MEDUSA M ethane E ngine - PowerPoint Presentation

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MEDUSA M ethane E ngine - PPT Presentation

D esign for U nmanned S mall A ircraft M anufacturing S tatus R eview University of Colorado at Boulder 02032015 Customer Dr Ryan Starkey Advisor Dr Jelliffe Jackson ID: 676018

engine ecu hours complete ecu engine complete hours data fuel signal test controller rpm phase lubrication control fds software board started remaining

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Slide1

MEDUSAMethane Engine Design for Unmanned Small Aircraft

Manufacturing Status ReviewUniversity of Colorado at Boulder02/03/2015

Customer: Dr. Ryan Starkey Advisor: Dr. Jelliffe Jackson Team Daniel Frazier Nathan Genrich Abram Jorgenson Christopher Jirucha Crawford Leeds Huikang MaAlexander Truskowski Carlos Torres Corey Wilson

1Slide2

OutlineOverviewScheduleManufacturingMechanicalElectricalSoftwareBudget

Project Overviewand Schedule Christopher JiruchaMechanical Alexander Truskowski

ElectronicsNathan GenrichSoftwareCrawford LeedsBudget Crawford Leeds2Slide3

Project Statement Project Description: Modify a JetCat P90-RXi mini turbo jet engine to run on gaseous methane fuel to address the USAF’s interest in the possible use of the methane gas as fuel.

Functional RequirementsEngine Control Unit (ECU)

Start, run, and shut down engineMaintain JetCat recommended safe operation conditionsLog dataFuel Delivery System (FDS)

Deliver up to 4.2g/s of methane to combustion can

Deliver kerosene/oil mix to bearings at stock rates

3Slide4

Project CONOPS and Objective

Current Stock Engine: JetCat P90-RXI

JetCat ECU

Injection point

Lubrication Line

RPM and Temperature from

ngine Sensor Board

Kerosene

Fuel/Lubricant

Commands to pump/solenoids

RC Signal

RPM < 130,000

Exhaust Temp < 700

RC Receiver

Shaft

4Slide5

Project CONOPS and Objective

Mass Flow Controller

Pressure Regulator

Safety Valves

Six Student

injectors

Methane Tank

Student ECU

Student Engine Board

RPM < 130,000

Exhaust Temp < 700

RPM and Temperature from Engine Sensor Board

Commands to pump/solenoids

Commands to Controller

Fuel Manifold

5Slide6

Fuel Pump

Kerosene TankLubrication SystemMass Flow Controller

Fuel SystemMethane Tank (175 ft3)Engine

Combustion Can

Turbine

Compressor

Nozzle

Logic Algorithms

Command Outputs

ECU

Thrust Command

Controller

Shut down Command

Starter

Motor

Throttle

Start

Stop

Startup Command

Input Receivers

Key

Physical Contact

Electrical Signal

Data

Provided

Purchased

Designed

Data Logging

Bearings

3.6V, 14.4 W

9.9V, PWM

0-12V

0.9 - 4.2 g/s

PWM

Injectors

Cold Junction Compensation

< 700

Amplification

0-3.3V

Injectors

Lubrication Solenoid

Differential Amplifier

0-2500 Hz Square Wave

6Slide7

SCHEDULE7Slide8

MEDUSA Original Work Plan (CDR)

Week 1Week 10

Week 15 ECU FDS Engine Integration Engine Repair Milestone Uncertainty

MSR

SFR

TRR

Where We Are

Original ECU phase I plan:

Electronics:

rototype

finished

during break

Software

: Coding

finished

during break

Electronic and software testing

begins

right

after break

ECU phase I

Current Plan:

Move two

weeks from

“Modified

ngine Integration

and

esting”

to ECU phase

ISlide9

MEDUSA Current Work Plan

Electrical

Software Labview ECU Integration Fuel Delivery Lubrication Engine Integration

Where We Are

MSR

ECU Phase I:

