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P15318: Gaseous Mass Flow Rate ControllerBrian Church, Anthony Salmin, Tyler Breitung, Ross Bluth, Michael Oplinger, Stephen MrozWeek 6 System Level Design Review - 10/2/14AgendaBackgroundProblem StatementCustomer RequirementsEngineering RequirementsHouse of QualityFunctional DecompositionConcept DevelopmentFeasibility AnalysisRisk AssessmentTest PlanProject Plan

Week 6 System Level Design Review - 10/2/14Current PrototypeDynamic range of flow of 100:1No means of flow rate controlNot ready for use in an automotive environment

Week 6 System Level Design Review - 10/2/14Problem Statement: Desired StateIncrease the flow rate accuracy to 0.5%A distribution plate for mixing CNG and air Smaller and lighter than current prototypeA Proportional-Integral-Derivative (PID) actuator control algorithm to increase flow rate accuracy

Week 6 System Level Design Review - 10/2/14Problem Statement: Project DeliverablesFully operational prototype that can be tested and verified with compressed airComplete technical design documentationComprehensive system operation instruction manualDocumentation of failure modesDemonstration at Imagine RITWeek 6 System Level Design Review - 10/2/14Problem Statement: ConstraintsLow costSimple installationSmall and lightweightDesign for manufacturabilityElectrical/Mechanical packaging for an automotive environment

Week 6 System Level Design Review - 10/2/14Customer Requirements: Last Time

Week 6 System Level Design Review - 10/2/14Customer Requirements: Changes

13ConstraintConstraintWeek 6 System Level Design Review - 10/2/14Customer Requirements: Now

Week 6 System Level Design Review - 10/2/14Engineering Requirements: Last Time

Week 6 System Level Design Review - 10/2/14Engineering Requirements: Changes

mass flow rate control31Week 6 System Level Design Review - 10/2/14Engineering Requirements: Now

Week 6 System Level Design Review - 10/2/14House Of Quality: ThenAccuracy of position sensorRepeatability of mass flow rate controlNumber of separate assembliesOperating voltageUsability with different gaseous fuelsDynamic range of flow controlCost of production deviceTemperature limitManufacturing labor costSize envelopeTotal weightOpen/close response timeFuel mixing shapeInstallation timeCompatible engine sizeOperating lifeNumber of full cyclesShock resistanceVibration resistanceTarget of Limit Value 0.5 5%26-18VYes100 to 1$100 80 CTBD86.5 cubic inches4 lbs50 msVortexTBD4.7LDifficulty(0=Easy to Accomplish, 10=Extremely Difficult)7851329386142Max Relationship Value in Column99999999999999948.648.677110Weight / Importance18712211411011011015085.152.789.248.636.536.548.612.23.13.14.86.9Relative Weight11.77.67.16.96.96.99.45.33.35.63.12.32.33.10.83.13.14.86.9Week 6 System Level Design Review - 10/2/14House Of Quality: NowAccuracy of mass flow rate controlRepeatability of mass flow rate controlLeakage rate of deviceOperating voltageUsability with different gaseous fuelsDynamic range of flow controlCost of production deviceNumber of separate assembliesTemperature limitSize envelopeTotal weightOpen/close response timeFuel mixing shapeCompatible engine sizeOperating lifeNumber of full cyclesShock resistanceVibration resistanceTarget of Limit Value 1% 1%25 cc/min6-18VYes100 to 1$100 280 C86.5 cubic inches4 lbs50 msVortex4.7LDifficulty(0=Easy to Accomplish, 10=Extremely Difficult)78713295386142Max Relationship Value in Column993999999999999999Weight / Importance22314572.613113113115543.572.672.648.443.514.514.558.158.182.3121Relative Weight13.894.58.18.18.19.62.74.54.532.70.90.93.63.65.17.5Week 6 System Level Design Review - 10/2/14Open Items from Last ReviewIssuesHow are we going to allocate the flow rate accuracy and response time between the systems? Actions TakenAccuracy ( 1%)80% Actuator/Valve10% A/D converter10% LeakageResponse time (50 ms) 80% Mechanical movement20% ComputationsCurrent StatusTake allocations into account during detailed design phase

Week 6 System Level Design Review - 10/2/14System Architecture

Week 6 System Level Design Review - 10/2/14Functional Decomposition

Week 6 System Level Design Review - 10/2/14Functional Decomposition: Receive Fuel

Week 6 System Level Design Review - 10/2/14Functional Decomposition: Regulate Flow

Week 6 System Level Design Review - 10/2/14Functional Decomposition: Delivering Fuel

Week 6 System Level Design Review - 10/2/14Functional Decomposition: Ensure Safety

Week 6 System Level Design Review - 10/2/14Morphological ChartWeek 6 System Level Design Review - 10/2/14

Morphological Chart ContinuedWeek 6 System Level Design Review - 10/2/14

Concept GenerationWeek 6 System Level Design Review - 10/2/14Four concepts generatedPrototypeModified PrototypeCost EffectiveHigh-Tech (Expensive)

Pugh EvaluationWeek 6 System Level Design Review - 10/2/14

Pugh Evaluation ContinuedWeek 6 System Level Design Review - 10/2/14

Pugh Evaluation ContinuedWeek 6 System Level Design Review - 10/2/14

Pugh Evaluation ContinuedWeek 6 System Level Design Review - 10/2/14

Selected ConceptThe Modified Prototype was ranked 1st in the Pugh EvaluationHowever, we still have to evaluate several component alternatives to meet the accuracy and cost deliverables

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Ball valveNeeds to be designed from scratch, low accuracyGate valveNeeds to be designed from scratch, low accuracyCam/ball Already implemented in a prototype, high accuracyRotating diskAlready implemented in a prototype, high accuracy

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Cam/ballSnailEggDwell

Snail Egg DwellWeek 6 System Level Design Review - 10/2/14FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Week 6 System Level Design Review - 10/2/14 Open ClosedFeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Rotating disk

Open

Closed

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Will the valve design have an impact on the flow rate accuracy?

