952017 Capstone Senior Design Project Ideas Summary Brief Company Overview Thermoelectric Waste Heat Recovery POETS Pulse Driver Circuit for Plasma Flow Control related to NASA contract ID: 640069
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Slide1
Joseph ZimmermanCU Aerospace LLC 9/5/2017
Capstone Senior Design Project IdeasSlide2
SummaryBrief Company OverviewThermoelectric Waste Heat Recovery (POETS)Pulse Driver Circuit for Plasma Flow Control (related to NASA contract)Slide3
CU Aerospace Synopsis
CU
Aerospace is
a high tech aerospace company growing at ≈ 20% per year
Founded in 1998
Location: Champaign, Illinois
M2 Building (downtown Champaign)
Total number of employees (FTE): 12
Partners6 Founding Partners4 Jr. PartnersCore Technology Business AreasModeling and Simulation, Plasma-based Technologies, Spacecraft Systems (Propulsion & Software), Laser Systems, Advanced Aerospace Composites, and Aircraft Safety SystemsProductsBLAZE 7 Multiphysics software, THERMOSYS™ MATLAB/Simulink toolbox, Propulsion Unit for CubeSats (PUC), VascTech sacrificial fibersPrincipal CustomersNASA, Air Force, DOE, Navy, MDA, JTO, NSF, Aerospace PrimesSlide4
Company Divisions
R&D efforts in a number of advanced product areas with focus shift towards product hardware/software…
BLAZE-VI
THERMOSYS
TM
Plasmadynamics &
Laser Systems
(Plasma Generation,
High Energy, & Diode Lasers)
Aerospace
Materials
(Self-Healing, Sacrificial, & TPS)
Spacecraft Propulsion
(Electric & Solar Sail)
Modeling & Simulation
(3D
Multiphysics
, Thermal Systems, Optimization Strategies)
BLAZE
TM
PUC
VascTech
TMSlide5
Project Idea #1POETS-sponsored joint MechSE-ECE teamPOETS: Power Optimization of Electro-Thermal SystemsPotential applications in various CUA products
“Thermoelectric Waste Heat Recovery in Mobile Systems”
Proposed project objectives:
Apply
thermoelectric effect
to convert waste heat from battery-powered supply to stored potential
Demonstrate the ability of thermal energy harvesting to extend the operational life of the mobile power supply
Consider impact on size, weight, and practicality of the mobile systemSlide6
Turbulent Separation Control TodayPassive flow control remains method of choice for commercial aircraft
VGs configured for takeoff, landing (~1-3% of flight time)Cruise penaltyMost active actuation approaches suited for either low-speeds or high-complexity
VGs on B737-700Slide7
Background Innovative Concept - Cyclotronic Plasma Actuator
Thermal-based actuation of boundary-layer flowLorentz force coupling of arc filament and magnetic field to produce angular velocity
Sweeping arc-filament plasma for vortex formation and enhanced mixing
Turbulent boundary-layer separation control
Focused E Field
Result: Low-Complexity, On-Demand Vortex GeneratorSlide8
Arc Breakdown Visualization
High-speed video of arc
breakdown (Ansell, UIUC)
Acquired at 100,000 fps, playback 10 fps (1/10,000 real-time)
Arc breakdown every 0.5 seconds in playback
Correlates to 20 kHz driving frequency of AC circuitSlide9
Project Idea #2CUA-sponsored ECE-team (2-3 people)Relates to joint CUA-UIUC NASA-funded programSeeking improved compact, higher power circuit for atmospheric arcs in plasma flow control actuators
“Tunable Pulse Circuit for Plasma Flow Control”
Proposed project objectives:
Design controller & transformer modules
as compact circuit for UAVs (< 250 cm
3
for
both modules)
100-150 W input, 24-36 VDC (battery) supplyDemonstrate tuning (5-50 kHz, varied duty cycle)Analyze circuit efficiencyTest / demonstrate circuit with CUA benchtop testbed actuator Slide10
Questions?Slide11
Back-up Slidesfor DiscussionSlide12
Testbed Design and Benchtop Experiments
Goals: Improve actuation authority with increasing power, understand actuation properties with design
Multiple electrode and permanent magnet configurations
Power scaling of circuit AC driving frequency and amplitude
GBS
Minipuls
2.2
Max 20
kV
p