ECU & ESB: Prototype manufactured and

tested

individually

Software: All

code completed

and

tested

individually

LabVIEW: LabVIEW code

completed

and

tested

individually

ECU phase I

ECU phase II

ECU phase III

FDS phase I

FDS phase II

SFR

TRR

Week 6

Week 10

Week 12

Week 14

Final system Test

ECU Phase II:

ESB manufacturing

completed

Electronic and Software integration

completed

ECU Prototype

passed

engine simulator test, requirements verified

ECU Phase III:

ECU manufacturing complete

ECU and ESB board verified

and ready to integrate with the modified engineFDS Phase I:FDS components ordered and received FDS components manufacturedFDS Phase II:FDS component tests completed and requirements verifiedLubrication experimental test completed and lubrication data collection completed

Final System Test:Modified engine integration completedModified engine test completed and

requirements verified

Spring Break9Slide10

MECHANICAL SYSTEMS10Slide11

Mechanical: Design Overview

Piping system with control valves

Deliver methane to injectorsWood test stand will be rebuiltNew rear mounted fuel injectorsDeliver methane to combustion chamber

11Slide12

Mechanical- FDS Test Stand Status

ItemStatusPressure RegulatorPurchasedPressure Relief ValveReceived

Mass Flow ControllerReceivedFuel ManifoldReceivedCheck ValveReceivedShutoff SolenoidReceived

Wood Test StandParts Purchased

Pipes

and fittings

Received

Methane

Local and in stock

Deadline Feb 12

5 Hours Remaining

12Slide13

Mechanical- Fuel Injectors Status

Mounted InjectorItemStatus1mm TubingPurchased

Internal NutCAM Designed for manufactureWasherManufactured PrototypeNozzleManufactured PrototypeStainless Steel Elbow/Adaptor

Purchased

Deadline Feb 22

30 Hours Remaining

13Slide14

Mechanical: Work Overview

ComponentAction ItemStartStatusDeadlineFuel DeliveryPurchase pipes and valves1/1

2/2Purchase materials for wood test stand1/12/2

Build wood test stand

1/20

2/7

Assemble test

stand and mount controllers and piping

2/1

2/7

Full FDS and fuel inject integration

2/1

2/7

Fuel Injectors

Internal

nut prototype

1/20

3/1

Washer prototype

1/20

2/20

Nozzle

prototype

1/1

2/20

Braze

1mm tubing to nozzle

2/2

2/20

Complete

Hours Remaining

Complete

Hours Remaining

10 Hours Remaining

Hours Remaining

Purchasing

Assembly & Manufacture

All Manufacturing Complete

1/1

2/20

Where we are

3/1

4/19

3/22

All Testing Complete

14Slide15

ELECTRICAL SYSTEMS15Slide16

Electrical: Design Requirement

ECU Board

Receives signals from sensor boardCommands Mass Flow ControllerSends signals to pump and solenoid

Engine

Control

Unit

16Slide17

ECU Board:

Component

AssemblyIsolated TestingFull Load TestingLED DriversCompleteCompleteNot StartedRS232 Drivers

Complete

Not

Started

RS232 Receivers

Compete

Complete

Not

Started

RS232 Connector

Compete

Complete

Not

Started

RS422 Drivers

Complete

Not

Started

422 Receivers

Complete

Not

Started

Dual

Comparator

Complete

Not

Started

Jan 1 5 Hours Remaining

Feb

LED’s

LED Drivers

RS-232 Driver

/ Receiver

Dual ComparatorRS422 DriversRS422 Receivers

Electrical: ECU Board StatusMicrocontroller17Slide18

Electrical: Design Requirement

Engine Sensor Board

Reads thermocouple and RPM SensorsSends signals to ECU

Engine

Sensor

Board

18Slide19

Engine Sensor Board:

