William Lentlie – Project Leader (ME)Tim Buckner – Lead Engineer (ME)Hope Alm – Mechanical Engineer
Shauna Traxler – Mechanical EngineerAndres Santizo Matheu – Industrial Engineer
P-12462 TOW TANK FOR TETHERED
HYDROFOIL
Faculty Guide: Ed HanzlikSponsors: Dr. Mario Gomes
EPA P3
• Project overview• System design• Actual design summary• Testing• Conclusions• Recommendations• Questions
AGENDA
http://www.cityofsouthlake.com/waterconservation
• To build a small scaled version of tethered hydrofoil to compare with a simulation provided by Dr. Mario Gomes in MATLAB.
• Create a tow tank capable of moving a platform at a constant specified speed over the top of a stationary body of water in order to recreate a river flow passing over a hydrofoil.
OBJECTIVE
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CUSTOMER NEEDSImportance Description How its being Accomplished
9Tow tank must be able to tow a platform above the surface of a stationary body of water at a
constant speed
Tank size meets specification
Motor Speed controlled with driver
Driver has different speed ranges
Calculated from F=ma+Fdrag
3The platform must allow an attachment of two
different instrumented systems, a set of stationary hydrofoils and a model of a translating
hydrofoil system
Tank size meets specification
Tank weight is below required by floor
Interface allows for different attachments
9 Tow length needs to be large enough to achieve steady state
Tank size meets specificationTank length = 16ft
Driver will control speed and accel/decel can be set for 0-30sec
9 System size should allow for appropriately scaled model testing
Tank size meets specification
Total approximate weight = 150lbs
Calculated from F=ma+Fdrag
3 Platform should be above or to the side of the water with no moving parts under water Cart has multiple attachment points
CUSTOMER NEEDSImportance Description How its being Accomplished
9Platform must allow for bolting of the
instrumented model away from the wall of the tank
Cart has multiple attachment points
9Measurements should be of high quality and
should be made with appropriate sampling rates and resolution
Encoder, DC driver speed sensor
Deflection calculations performed in ANSYS
Measurement device should match specification
DC drive accuracy ± 1/2 rpm, encoder mounted
Measurement device should match specification
Measurement device should match specification
Timed in Labview
9 The tank must be safe for the operator and those around them
Ergonomics was considered in the height of tank
9 The tank must not damage the surroundings Membrane or sealant will be used to stop leaks
3 The tank must be cost effective Cost meets budget
3 Easy to use and to train new usersLabview useability will be a priority
Users Manual / Video will be provided
9 Tank should not interfere with operation of models P12463 is aware of the size constraints
ENGINEERING SPECSSpecification Value
Size <= 19ft in length and 50in in width
Weight 300 lbf/ft^2System Cost < $2000
Distance Cart Travels 16ft
Velocity of Cart 3.28 ft/sTowing Velocity Variation 0-3.28 ft/s
Towing Force 60lbsMax Sideways Deflection of Rail System 1/32" Center of Platform From Edge of Tank 1 <= 8 in
Data Sampling Rates 500 HzResolution of Velocity Data (0.032 +/- 0.164) ft/s
Resolution of Force Data (.1 +/- .2) lbf Resolution of Distance Data (3/8 +/- 1 7/8) in
Resolution of Time Data (0.001 +/- 0.01 s)
Setup Time (By User) < 30 min
Can Test Different Models and Hydrofoil Sets > 2 sets
Compliance with Accepted Safety Protocols and Regulations In Compliance with All Standards
Tank is Designed so Model is Not Restricted in its Motion
Tank does not Interfere with Model
Tank assembly does not damage its surroundings Tank causes no Damage
Training Time (1st Time) < 60 min http://engineeringmyfuture.webs.com/
PROJECT TIMELINESept 11
• Planning: Customer Needs & Engineer Specs
Sept 11• Concept Development: Brainstorm, Concept Evaluation
Oct 11• System Review: Pool vs. Tank, System Architecture
Nov 11• Detail Design Review: BOM, Feasibility Analysis
Dec 11Jan 12
• Manufacturing: Mini-Tank, Full Scale Tank
Feb 12• Testing: Functionality, System Interaction
Feb 12• Final Product: Delivery, Final Presentation
Proposed concepts for the tank materials.• Wood structure and
wood panels• Steel structure and
wood panels• Steel structure and steel
panelsProposed concepts for rails and cart• Angle iron rails and skate
bearings• 80/20 linear motion
system• Machined bottom
supported rail
CONCEPT GENERATION
ANALYSISForces applied
• Hydrostatic Force at maximum height
• Point load of 200 lbf (889.64 N)
Constraints• Deflection: 1/32”
(7.94e-4 m)• Yield Stress: 50 ksi
(345 Mpa)
Dimensions [in] FOS Stress FOS DeflectionAngle Iron 2x2x.125 (Length) 6.42 2.25
Length with -100lbf point load 0.67 0.28Length with +100lbf point load 0.83 0.37
Angle Iron 2x2x.375 with 2x2x.25 20.45 9.64Length with -100lbf point load 4.39 1.93Length with +100lbf point load 6.34 3.09Length with -200lbf point load 2.38 1.06Length with +200lbf point load 2.85 1.34
FINAL DESIGN• 3/8 in (9.525 mm) thick, 2” SQ. (5.080 cm)
Angle iron• 1/4 in (6.350 mm) thick, 2” SQ. (5.080 cm)
Angle iron• 3/4 in (19.050 mm) thick Plywood• 16 feet (4.877 m) long 80/20 Aluminum • 3/4 hp (559.270 w) Motor• 1/16 in (1.588 mm) diameter Aircraft Cable• 6 in (15.240 cm) diameter Pulleys
• Tanks dimensions: 16 feet (4.877 m) long, 2.5 feet (0.762 m) wide, and 2 feet (0.610 m) high.
