chosen because of the pre"ious +IT micro,turbine

teams The first design was 1B2 an inch and produced 1< >( the second design was a 1B)

of an inch and produced 0: > Much of the power loss was attributed to housing design

problems( which lead last year-s team to de"elop a turbine within that si#e range 7ast

year-s turbine produced 1= >

*2


33/64


The tip speed of the turbine blades was calculated to be optimal at approimately

)00(000 rpm( this is much larger than the generator and more importantly the bearing can

handle The maimum practical "elocity for the turbine is about 100(000 rpm +esearch

into the blade si#e( based on ;lockhart-s paper Kperimental and Simulation $nalysis of

Microturbines states that the smaller the blade thickness the greater the torCue

performance

The length and number of blades also follow ;lockhart-s logic The pitch

diameter of the blade should be as large as possible so that the pitch diameter is in the

middle of the blade The number of blades should be maimi#ed to the point that the !et

is not being impinging by the net blade If the net blade impinges the current blade

then it would greatly decrease the turbine efficiency

The ma!or limiting factors on turbine design are the machining cost and lead time

Three dimensional turbine designs are more efficient but cost much more The pelton

type turbine is one of these three dimensional turbine designsJ it has a ridge that follows

the edge of the blade radially The pelton type turbine would cost well o"er our entire

budget ur budget and practicality of ha"ing an easily machined and replaceable turbine

greatly limits the turbine designs that can be considered

7ast year-s team designed their own turbine using two set parameters( 100(000 rpm and

5B1: in outer diameter These parameters lead the team to design 0052 in high blades

with a pitch diameter of 026 in Hsing eCuation 5,1 they calculated that there should be

< bladesG

2

2'2B&1

R

dr

n

+

=

&Cuation 5,1'

**


34/64


n is the number of bladesJ r is the pitch radiusJ d is the !et diameterJ and + is the o"erall

turbine radius $ range of 001 and 00* inches was used for the !et diameter The blade

thickness was set at 5 degrees and the tip angle was determined to be *= degrees To

decrease the chance of the back of the blade hitting the !et flow a low profile design was

used The final turbine design is shown below in figure FFFF

;ig 5,1G .lade ;ig 5,2G Turbine Design

The pre"ious team used ngineering ;luid Mechanics to "alidate the design The

mass flow rates were calculated using the following eCuationG

'''&cos&1& = rvQrT jet &Cuation 5,2'

>here T is torCueJ r is pitch diameterJ L is working fluid density a correction factorJ 4

is "olumetric flow rateJ "!et is the "elocity of the !etJ and N is the turbine-s rotational

"elocity The efficiency of the turbine was also calculated using another eCuationG

''cos&1'&1&250

2

==

jetjetjet v

r

v

r

Qv

P&Cuation 5,*'

>here the efficiency is eCual to the power output di"ided by the incoming kinetic energy

This eCuation( howe"er( is limited as the efficiency is also dependant on the other

components of the micro,turbine system

*)


35/64;ig 5,*G /ap ;$


*. ousing 0nalysis ; Synt)esis

Through the feasibility assessment( a similar design to last year-s microturbine

housing was de"eloped The ma!or difference in this year-s design is the implementation

of two indi"idual inlets to the turbine passage This allows the pre"iously designed flow

channel to be eliminated from the design The elimination of this flow channel allows for

less comple geometry for ease of machining( as well as smaller diameter housing for a

more compact and lighter weight design

%ery similar to last year-s design( this year-s housing is focused around the

turbine passage The bearings in the housing( as well as the housing cap( will help to

align the turbine concentrically in the housing Since last year-s turbine design is being

implemented into this year-s design( the turbine passage will be the same dimensions as

last year with a diameter of 0*** and a depth of 0115

In order to cut down on the head losses in the housing( the inlet and outlet ducts

are straight through This will eliminate the losses which occurred in last year-s design

with the =0 degree outlet channel 3ressure losses from the cap will be contained by an

o,ring that is fitted into the housing cap The cap will be held into place with two bolts(

which will also align the generator and it-s bracket on the opposite side of the housing

Since the housing cap concentric with the housing( it is self aligning and will pro"ide for

a more precise alignment of the turbine and it-s shaft

*..1 ousing FE0

0nalysis

Through the use of

;inite lement $nalysis of

*5


36/64

;ig 5,)G ?ousing ;$


the housing( it was determined that the *0O fiberglass reinforced ylon :B: would

withstand the high pressures under our current design The ylon :B: *0O ;iberglass

+einforced has a tensile strength of 2*(20: psi( along with a density of 1*< gBcmP* The

target pressure inside of the housing for our design is 100psi( howe"er a safety factor of

