11/9/2012 p13263 – hybrid engine test...

11/9/2012

P13263 – Hybrid Engine Test Stand Detailed Design Review Packet

Team Steam

Table of Contents

Test Stand Assembly ........................................................................................................................ 1

Family Tree ........................................................................................................................................ 2

System Architecture ........................................................................................................................ 3

MSDI Gantt Chart ............................................................................................................................ 4

MSDII Gantt Chart ........................................................................................................................... 5

Mechanical Drawings ................................................................................................................ 6-30

Fan Size Calculations .................................................................................................................... 31

Systems Wiring Diagram ............................................................................................................... 32

DC Motor Driver Diagram ............................................................................................................ 33

DC Motor Load Calculations ....................................................................................................... 34

Electrical Schematics ............................................................................................................... 35-40

Control Board Layout ................................................................................................................... 41

LabVIEW Pseudocode .................................................................................................................. 42

Assembly Manual (Working Document) ................................................................................... 43

Operations Manual (Working Document) ................................................................................ 44

Test Plan (Working Document) .................................................................................................... 45

P13263

Hybrid Gasoline/Steam Engine DDR Schedule

Date, Time, Location: Friday 9 November, 11:00AM, 09-44335

11:00AM to 11:10AM -Intro project/Project overview 11:10AM to 11:40AM -Mechanical (support, engine/generator coupling, engine control, sensors)

(may be topic of interest for Professor Humphrey and Phil Vars)

11:40AM to 12:20pm -Electrical (control system/digital logic, power systems, data acquisition)

(may be topic of interest for Professor Wellin and Professor Slack)

12:20pM to 12:30pm -wrap up

Information: Is available on our EDGE website: https://edge.rit.edu/edge/P13263/public/Home

https://edge.rit.edu/edge/P13263/public/Home

Hybrid Engine

Test Stand

Test Fixture

Mechanical

Rigid Support

Engine-

Generator

Coupling

Consumable

ManipulationSensors

Thermocouple Beam Interruptor

Electrical

Control System

Digital Logic

Power

Computer

Interface

Software

Front End GUIBack End

Calculation

Data Acquisition

National

Instruments -

GPIO

Omega -

Thermocouples

5 HP, 4 stroke

Internal

Combustion

Engine

Laptop w/

Labview

Thermocouples

Solid State

Relay(s)

Stroke

Sensor

120V 60Hz

AC

Graduated

Cylinder

(Fuel Tank)

Relay

Exhaust

Valve

Intake

Valve

Direct

Injector

H2O Tank w/

in-tank

120PSI Pump

X1 Signals

8-input,

2-output

DAQ

X1 Signals

X3

X2 Signals

Legend

Mechanical Link

Electrical Hookup

Sensor Signals

Engine Mods / Additions

Control Signals

10HP, PMDC

Electric

Generator

3kW

HeaterCoupling

TDC

Detector

UTC-

USB

USB

Controller

x3

DC Power

Supply (3.3V,

5V, 12V)