-p driving voltageMax 60 mA current output5-20 kHz driving frequency
0-100% duty cycle control
B
urst frequencies 0-400 Hz
Alternative benchtop approaches:
Investigated so far:
60 Hz, RF
Future work: pulsed DC
GBS
Minipuls
2.2Slide13
Testbed Configurations
13.56 MHz
excitation
Large
cavity
Etched PCB w/
embedded magnet
Modified
commercialspark-plugsVarious coaxial formats appliedExcitation mechanisms: 5-20 kHz AC pulse, burst mode60 Hz bipolar13.56 MHzReconfigurablecoaxSlide14
Embedded Magnet ConceptsEtch electrode patterns on copper-clad circuit board (chemical etch or CNC mill)Attach / embed ring, disc, or bar magnet below board Initial bench test with copper-clad FR4Can be applied to alumina substrate (samples of curamik® obtained)Potential for integrated cooling / simplified circuitry
Blown Arc
Coax
Top
Bottom
Side
Flow
B-field
E-field
ACSlide15
60 Hz Excitation vs. VoltageCyclotronic plasma actuator using 60 Hz bipolar excitation. Plasma pulses at 120 Hz (Tplasma = 8.33 ms). Exposure time is 1/15 s (66.7 ms, ~8 plasma pulses). 0.125” diameter inner electrode 110 copper rod w/ rounded at the tip, the is a 0.25” I.D. zinc-plated brass outer electrode, and the insulator is nonporous alumina ceramic.Center electrode tip is positioned 0.125” below the outer electrode, recessed in the alumina tube such that the rounded tip is positioned approximately 1/32” above the alumina. At low primary voltages (just above breakdown), the plasma takes on a filamentary appearance.
As voltage increases (and also the plasma current) the rotation rate increases and the appearance becomes more disc like. Slide16
V-I Results13 kHz (GBS Minipuls)
60 Hz (12 kV transformer)Readings from Minipuls Board, ACDelcoTektronix P6015 HV Probe, IridiumIX
Pearson 411 Current Monitor,
IridiumIX
Similar
V
pk-pk
across sparkplug at breakdown
Voltage drops as plasma impedance changes with increased currentSlide17
Minipuls V-I ResultsACDelco, 4 mm gapIridium IX, 2.5 mm gap5.2 kHz
13.2 kHz18 kHz6.8 kHzSlide18
Comparison of Arc Rotation with Actuator Configurations
Video acquired at 5,000 fps with playback 60 fps (1/83 real time)
Arc forcing, rotation rate dependent on coax, magnet, and circuit configuration
Configuration can be tailored to change actuation effect or in-situ variation in arc rotation (for electromagnet)
Case 1
Case 2
Case 3
Case
Spark Plug
Magnet Dimensions
Centerline
B-Field (G)
Arc Rotation
Rate (RPM)
1
NGK Iridium IX #3521
(2.5 mm gap)
1.5” OD x 0.75” ID x 0.75” Th.
675
6,173
2
3.0” OD x 0.75” ID x 0.5” Th.22509,80433.0” OD x 0.78” ID x 1.0” Th.250010,6384
ACDelco #41-902 (4 mm gap)1.5” OD x 0.75” ID x 0.75” Th.6753,78853.0” OD x 0.75” ID x 0.5” Th.22504,505
63.0” OD x 0.78” ID x 1.0” Th.25004,762Slide19
Flat Plate Velocity Profiles
Boundary-layer profiles:Compare to effect of passive VGs(Velte et al., 2009)
Similar profile
upstream of
actuation
Local velocity
defect from
actuation
Flow recoveryand increasedBL momentumMarginaleffect onunactuatedflowSlide20
Streamwise Flow FieldDevelopmentMax vorticity
Max unsteadiness
Actuation induces development of shear layer
Concentrated vorticity deflected away from wall
Subsequent increase in unsteadiness in velocity (
σ
V
)
Suggests enhanced mixing of flow field
Strategic placement of actuators is important!
Additional work planned to investigate control of separated BLSubsequent study will characterize three-dimensional structure, use on airfoil modelSlide21
VG and Plasma Recovery Comparison
E
ffects of
plasma actuator qualitatively similar to conventional VG
Plasma actuator underpowered resulting in lower difference in
Δ
C
p
VG may be oversized for application (h > δ)
Phase I electronics limited power input significantly increase power/current to plasma in Phase II to obtain similar VG ΔCp
performance while retaining on-demand actuationDBDSingle Cyclotron(Underpowered)Single VGSingle Cyclotron(Underpowered)Single VG
No
Control
VG Strip