*0 was added for this case since there are such high pressures as well as human

interaction during testing >ith this in mind( the housing was tested at *00psi( assuming

that there is not leakage past the o,ring seal The abo"e analysis showed the maimum

stress in the housing under a *00psi load to be 6


37/64


the housing $ lighter weight alternati"e is ylon :B: with 10O /arbon ;iber +einforced

pro"iding 1


38/64


*..' Cou$ling Selection

ne of the ma!or issues eperienced by the pre"ious microturbine design was the

selection of a coupling to connect the turbine shaft to the generator shaft Through much

research( it was determined that their best selection for a coupling was a small piece of

shrink tubing The main reason for this was the fact that all of the micro couplings

researched were not rated for the high rotational speeds or did not ha"e the necessary

rigidity

$ bit of research was done this year to search for any new technologies which

may allow for a more rigid and high speed coupling( howe"er no couplings were found

This leads us back to the pre"ious team-s use of the shrink tubing as a coupling between

the two shafts It was estimated pre"iously that there is approimately 1O loss in the

shrink tubing coupling

*.% Fuel System Selection ; 0nalysis

The fuel system became the critical aspect of this years Microturbine Senior

Design pro!ect The fuel system in the past used laboratory gas cylinders in con!unction

with flow regulation eCuipment This laboratory setup was used to as a result of the

pre"ious generation-s goalsG design a turbine and housing to be placed on a M$%( without

consideration of the fuel system The goal this year is to include the fuel system into the

M$%( thus reCuiring it to be lightweight and miniature

*.%.1 Fuel Selection

The fuel to be used for the microturbine had to meet three main criteria to be

selected Those criteria were its weight( its flow properties( and the a"ailability of the

*


39/64


gas $s a result of these conditions( and based on the feasibility assessment of the gases(

itrogen was chosen as the optimal gas to be used itrogen has a lower molecular

weight than either compressed air or carbon dioide Hnder our storage and flow

conditions( the nitrogen acts as an ideal gas( thus simplifying the flow regulation ;inally(

nitrogen is a widely used and easily a"ailable gas

*.%. Tubing ; Connectors Selection

$s the housing and fuel canisters were designed and selected( the tubing and

connections remained a secondary thought to be determined once other aspects of the

design were known Throughout the process( the general concept to be used was a

connection at the fuel canister( tubing( and another connection at the housing

/onsideration into the puncture of the fuel canister presented additional connections that

would be reCuired

$s the method of puncture was determined( which would be a supplied puncture

de"ice a"ailable from the fuel supplier( the tubing and connection issue took a turn It

was decided that the number of connections and si#e of the system could be reduced by

use of a straight male,to,male threaded coupler connecting the puncture de"ice directly to

the housing

*.%.% Flo< 8egulation

;low regulation was a fairly simple component of the system to select Due to the

primary reCuirements of light weight and small si#e( a simple choked flow would be

optimal for our design $ micro,no##le fabricated in the +IT Microelectronics laboratory

is the desired method for regulating the mass flow of the nitrogen The micro,no##les are

fabricated out of a silicone wafer through simple means and reCuire minimal

*=


40/64


manufacturing time Due to the molecular structures of the silicone( a tapered !et no##le

is formed This is a desired feature as it increases the efficiency of the no##le

*.%.' Fuel System 0nalysis

The most critical piece to the fuel system to be determined was the Cuantity of gas

reCuired The first step in analy#ing this is to determine the type of flow which the

system will be eperiencing .ased on criteria from thermodynamics( an ideal gas is

assumed when operating temperature is greater than twice the critical temperature( and

operating pressure is less than fi"e times the critical pressure of the gas .ased on

thermodynamic properties of nitrogen( our system is within this criterion( therefore

allowing for ideal gas flow calculations

The Cuantity of fuel reCuired is dependent on the desired runtime of the system

The goal of the design is for a runtime of three minutes The use of the choked flow

no##le results in a constant eit "elocity of Mach 1 of the fuel along with a constant eit

area Determination of the density of fuel within the canister is deri"ed by

V

Mo = &Cuation 5,)'

where o is the density( M is mass( and % is "olume

.ased on the chemical characteristics of the chosen gas( nitrogen( and the

assumption of constant room temperature eit flow( the eit "elocity is calculated by

RTMVexit = &Cuation 5,5'

where exitV is the eit "elocity( M is the mach number( is the specific gas ratio( + is

the ideal gas constant( and T is the temperature

.ased on the eCuation of mass flow(

)0


41/64


exitexitm

QQ=

&Cuation 5,:'

the "ariable we are left with is the density of the nitrogen in the flow Determination of

the eit area of the no##le to be 100 micrometers resulted in a mass flow rate of 15*10 ,)

lbsBsec In a choked flow system( this mass flow will remain constant( thus through

simple calculation an initial reCuired mass for the three minute runtime is determined