5V

Remote

Start / Load

System

X6 Signals

x2X2

x2

USB

12V, 5V

12V

Project Scope

X4 Signals

x1

x3

Shunt

Resistor

Voltage

Dividers

Encoder

Switching

Throttle

/Choke

ID Task Name

45 Project Management Review

44 Detailed Design Review

11 Detailed Design

43 Design Engine Mount

42 Debug Controls

41 Design Locations for Circuity

40 Update Customer Needs/Constraints/Specs

39 Design location for bug box with controls

37 Design mounting pad and wires for external heaters

38 Design Fuel Delivery Systems

36 Design mount for the laptop

35 Design location for fuel and water tank

34 Design Safety Enclosure

33 Design Water Delivery System with dummy injectors

32 Design Power Electronics

31 Outline MSD II Plan

30 Outline Test Plan

29 Outline Operations Manual

28 Outline Assembly Manual

27 Annotate Wire Harnesses on Stand

26 Design Wire Diagrams

25 Design Systems Level Drawings

24 Design Throttle and Choke Control

23 Update the bill of materials

22 Acquire computer with LabView

21 Design data acquisition VI (GUI + "driver") [Not building in LabView]

20 Choose DAQ to observe and record

Joe

Dave

Joe & Tim

Matt & Tim

Joe & Tim

Matt

Joe

Matt

Joe

Dave

Dave

Matt

Trevor

Tim & Trevor

Dave & Matt

Tim & Joe

Tim & Dave & Joe

Matt

Dave & Matt

Dave

Trevor

Dave

Tim & Dave & Joe

26 2 9 16 23 30 7 14 21 28 4 11 18

Sep '12 Oct '12 Nov '12

Task

Split

Milestone

Summary

Project Summary

External Tasks

External Milestone

Inactive Task

Inactive Milestone

Inactive Summary

Manual Task

Duration-only

Manual Summary Rollup

Manual Summary

Start-only

Finish-only

Deadline

Progress

Page 1

Project: HybridEngineGant Chart

Date: Mon 11/5/12

ID Task Name

19 Design Motor Output Coupling to Load

18 Select & Design Engine Load

17 Design Shaft Encoder

16 Choose Temperature Sensors and decide where to place

13 Benchmark Stock Engine

15 Build a temporary engine mount for prelim testing

14 Acquire gas tank

12 Calculate Thermo Expansion Rates

8 Systems Design

10 Systems Architecture

9 Pugh Matrix

6 Concept Development

7 Functional Decomposition, Brainstorming

2 Project Planning

5 Constraints

4 Engineering Specifications

3 Customer Needs

1 MSD I P13263

Joe & Matt

Dave & Tim

Trevor & Matt

Trevor

Joe & Dave

Tim

Joe & Trevor

26 2 9 16 23 30 7 14 21 28 4 11 18

Sep '12 Oct '12 Nov '12

Task

Split

Milestone

Summary

Project Summary

External Tasks

External Milestone

Inactive Task

Inactive Milestone

Inactive Summary

Manual Task

Duration-only

Manual Summary Rollup

Manual Summary

Start-only

Finish-only

Deadline

Progress

Page 2

Project: HybridEngineGant Chart

Date: Mon 11/5/12

Power supply

Control Circuit

120 VAC

5V

DAQ-1

6 stroke en

ablerese

t

Encoder

Piston

po

sInjection

pt.

Intake indicator to oscope

Exhaust indicator to oscope

P0.0

P0.1

5V

P0.2

SSR-15V

P0.3

12VSM-1

DC Motor driver

P0.4P0.5P0.6P0.7P1.0

12V 5V

DS B1.0DS B1.1

DS B1.2DS B1.3

DS B1.5DS B1.4

DS B1.7DS B1.8

DS B1.6

120VAC

J2.0

J7.0 J7.3

J2.2

J1.3

J1.1

J3.1

J3.3

J3.2

12V

J1.2

J5.2

J5.1

J5.3

J6.1

J6.3

J8.1 J8.2 J8.3

J4.3

J4.1

Signal Conditioning

DESCRIPTIONDESCRIPTIONDESCRIPTION

P13263/System Wiring Diagram

H1

H2

H3

DS B2

H7

Isolated GND

GND rtrn for indicator signals

SSR-2

Connection Legend

= soldered conection

= free hanging wire

injector

12V

5V

H6

H5

H8

SS-1

Lap Top

USB-H1USB

USB

1

2

3

4

Tem p sensor 1

Tem p sensor 2

Tem p sensor 3

H4J4

J3

J1

J2

J7

DS B1

J5

J6

J8

+ -

+

-

SI G

+

-

-

+

SI G SI G

J9.1 J9.2J9

H9

GND

Heater Load

= bolted to chassis

= connector

Shunt Resi stor (R7)

