PowerPoint Presentation

Adam HertzlinDustin BordonaroJake GraySantiago MurciaYoem Clara

P14651: Drop Tower for Microgravity Simulation Week 3 Review Open ItemsHow many pumps are needed?Benchmark NASA Drop Tower componentsResearch designs to hold vacuum pressureDetermine location for Drop TowerCreate working design w/o cost considerationsMeet with DeansMeet with Grad StudentsAgendaBackgroundProblem StatementStakeholdersCustomer RequirementsEngineering RequirementsSystem AnalysisRequirements MatrixBenchmarked ComponentsFunctional AnalysisConcept and Architecture DevelopmentEngineering AnalysisRisk AssessmentTest PlanNew Focus as of Sep 30BACKGROUNDProblem StatementCurrent StateEx) NASA Space Flight Center100 meter 4.5 sec dropUltimate Pressure: 10-9 TorrLimited VisibilityDesired StateP14651 Drop Tower9-12 meter ~ 1.5 sec drop15-30cm diameter tubeObject visible during dropContinuous Lift / Release SystemAppropriate pump(s) for required pressureEducational and fun for all agesProblem Statement ContdProject Goals:Fast Cycle TimeCost efficientAesthetically pleasingPrecision in measurements (1% estimation of standard gravity)Adaptability for multiple / future usesMinimal vacuum loss Constraints: Location and design approval from the Dean(s).Material availability/size (ex. tube, pump)Budget $3,000

Additional DeliverablesUsers Guide for operationDesigned Lab Experiments:Determine gravity in the vacuum within 1% errorCompare drag at different pressures and drag vs. accelerationAdditional vacuum related experiments

Project Stakeholders

Dr. Kandlikar

MSD Team

Middle School StudentsRIT Graduate and Undergraduate Students

RIT Faculty

RIT Prospective Students

RIT College Dean(s)Middle School Teachers

8Customer NeedsImportanceDescription9Minimal Down Time of Tower9Clear Visibility of Entire Drop9Capable of Dropping more than (1) object9Educational, but exciting for middle school students9Calculate Drag Coeffecient9Calculate Gravity (within 1% error)9Effective Data Collection9Safety3Maximum Justified Drop Tower Height 3Multiple Use Capabilities3Intuitive Operation3Adjustable Pressure (Atmospheric to High Vacuum)3Minimize Production CostEngineering SpecificationsImportanceMain Source Engr. Requirement (metric)Unit of MeasureComments/Status9CR7Measure Relative Object PositionmWith postion/time sensor9CR7Measure Relative Object Drop TimesecWith postion/time sensor9CR12Measure PressurekpaPressure gage9CR1Cycle Run TimeminTime from one test to another9CR1Continuous Lift MechanismYes / NoTower runs on its own9CR10Pressure Leak Rate Minimizedkpa / secSeal all gaps9CR14Aesthetic Structure with SupportsYes / NoVisually Pleasing, permanent structure9CR7No Horizontal MotionmmNo horizontal motion3CR9Tower HeightmTall as possible in chosen location3CR3Tower Cross - Section (Diameter)cmAvailaility and least view distortion3CR12Pump Flow Ratem3/secValue determined by tube size and desired time3CR7Measure TemperatureCelciusThermocouples, inside or outside environmentSYSTEM ANALYSISRequirements Matrix

Benchmarked ComponentsMicrogravity DeviceExisting TechnologiesDescription/NotesFeasibilityPictureNASA Marshall Space Flight Center (100m drop~4.5sec)1) Detachable Base2) Isolation Valves 3) Drop Tube 4) Vacuum Pumps 5) Control Panel 6) Gaskets/ Connections 1) Detachable base has integrated catch system, and is attached via CAM locks 2) Isolation valves allow for section off of pipe sections 3) Multiple vacuum pumps for uniform vacuum within the tube, roughing pumps for starting from atmospheric pressure and turbo molecular pumps for higher vacuum1) Good feasibility of detachable base and CAM locks 2) Isolation valves may not be feasible for budget constraints 3) Vacuum pump feasibility depends upon pump availability and budget constraints due to high cost of turbo molecular pumps 4) We can use the same surface finish and gasket material potentially in our designNASA Zero Gravity Research Facility (132m drop~5.18sec)1) Inside 142m long 6.1m diameter vacuum chamber 2) 5 Stage Vacuum Pump Process 3) Overhead Crane 4) Release Mechanism 5) Catch Mechanism1) Vacuum reaches 0.05 Torr. 2) Drag is reduced to less than 0.00001g 3) ~ 1 hour to evacuated chamber 4) Experiment vehicle protects hardware 5) Catch mechanism is composed of polystyrene beads which dissipate the 2500 lb. experiment vehicle's kinetic energy1) Catch mechanism/beads could be a possible solution