• Max cart towing velocity: 3.21 ± 0.10 ft/s (0.950 ± 0.025 m/s)• Max volume of water: 599 US gallons (2,265 L)• 2 modular pieces, capable of being disassembled, moved, and
reassembled by 2 people
FINAL PRODUCT
• Velocity Range• Distance Accuracy• Start Up Transients• Cable Wear
TESTING TECHNIQUES & DIFFICULTIES
TESTING RESULTS
BUDGET
http://shannonpenrod.wordpress.com/2010/06/29/money-makes-the-world-go-around/
Tank QTY COST Tank Walls 23/32" Plywood - 4' x 8' Sheets 4 $87.48 Tank Walls 23/32" Plywood - 4' x 8' Sheets - Mini-Tank Design 1 $21.87 Tank Walls #10 x 1in. Flat Head Phillips Drive Wood Screw (100 pcs) 1 $21.87 Tank Support 2" x 2" x 1/4" Steel Angle - 22-7/8" LG. - Mini Tank & Large Tank 4 $87.48 Tank Support 2" x 2" x 1/4" Steel Angle - 25-3/4" LG. 2 $43.74Motor DC Motor Motion Transfer from Motor 1 $0.00 DC Drive Speed control and Power Supply 1 $0.00 Speed Sensor Feedback loop to DC driver 1 $0.00Motion System 1/16" Cable Wire Rope - Aircraft Cable 1/16", 7x7, by the foot 100 $13.00 Drive Pulley Transfers Motion 1 $9.16 Pulley Pulley with plain bronze bearings 1 $10.50Rail and Platform Length Rails 1" x 1" T-Slotted Extrusion 2 $64.88
Width Rails and Supports 1" x 1" T-Slotted Extrusion-97" 1 $29.08
Initial Budget: $2,000Expanded Budget: $2,500
Final Expenses: $2,169.05
• Waterproofing plywood
• Liner management
• Leak detection
• Tow cable management
• Safety
CHALLENGES
CONCLUSIONS
Customer Needs and Objectives
Importance Description How its being Accomplished Comments
Tank size meets specificationMotor Speed controlled with driverDriver has different speed ranges
Calculated from F=ma+Fdrag Need was removed by customerTank size meets specification
Tank weight is below required by floorInterface allows for different attachments
Tank size meets specification
Tank length = 16ftCart cannot travel full 16 ft, because of
boom arm lengthDriver will control speed and accel/decel
can be set for 0-30secTank size meets specification
Total approximate weight = 150lbsCalculated from F=ma+Fdrag
CN5 3Platform should be above or to the side of the water with no
moving parts under waterCart has multiple attachment points
CN6 9Platform must allow for bolting of
the instrumented model away from the wall of the tank
Cart has multiple attachment points
Encoder, DC driver speed sensor Labview motor control needs attention
Deflection calculations performed in ANSYS
Measurement device should match specification
DC drive accuracy ± 1/2 rpm, encoder mounted
Measurement device should match specification
Measurement device should match specification
Timed in Labview
CN8 9The tank must be safe for the
operator and those around themErgonomics was considered in the height of
tank
CN9 9The tank must not damage the
surroundingsMembrane or sealant will be used to stop
leaksLiner does not satisfy concerns on leak
prevention
CN10 3 The tank must be cost effective Cost meets budgetWent over initial budget of $2000, but
stayed well under secondary budget of $2500
Labview useability will be a priorityIn process of creating Labview
DirectionsUsers Manual / Video will be provided
CN12 9Tank should not interfere with
operation of modelsP12463 is aware of the size constraints
Needs were removed by customer
CN7 9
Measurements should be of high quality and should be made with appropriate sampling rates and
resolution
CN11 3 Easy to use and to train new users
CN3 9Tow length needs to be large
enough to achieve steady state
CN4 9System size should allow for appropriately scaled model
testing
CN1 9
Tow tank must be able to tow a platform above the surface of a
stationary body of water at a constant speed
CN2 3The platform must allow an attachment of two different
instrumented systems, a set of
http://flowers.cdd5.com/showthread.php/amigo-semaforo/
1) Upgrade the plastic liner to a more durable material.2) Upgrade tow cable and/or drive pulley.3) Place windows in the tank walls to allow in water visibility. 4) Upgrade the plywood panels (walls) to sheet metal panels or glass panels5) Improve rail mounting to tank
FUTURE UPGRADES
http://www.pondlineronline.co.uk/
• EPA P3• Dr. Mario Gomes• Prof. Ed Hanzlik• Prof. John D. Wellin• Dr. Steven Day• Kelsey McConnaghy• Rob Kraynik• Jan Maneti• Dave Hathaway• FMS• Mahany Welding Supply
ACKNOWLEDGEMENTS
QUESTIONS
http://fhalosangeles.net/first-time-buyer-questions/