P1.3

SSR-3

5VWater Pump

12V

J10.1

J10.2

J10H10

Note: wiring is 20a wg unless otherwise spec ifi ed

DESCRIPTIONDESCRIPTION

P13263/DC Motor Driver

Connection Legend

= soldered conection

= free hanging wire

= bolted to chassis

= connector

XFRM-1

MDC-1

BR-1

SR-6

SR-5

SR-4

SR-7

120VAC

48 VAC 48VDC

S1

A2 A1

S2

= bolted connection

5V

SR-8

12V

H5

J5

H5.1 H5.2 H5.3

To Heater Load

= 22AWG wire

= 4 AWG wire

= 16 AWG wire

Electric Load for DC Motor

Initial Load Plan

- Initial idea was to use light bulbs to load the motor

- It was then realized that any 110V appliance will only apply about 40% of its rated power

consumption to our 72V system

- We are looking to apply 1500W of load, this is equal to half our engines power output

o That’s a lot of light bulbs

Current load plan

- The we found a household space heater consumes 1500W at 110V

o In our system:

→

→ R=8.06 Ω

Therefore: We can use two 1500W (ideally one 3000 W heater ) space heaters to provide

our engine with a 1285.2 W load. 1285.2W will provide us a sufficient load just

under half the peak power output capability of our gas engine (gas engine can

output 3700 W).

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

IntakeValveControl

WaterInjectionControl

SixStrokeEnable

Reset

StrokeIndicator

InjectTrigger

ExhaustValveControl

0

0

0

Title

Size Document Number Rev

Date: Sheet of

ECU-001 0

Motor Controller

B

1 1Tuesday, November 06, 2012

Title


Date: Sheet of

ECU-001 0

Motor Controller

B


Title


Date: Sheet of

ECU-001 0

Motor Controller

B


U4D

CD4081B

U4D

CD4081B

13

12

11

U5C

CD4071B

U5C

CD4071B

8

910

U4C

CD4081B

U4C

CD4081B

8

910

U7A

CD4071B

U7A

CD4071B

1

23

U4B

CD4081B

U4B

CD4081B

5

64

U6C

CD4081B

U6C

CD4081B

8

910

U8A

CD4013A

U8A

CD4013A

SE

T6

D5

CLK3

Q1

Q2

RE

SE

T4

R3

1MSET = .5

R3

1MSET = .5

U3C

CD4081B

U3C

CD4081B

8

910

U6A

CD4081B

U6A

CD4081B

1

23

U7BCD4071BU7BCD4071B

5 64

U2B

CD4009A

U2B

CD4009A

5 4

U5D

CD4071B

U5D

CD4071B

13

1211

U3A

CD4081B

U3A

CD4081B

1

23

U1B

CD4013A

U1B

CD4013A

SE

T8

D9

CLK11

Q13

Q12

RE

SE

T10

U1A

CD4013A

U1A

CD4013A

SE

T6

D5

CLK3

Q1

Q2

RE

SE

T4

U2C

CD4009A

U2C

CD4009A

7 6

U3D

CD4081B

U3D

CD4081B

13

1211

U5B

CD4071B

U5B

CD4071B

5

64

U2D

CD4009A

U2D

CD4009A

9 10

U4A

CD4081B

U4A

CD4081B

1

23

U2E

CD4009A

U2E

CD4009A

11 12

U2A

CD4009A

U2A

CD4009A

32

U6D

CD4081B

U6D

CD4081B

13

1211

R11kR11k

C2

1n

C2

1n

U3B

CD4081B

U3B

CD4081B

5

64

V1

5V

V1

5V

C1

1u

C1

1u

U9A

CD4081B

U9A

CD4081B

1

23

U6B

CD4081B

U6B

CD4081B

5

64

U5A

CD4071B

U5A

CD4071B

1

23

Date/Time run: 11/06/12 19:43:47

** Profile: "SCHEMATIC1-tewst" [ E:\RIT\Senior Design\PSpice Sims\SimulationFiles-PSpiceFiles\SCHEMATIC...

Temperature: 27.0

Date: November 06, 2012 Page 1 Time: 19:44:36

(A) tewst.dat (active)