Benchmarked Components ContdMicrogravity DeviceExisting TechnologiesDescription/NotesFeasibilityPictureNASA Glenn Research Center (24m drop~2.2sec)1) Drag Shield System 2) Rectangular Frame 3) Lift Mechanism 4) High Speed Cameras 5) Airbag Catching System1) Drag shield removes air resistance 2) Airbag dampens force of impact and protects components 3) Cameras and onboard computer monitor drop1) Drag shield is not feasible, we are using a vacuum tube 2) Lift mechanism may have possible similarities 3) Catching system may not work in a vacuum environmentDryden Drop Tower (22.2m drop~2.13 sec)1) Cable Guided Drag Shield 2) Open Enclosure 3) Magnetic Field/Eddy Current Deceleration 4) Air Collet Release Mechanism 5) Single Floor/ Single Person Operation 6) Aesthetically Pleasing 7) Usuable for PSU students, grad students, and k-12 level activities Tower height is 31.1m 2) Can routinely drop in 10 minutes 3) Deceleration takes 3.5m 4) Automated retrieval takes 5 min1) Can take design cues for aesthetics 2) Could use some ideas for educational aspect for students, grad students and k-12 3) Release mechanism could have merit 4) Deceleration method probably not feasible

Functional Decomposition

Morph ChartPossible Solutions#Components123451Break Door SealRelease Lever ClampUndo BoltsUnscrew Cap--2Close Isolation ValveManual PnematicElectrical-None3Carry Object to Tower TopWalk UpstairsThrow ObjectPulley SystemElevatorNone4Supply PowerElectricalBatteryNatural Gas-None5Hoist DeviceClaw & CableCapsule GrabberSlingshotRobotic ArmNone6Release PlatformShaped Platform----7Seal DoorsLever ClampBoltedPipe Cap Screw--8Seal ValvesPTFE TapeMelting Together---9Seal PipingSealant CompoundMelting TogetherSilicon Seal--10Close ValveClose/Open Level ArmTwist ValveCheck ValveElectrical Power Valve-11Vacuum Pressure GageDigital-High VacuumAnalog Display---12Thermo CoupleWire TypeInfered Sensor---13Position/Time Sensor

Laser SensorMotion SensorsStop Watch / RulerVideo Tape -14Release MechanismMagnetDoors---15Damping MaterialNetRubberGelSpring Locking Device-16Open ValveClose/Open Level ArmTwist ValveCheck ValveElectric Valve-17Tower Anchoring SystemDrill into WallsConnecting to RailingAttach to CeilingAll-18Tower BaseTee w/ Removable CapDetachable Base (NASA)Door Base--Morph ChartPossible Solutions#Components123451Open ValveLever ArmTwist ValveCheck ValveElectrical ValveNone2Break Door SealRelease Lever ClampUndo BoltsUnscrew CapNone3Isolate Tube SectionManual I.V.Pneumatic I.V.Electrical I.V.None4Seal DoorsRelease Lever ClampUndo BoltsUnscrew CapNone5Seal ValvesPTFE TapeMelting TogetherNone6Seal PipingPipe Sealant CompoundMelting TogetherSilicon SealNone7Close ValveLever ArmTwist ValveCheck ValceElectrical Power ValveNone8Turn Pump OnMechanical SwitchThrough Software9Grab ObjectMagnetClawAngled Platform10Supply PowerElectricalBatteryNatural GasNone11Vertical LiftMagnetCapsulePlatformNone12Center ObjectMagnet LocatorCapsule LocatorShaped PlatformNone13ReleaseMagnetDoor HatchNone14Pressure GageDigital-High VacuumAnalog DisplayNone15Thermo CoupleWire TypeInfrared SensorNone16Position/ Time SensorVertical SensorMotion SensorsStop Watch / RulerCameraNone17Damping MaterialNetPlasticGelSpring Locking DeviceNone18Tower Anchoring SystemDrill into WallsConnect to RailingAttach to CeilingAllNoneCONCEPT & ARCHITECTURE DEVELOPMENTEarly Concept Draft