Answer: Yes!

Current status

Need to develop equations/models Cam profilesSlots in rotating disks

Need to relate angular rotation of actuator to flow rate

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Will changes in pressure and temperature affect the mass flow rate?

m Mass flow rateA Area of valve openingP PressureT Temperature Specific Heat RatioR Gas Constant

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Will changes in pressure and temperature affect the mass flow rate? Volume remains constant in chamberAs temperature increases, pressure increases due to basic thermodynamics

7.07% > 3.0%

Answer: Theory shows that we will need pressure and temperature sensors to have accurate flow.

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Is it feasible to use a thermocouple, RTD, or thermistor for our temperature measurements?

PartTemperature RangeAccuracyTolerance (res)Thermal Time ConstantCost ($)TypeHEL-777-A-U-0-55C ~ 150C0.2%18RTDPPG102A6-200C ~ 600C0.15C0.06%1.2 Sec Nomial22RTDTFPT0603L1001DV-55C ~ 150C0.5%2ThermisterPT103J2-80C ~ 150C0.2C0.2C10 sec in still air3Thermistor192-303QET-A01-60C ~ 150C0.2C15 sec time constant9ThermistorNTCLE203E3103FB0-40C ~ 150C1%13s (1.7 response time)1.24ThermistorMTSS SeriesT-Type (200 to 350 C )1.027ThermocoupleTC-T-NPT-G-72T-Type (200 to 350 C )1.038ThermocoupleHTTC36 SeriesT-Type (200 to 350 C )1.025Thermocouple

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Is it feasible to use a general purpose, flush diaphragm, or PCB mountable pressure transducer?

PartAccuracyPressure RangeTemperature RangeTotal error bandCost ($)SSCMAND010BG2A50.25%0 ~ 145 PSI-40C ~ 85C2%45.00TSCDANN150PGUCV0.15%0 ~ 150 PSI-40C ~ 85C32.8540PC500G2A0.2%0~500 PSI-40C ~ 125C48.00NBPDANN150PGUNV0.25%0~150 PSI-40C ~ 125C13.00M7139-200PG-5000000.25%200 PSI-40C ~ 125C1%54.00

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Can a microcontroller can be used to control GMFRC?

Expecting shock and vibrations over extended periodTemperatures in engine compartment can reach 85CNeeds to read raw sensor data, convert to digital data, determine necessary actuator position, and control actuator positionWant 1% accuracyActuator needs to go from fully closed to fully open in 50 msMicrocontroller costs needs to be within budgetWeek 6 System Level Design Review - 10/2/14FeasibilityQuestion: Can a microcontroller can be used to control GMFRC?

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: How much power will our system draw?

Week 6 System Level Design Review - 10/2/14

FeasibilityQuestion: Do we need to add a cooling method to prevent overheating?

Answer: If we can use Electronics with a high enough temperature resistance.No

Week 6 System Level Design Review - 10/2/14FeasibilityQuestion: Will we be able to meet our budget requirements?

Week 6 System Level Design Review - 10/2/14

Proposed Test SetupWeek 6 System Level Design Review - 10/2/14

Test PlanTest fuel mixingUse CFD analysis to confirm distribution plate mixes fuel and airTest valveRun compressed air through device and open and close valveTest microcontrollerGenerate values to simulate varying sensor readingsTest response timeHave microcontroller open and close actuatorTest with installed sensorsVary sensor variables to test microcontroller responseTest voltage regulatorVary input voltageTest leakagePressurize system and measure amount lost due to leakageTest flow rate accuracy and repeatabilityConnect device to compressed air tank and measure output

Week 6 System Level Design Review - 10/2/14RISKWeek 6 System Level Design Review - 10/2/14

RISK ContinuedWeek 6 System Level Design Review - 10/2/14

RISK ContinuedWeek 6 System Level Design Review - 10/2/14

RISK ContinuedWeek 6 System Level Design Review - 10/2/14

Project Plan

Week 6 System Level Design Review - 10/2/14Goals for Week 9Proof of concept select a concept for valve designSelect method of measuring pressure and temperature (sensors) as well as how they are to be mountedDetermine how fast the microcontroller needs to be and select oneDetermine where to find test equipment to test our device (CAST or offsite)Pressure/Temperature Excel spreadsheet completeGenerate pseudo-code for the controlling the actuator

Week 6 System Level Design Review - 10/2/14Week 6 System Level Design Review - 10/2/14Questions?Week 6 System Level Design Review - 10/2/14Reference SlidesDistribution Plate

Week 6 System Level Design Review - 10/2/14Current Prototype Cross-SectionWeek 6 System Level Design Review - 10/2/14