Time Time

0s 0.2s 0.4s 0.6s 0.8s 1.0s

SIXSTROKEENABLE

STROKEINDICATOR

RESET

INJECTTRIGGER

INTAKEVALVECONTROL

EXHAUSTVALVECONTROL

WATERINJECTIONCONTROL

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

CD4504

1-Vcc

2-Aout

3-Ain

4-Bout

5-Bin

6-Cout

7-Cin

8-Vss

16-Vdd

15-Fout

14-Fin

13-Select

12-Eout

11-Ein

10-Dout

9-Din

OPB917BZ

Anode

Cathode

Vcc

Out (TTL)

GND

OPB917BZ

Anode

Cathode

Vcc

Out (TTL)

GND

InjectTrigger

StrokeIndicator

D-sub HarnessD-sub Harness

D-sub HarnessD-sub Harness

Inside Controls BoxOutside Controls Box

StrokeIndicator

InjectTrigger

5Vdc

GND

5Vdc

GND

InjectTriggerTTL

StrokeIndicatorTTL

InjectTriggerTTL

StrokeIndicatorTTL

0

VCC_BAR

Title


Date: Sheet of

ECU-002 0

Optical Encoder Input Level Shifting

A


Title


Date: Sheet of

ECU-002 0


A


Title


Date: Sheet of

ECU-002 0


A


R5

180

R5

180

R4

180

R4

180

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

National Instruments

1-GND

2-AI0

3-AI4

4-GND

5-AI1

6-AI5

7-GND

8-AI2

9-AI6

10-GND

11-AI3

12-AI7

13-GND

14-AO0

15-AO1

16-GND

17-P0.0

18-P0.1

19-P0.2

20-P0.3

21-P0.4

22-P0.5

23-P0.6

24-P0.7

25-P1.0

26-P1.1

27-P1.2

28-P1.3

29-PFI0

30-+2.5V

31-+5V

GND

USB Interface

To PC

MiniFit

1

JXPX

2

1

2

3 3

D-sub Harness. doesnt really need MiniFit

SixStrokeEnable

Reset

SM-1 J3.2

12Vdc

GND

5Vdc

Vgen

Ishunt

Vload

XfmrON

JumpStart

LoadOn

5VdcLoadOn

Vload

Ishunt

0

0

Title


Date: Sheet of

ECU-003 0

National Instruments DAQ

A


Title


Date: Sheet of

ECU-003 0


A


Title


Date: Sheet of

ECU-003 0


A


RL

4

RL

4

R6

270k

R6

270k

SSR-1

Relay

SSR-1

Relay

S

LS-1

SolenoidS

LS-1

Solenoid

1

3

R9

10k

R9

10k

SSR-4

Relay

SSR-4

Relay

Rshunt

.5m

Rshunt

.5m

5

5

4

4

3

3

2

2

1

1

D D

C C

B B

A A

Mains to 12V, 5V DC

D-sub Harness

GND

12Vdc

5Vdc

MiniFit

1

J1P1

2

1

2

3 3

D-sub Harness

HOT

Neutral

EMR

HOT

Neutral

EMR

Mains

GND5Vdc

Reset

StrokeIndicatorTTL

IntakeValveControl


SixStrokeEnable

InjectTriggerTTL

ExhaustValveControl

5Vdc

12Vdc

GND


12Vdc

5VdcXfmrON5VdcJumpStart

Vgen

0

0

Title


Date: Sheet of

ECU-004 0

Power Electronics

A


Title


Date: Sheet of

ECU-004 0

Power Electronics

A


Title


Date: Sheet of

ECU-004 0

Power Electronics

A


SSR-3

Relay

SSR-3

Relay

DSB1A

CONN ASY DSUB

DSB1A

CONN ASY DSUB

1A2A3A4A5A6A7A8A9A

~

~

+-

V2

BRIDGE

~

~

+-

V2

BRIDGE

SSR-X

Relay

SSR-X

Relay

S

Inj

H2O InjectorS

Inj

H2O Injector

1

3

SSR-2

Relay

SSR-2

Relay

TX1TX1

+ C410mF

+ C410mF

+ C310mF

+ C310mF

Initialize Program Open Ports Create/open CSV file Set 4 cycle mode signal low Enables 4 cycle valve digital logic Set 6 cycle mode signal high Disables 6 cycle valve digital logic Set specified sample rate Set specified throttle % Pulse width modulation Data acquisition Read temperatures x3 thermocouples with signal conditioning Read TDC / RPM sensor LED/ Photodiode (encoder) Read crank position LED/ Photodiode (encoder) Read load voltage A VA Read load voltage B VB Calculate power P = (VB * VA / RS)*G^2 RS = Shunt resistance G = Negative gain Store and display data Store RPM, temp, & power data into arrays Display data in GUI Automatic engine start sequence If (Start button signal high & RPM < 10)