BaselineIdealCheapFeasibleRandomPughs Matrix Component ConceptsPughs MatrixIteration #1CriteriaBaselineIdealCheapFeasibleRandomNo horizontal motion during free-fallDATUMsss-Vacuum environmental control+ss-Fast cycle time+--sData accuracy+-s+Properly restrained+-+-Aesthetically pleasing+-s+Low cost-++-Can be done in 2 semesters-s-sEducational and fun+-ss# of operators+s+s5-41-22CriteriaBaselineIdeal CheapFeasibleRandomNo horizontal motion during free-fallsDATUMss-Vacuum environmental control----Fast cycle time----Data accuracy---sProperly restrained--s-Aesthetically pleasing--ssLow cost+++sCan be done in 2 semesters++s+Educational and fun----# of operators--s--5-5-3-5Capsule Designs

Selected Concept

Selected Concept: ArchitecturePipingMain Tower PipingTee Shape Base w/ Removable CapTee Shaped CouplingsStandard CouplingsBase Flange for Tower SupportSealing CapValve / ClampsRelease Level ClampsPressurizing ValveManual Isolation ValvesSensorsLaser SensorsThermocouple SensorMultifunctional DAQPumpVacuum PumpDigital Vacuum GageFittingsCatch / ReleaseRelease PlatformPolystyrene Beads for DecelerationOtherPulley SystemBasketSelected Concept: Theory of OperationSelected Concept: Approximate Cost30ft Drop Tower Pricing6in Diameter8in Diameter12in DiameterItem MaterialQuantityPricePricePrice2 Stage Rotary Pump-2$352.34$352.34$352.34Bulk Head FittingsPlastic1$13.16$13.16$13.16Clear Acrylic SheetClear Acrylic1$24.59$24.59$24.59DAQ-1$99.00$99.00$99.00Glue (1 Quart)Clear Cement2$76.04$76.04$76.04Ideal VacSealThermal-plastic 1$49.75$49.75$49.75Isolation Valve-2$4,012.00$4,880.00$9,984.00Laser Distance Sensor-2$1,000.00$1,000.00$1,000.00Pipe (8ft)Clear Cast Acrylic4$1,022.72$1,568.64$3,925.80Polystyrene BeadsPolysteren Beads1$40.00$40.00$40.00Pressure Sensor-4$700.00$700.00$700.00Slip CapWhite PVC2$75.14$109.48$1,355.76Slip-FlangeDark Grey PVC5$382.00$275.64$347.38Slip-Slip CouplingWhite PVC3$109.23$217.86$486.40Slip-Slip-2inFPT TeeWhite PVC4$556.00$697.40Slip-Slip-Slip TeeWhite PVC1$125.37$125.37$125.37Thermocouples-1$30.00$30.00$30.00TAX (Based on 8%)--$693.39$820.74$1,488.77Total Cost:$9,360.73$11,080.01$20,098.36Engineering AnalysisEngineering AnalysisGravity Calculations% Error in gravity calculationsDrag Force CalculationsTube ConductancePump down (evacuation) timeUltimate Pressure RequiredCritical Pressure for Tube Dimensions

Gravity Calculation with 1% ErrorFree Body Diagram of Object

Drag Force (Air Resistance)Conductance

Effective Pump Speed Evacuation Time

VP10D CPS Vacuum Pump

2 Stage Rotary Pump15 micron Ultimate VacuumPump Speed 10 cfmPrice: $417.89

Pressure RequirementThe pressure required for accurate gravity calculations can be calculated using the previous equations and the following assumptions:Max Tube Height = 12 metersConstant AccelerationMax Object Mass = 2.27 kg Max Drag Coefficient = 2.0Max Projected Area = Cross Sectional Area for 10 cm DiameterAllowable Error in Gravity due to Pressure = 0.01%These assumptions yield an allowable pressure of 103 Pa (0.773 Torr or 773 microns)