.ased on this information( an initial mass of 1*: grams of nitrogen in each of the two

fuel canisters is reCuired

)1


42/64


1(0 #uture Plans

.1 Test Setu$

To sa"e the nitrogen in the fuel canisters( the turbine and housing will be tested

first with large tanks of laboratory nitrogen $fter the design concept is pro"en( we will

test our fuel canister system

In order to test the system to find the desired outputs( the pre"iously designed test

setup will be used This system uses pressure sensors( a flow meter( and thermocouples(

as well as current and "oltage sensors to aCuire the data through 7ab%iew The open loop

control system reads the incoming pressure then is regulated by a ser"o "al"e located on

the inlet air pipe to the stagnation plenum The system is able to read the inlet

temperature T( pressure 3( and "olumetric flow rate % to calculate mass flow rate( as well

as current and "oltage to find power and efficiency

The pressure sensor is rated to 200 psi and the turbine should operate at 100 psi

The flow meter has a range of 10 7Bmin A 120 7Bmin( and the airflow is epected to be

between )0 7Bmin A =0 7Bmin The analog data of the sensors will be con"erted to digital

for 7ab"iew to be able to compute e"erything The 7ab"iew setup allows us to see the

power output graphically as it runs and see the best conditions for the micro turbine to

run

)2


43/64

;ig :,1G Schedule


. Sc)edule

The attached 9antt chart displays the proposed schedule for the design

de"elopment of our pro!ect 8ey e"ents are shown to gi"e the team goals for timely

completion of pro!ect components as well as the o"erall pro!ect The start and

completion dates are listed by each componentJ the "ertical arrows indicate task

dependencies

)*


44/64

;ig :,2G .udget


.% udget

The micro,turbine pro!ect team has a 1000 budget "ia a +IT grant that is

intended to co"er all ependitures associated with the pro!ect The team plans on

spending :6:enerator 2%%8%% 1 1 2%%8%%

O?era!! Cost 78@3

))


45/64


46/64


Re*erences

$nderson( Eohn D( Er ;undamentals of $erodynamics *rded ew RorkG Mc9raw,?ill/ompanies( Inc 2001

/allister( >illiam D Er Introduction to Materials Science and ngineering( )th dition ewRorkG Eohn >iley @ Sons( 2000

Desai( % + and M $#i# K3arametric "aluation of /ross,;low Turbine 3erformanceEournal of nergy ngineering( %ol 120( o 1( $pril 1==) 16 A *)

Doty( ;D( .7 Miller( and 9S ?osford K?igh fficiency Microturbine Technology 2: th

Intersociety nergy /on"ersion ngineering /onference .oston $ugust 1==1

;o( +obert > and $lan T McDonald Introduction to ;luid Mechanics 5thed ew RorkG Eohn>iley @ Sons( Inc( 1==


47/64


%ppen&i

%( %ppen&i % 3 Turbine Per*ormance 4rap!s

&.ased on 0)01* Design'

)6


48/64


)


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)=


50/64


( %ppen&i 3 Turbine Per*ormance Data&.ased on 0)01* Design'

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51/64


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52/64


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53/64


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2% 18)% 18))+-%3 2%

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Ma5 Power ,ut-ut @fficiency v!

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P 9-sig; 9>g=&%; &.ot 9>g=s; Power 9W;

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@fficiency v! Pressure 9$ W ,ut-ut;

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C( %ppen&i C 3 Mass #lo6 Calculation

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Mass 3lowRate

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56


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D( %ppen&i D 3 #inite 7lement %nalysis /n 8ousing 9 Cap

5


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5=


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The abo"e seen boundary conditions were set upon the housing cap in order to test for

failure under the worst case scenario of *00 psi $ *00 psi pressure was placed on the contacting

face( side below the o,ring( and also the contact area for the bearing due to a pressure on the

bearing .oundary conditions on the cap were placed such that the sides of the cap as well as the

bearing hole were constrained from mo"ing in the radial direction due to the fact that the housing

and bearing will help to hold these constraints The holes for the retaining bolts were constrained

to simulate the bolts holding the cap into the housing( which is "isible in the deflection under

loading The maimum stress seen under these conditions was determined to be *6)0 psi( which

falls within the maimum tensile strength of the reinforced nylon of 11(500 psi

:0


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:1


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:2


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7( %ppen&i 7 3 Turbine Per*ormance Data

:*


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Date post:	01-Jun-2018
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Micro Turbine III PDR

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