Set transformer relay signal low Set throttle to 80% Pulse width modulation Set choke relay signal low Wait 1s Set motor power relay signal low Wait 3s OR RPM > 500 Set transformer relay signal high Set motor power relay signal high Set choke relay signal high Set specified throttle % Pulse width modulation

If (water cycle button is pressed) Set 4 cycle mode signal high Disables 4 cycle valve digital logic

Set 6 cycle mode signal low Enables 6 cycle valve digital logic Store and display data Store data into arrays Display data in GUI Done Save data to CSV file Close ports

1

Hybrid Engine Test Stand

Assembly Manual

Outline

P13263

11/7/12

(CAD of Final Test Stand)

2

Parts List (See Bill of Materials)

Hardware

‐#2 Wood Screws 8 x 2.5” (quantity 50)

‐10‐32, 1.25” long cap bolts

‐3/8”‐16, 1” long bolts

‐3/8”‐16, 1.5” long bolts

‐3/8”‐16, 6.5” long bolts

‐3/8”‐16 hex nuts

‐10‐32 hex nuts

Materials

‐Wood 2 x 4 at ___” total length required

‐Aluminum Base Plate 0.5” thick, 12” wide, and 26” long

‐8” x 8” x 0.25” 1018 Steel Plate

‐1” square aluminum bar stock

‐Transformers and transformer base plate

‐Kohler CH5 single cylinder gasoline engine

‐D&D Motor Systems Inc. 10 HP DC Motor, model # ES‐15‐26

‐Box Fan

‐Bud box

‐Power supply

‐Transformer plate

‐Transformers (large and small)

‐Water Injector

‐Water Tank

3

‐Gas Tank

Tools

‐5/8”‐18 tap

‐10‐32 tap

‐Vertical Mill

‐Lathe

‐Water cutter

‐Various end mills and drills

‐Various hand tools

Mechanical Component Sub‐Assemblies

Wood Base Assembly

‐Cut wood to required length of…

Motor Bracket Assembly

‐See Mechanical drawings to machine motor brackets 1, 2 and base

‐Use calipers to scribe a line down the center of both motor bracket base plates

‐Constrain motor bracket 1 and one of the motor bracket base plate’s perpendicular along scribed

center line and weld together

‐Repeat for motor bracket 2 assembly

Shaft Encoder Assembly

Injector Assembly

‐Fittings to water tank

Motor Alignment Mounts

4

5/8”‐18 Coupling Threading

Electrical Component Sub‐Assemblies

Mount Transformer

‐Secure small and large transformer to transformer base plate with 10‐24 bolts and nuts (4 each)

Bud Box

‐Assemble control circuitry

Test Stand Assembly

Securing Base Plate to Wood Base

‐Wood screw

‐Anchoring 3/8”‐16 bolts

Fasten Motor to Base Plate

Fasten Engine to Base Plate

Motor Alignment Mounts

Fasten Motor Brackets

Mount Gas and Water reservoir

Engine to Motor Coupling Assembly

5

Encoder Bracket Adjustment

Plexiglas Top

Wood Sides

Box Fan

Front Door and Hinge Assembly

Test Stand Wiring

Create system wire harness

‐Reference system wiring schematic and build harness with male ends of mini fit junior connectors on

harness end and female connectors on component end of system

Hybrid Gasoline Steam engine Test Stand Operations Manual

Model: Steamer 1.0

Contents Getting Started Saftey Coupling your engine with the test stand LabView user interface Adjusting engine timing Collecting data

Getting Started Congratulations! You are now the owner of the Steamer 1.0, an engine test stand with the capabilities of testing a hybrid gasoline/steam engine.