Risk AssessmentIDRisk ItemEffectCauseLikelihoodSeverityImportanceAction to Minimize Risk1Pipe Implodes under PressureSafety HazardProject ruinedPipe wall thicknessMaterial133Determine critical pressure of pipe, with safety factor2Damages to pipeLoss of visibilityLoss of VacuumShippingHuman Error224Careful shipment and assemblyPick location where pipe is safe from accidental damagesDetermine pipe resistances to scratches, crack, etc.3Pump Over heatLoss of efficiencyFire hazardPump replacementImproper pump sizePoorly ventilatedLeft on122Adequate space around pump for ventilationTurn pump off when not in useLimit the number of consecutive runs if neededAnalyze pump specifications 4Tower Falls OverSafety HazardDamages to SurroundingsProject RuinedPoorly supportedEarthquakeWeak structure133Ensure tower can withstand its own weightDevelop sturdy designAttach tower to surrounding wall, railings, etc. at different heightsIDRisk ItemEffectCauseLSIAction to Minimize Risk5Any sealing leakLoss of VacuumNoisyIncreased depressurize timeBad SealantGaps in o-ringsSurface impurities326Require minimal seal pointsResearch proper sealing techniques for each componentMonitor pressure change6Object Impact breaks BaseObject destroyedSafety hazardPipe base brokenLoss of vacuumCannot support objects force122Determine maximum force on impact (including safety factor)Properly correct for that force with cushion, net, etc.7Laser Sensor Looses itemLoss of data(position and time)Improper sensor alignmentSensor range inadequatePower loss224Determine whether vertical position sensor can detect all objectsProperly align sensor(s) with objectEnsure pipe connection can withstand that force8Inaccurate Gauge ReadingImproper data displayImproper vacuumCheap gagesNot calibrated correctly111Calibrate all gage regularly (note in manual)Purchase accurate & Reliable gages (tolerance)9Stolen componentsDevice unusableComponents left out/unlocked122Bring components out when neededLock components up when not in use (near or away from tower)IDRisk ItemEffectCauseLSIAction to Minimize Risk10Loss of DataCant calculate gravity, drag and other dataLoss of powerSoftware malfunction122Ensure Proper Electrical ConnectionsCapture all required dataPossible sore multiple run data11Unsuccessful Release of objectsItems does not fallHorizontal motion occursUnsynchronized releaseMechanism doesnt openRelease timing offLoss of power224Release objects simultaneouslyPlatform adequately centers objectsRobust latching mechanism12Lifting device MalfunctionItem does not liftNo dropping experimentBroken wire/ clawLoss of powerImproper motor power224No lifting device, load form topAbility to easily hold weight & size of objectsEnsure wire/cable does not get stuck13Improper use of systemCompromises system integrityPoorly written manualComplicated operationUnauthorized use111Create intuitive design Create detailed operators manualLimit use to qualified individualsTop Locations: #1 selection

Thomas Gosnell Hall

Thomas Gosnell Hall Floor planAvailable Height:1- 462 - 433 39 Top Locations: #2James E. Gleason Hall

James E. Gleason Hall Floor plan

Top Locations: #3Institute HallInstitute hall floor planDoorStairsNorthAvailable Height:77-6Top Locations: #4Golisano Institute of Sustainability

Golisano Institute of Sustainability Floor plan

Test Plan#Test DescriptionComments/Status1Lift Mechanism (scaled model)Small model if needed, without tube2Test Release MechanismDrop Object from any height with chosen mechanism3Position sensor accuracySensors can be mounted and tested without tube4Vacuum pump qualityConnect vacuum to pressure gage only5Pressure gage accuracyConnect vacuum to pressure gage only6Temperature gage accuracyCalibrate Sensor7DAQ device inputstemp, pressure, position, & time captured8Computer Software Outputscomputer outputs based on certain inputsScheduleMSD I Project ScheduleSeptemberOctoberNovemberDecember23456789101112131415161718 Select & Approve Location Development Calculation Components Calculation Research Components Obtain Costs System Design Sub-System Design Detailed Design Complete Design Develop Bill Of Materials Order Long Lead Time ItemsNew FocusTower should be capable of running continuouslyMinimize time when tower is not is useDeclare prioritiesWhat range of experiments will we be performingDo cost / benefit analysis for tower heightNot simply based on wow factorConsider other stakeholder opinionsDean Palmer, Undergraduate ProfessorsPossibly make a scale model of final concept3-5ft tall prototypeMoney is not an issue, with a great designUp to $20,000 if the ideas are worth the investment

Questions?