Safety Safety precautions should always be taken when working with or around the Steamer 1.0. Recommended safety equipment: -Safety glasses -Ear plugs or ear muffs -Gloves if interacting directly with engine

Coupling your engine with the test stand -the Steamer 1.0 uses the Kohler CH5 mounting hole pattern -mount engine to mounting plate using the provided hardware -attach fuel supply plumbing using provided hose fittings

LabView User Interface -the Steamer 1.0 is set up to interact with SteamerVeiw, a program written to interface with your hybrid steam engine -stall the SteamerView software on a LabVeiw enabled computer -use the standard USB 2.0 provided to connect the USB hub to the computer -the GUI will walk you through the rest of the set up

Collecting data -The SteamerVeiw software is designed to automatically collect data every time the engine is started, this ensures that every occurrence of your hybrid engine is captured

Adjusting engine timing -once you engine is properly installed on the test stand the timing can be adjusted manually by adjusting the light blocker disk

Project: Hybrid Engine Test Stand

Revision #: 6

Spec. # Source Specification (metric)Range of Values

Comments/Status Test Mode Procedure

S1 CN1 Measure engine shaft output power [W] 0 - 7400 measure up to 10 HP Analyze Root Mean Squared Error Analysis of Components used in CalculationsS2 CN1 Measure exhaust temperature [°C] 0 - 500 315C ~ upper limit Observe Verify thermocouple accuracy is rated within precision on the spec sheetS5 CN1 Measure/Calculate water input flow rate [litre/hour] 0-5 est 1.7L/h Test Run engine on hybrid mode and measure water consumed for designate timeS6 CN1 Measure/Calculate fuel use [litre/hour] 0-5 accurate Test Run engine on hybrid mode and measure fuel consumed for designate timeS7 CN1 Measure air input temperature [°C] -10 - 35 accurate Observe Verify thermocouple accuracy is rated within precision on the spec sheetS8 CN1 Sample test data [Hz] 840-20,000 at least 1 order mag > engine hz Observe Verify that output data contains data points for appropriate sample rateS9 CN2 Digitally store test data [MB] .1-100 Demonstrate Run the test stand and verify the file sizeS10 CN3 View test data in GUI Demonstrate Run the test stand and verify the GUI loads and outputs current data pointsS11 CN5 Control water input flowrate [kg/s] 0-3.7L/h assume idea value is 1:1 water:fuel Test Compare water consumed to fuel consumed during the testS12 CN4 Store at least 500mL of water .5-3.7 1 gallon is too large Observe Water tank can hold at least rated volumeS13 CN6 Store at least 50mL of fuel .5-3.8 1 gallon is too large Observe Fuel tank can hold at least rated volumeS14 CN4 Test Stand can securely support 2x engine weight [kg] 40-50 2 piece standS15 CN7 Measure cylinder temperature 0 - 500 accurate Observe Verify thermocouple accuracy is rated within precision on the spec sheetS16 C5,CN10 Loaded stand cannot be heavy [kg] 30-150 Reasonable weight for 2 people to pushS17 C6,C7,CN10 Stand width < door width [m] .61-.91 3 ft door width Demonstrate Pass test stand through a doorS18 C6,C7,CN10 Stand length < door height [m] 0.31-2.07 next largest length, keep under 5 ft Demonstrate Pass test stand through a doorS19 CN9 Provide mechanical interface for Kohler CH5 engine Demonstrate While system is runningS20 CN8 Powered by 120V 60Hz RMS source Test Device runs off of a single breaker. Use a power meter to confirm below 20A

Spec. #: enables cross-referencing (traceability) and allows mapping to lower level specs within separate documentsSource: Customer need #, regulatory standard (eg. EN 60601), and/or "implied" (must exist but doesn't have an associated customer need), constraintDescription: quantitative, measureable, testable details*This table can be expanded to document test results

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