Component

Assembly

Isolated

Testing

Full Load Testing

Thermocouple IC

Complete

Not

Started

LDO Regulators

Complete

Not

Started

RS 422 Drivers

Compete

Complete

Not

Started

RS 422 Receivers

Complete

Not

Started

Duel

Comparator

Complete

Not

Started

High Side Drivers

Complete

Not

Started

Jan 1 5 Hours Remaining Feb 22

Thermocouple IC

LDO Regulators

High Side Drivers

Comparator

RS422 DriversRS422 ReceiversRS422 ReceiverDifferential AmplifierHigh Side DriversElectrical: ESB Board Status

19Slide20

Electrical: Work Overview

Action ItemStartStatusDeadlineConcernsBreadboard Assembly1/1

2/1Individual Component Tests2/12/5Isolated Full Load Test2/62/22Most bugs will occur here

Integrate ECU and ESB

2/23

3/15

Manufacture

PCB

Boards

3/15

3/22

Integrate With

Engine Controls

3/15

3/22

PCB Boards Rev 2

3/22

3/29

Run with

MatLab

Simulator

3/22

4/5

Software must be done

Run with actual Engine

4/5

4/19

Difficulty just running on kerosene

Breadboard

Full Load

ECU& ESB

Controls

Simulation

Engine Testing

1/1

Complete

15 Hours Remain

10 Hours Remain

1 Week Turnaround

15 Hours Remain

2/22

Where we are

3/15

4/5

4/19

3/22

20Slide21

SOFTWARE21Slide22

ECU Software: Overall Design5 Critical routines – same as CDREngine Maintenance (CR.1)Check for extremesEngine Start Up (CR.2)Start the engine from user inputEngine Shut Down (CR.3)

Shut down the engine from user inputEngine Running (CR.4)Allow throttle controlEmergency Shut Down (CR.5)Shut down engine in case of extreme

22Slide23

ECU Software: Status ItemStart

StatusDeadlineConcerns & NotesFamiliarize with IDE1/11/20Longer than expected. 2 weeks behind CDR expectation.

Program the Chip1/151/25Basic I/O (LED Blink)1/151/25Interrupt Modules1/252/20

High Risk

Logic Template

2/1

2/20

Compartmentalized

Testing

1/20

2/20

Integrate Software

2/22

3/7

Minimal

Simulator Testing

3/8

3/22

Software Bugs

Test

Review

3/22

4/19

Glitches during full engine test

Complete

40 Hours Remain

0 Hours Remain

20 Hours Remain

Familiarization

Individual Modules

Integration

Simulation

Engine Testing

1/1

1/25

Where we are

3/7

4/19

3/22

20 Hours Remain

0 Hours Remain

2/20

N/A

23Slide24

BUDGET24Slide25

MEDUSA Budget

TestingShipping & OtherFDSECU

Remainder ECURemainder FDSMarginUnspent

Total

used = $ 3223.25

Total

remainder = $

1776.75 Margin

= $726.75

25Slide26

MEDUSAMethane Engine Design for Unmanned Small Aircraft

Manufacturing Status ReviewUniversity of Colorado at Boulder02/03/2015

26Slide27

BACKUP SLIDES 27Slide28

Spring Work Plan (Worst Case)

Where We AreMSR

SFRTRR28Slide29

Verification and Validation 29Slide30

Pressure Transducer

2L Pressure Vessel

Pressure Relief ValveFDS V&V: Fuel Delivery System

Methane Tank

Pressure Controller

Pressure Relief

Shutoff Solenoid

Pressure

Regulator

Fuel Manifold

Injectors

Check Valve

Purpose

CPE3: Verify FDS delivers up to 4.2g/s of methane

Use full FDS system

Inject into pressure vessel

Measure mass flow

Pressure vessel simulates engine pressures

Relief valve keeps constant pressure

Perform test across range of safe pressures

57Slide31

FDS V&V: Lubrication SystemPurpose:CPE 4:Verify Stock lubrication conditions maintainedPump fuel and lubricant into graduated cylinders

Compare with flowmeter values from engine tests58Slide32

Lubrication TestPurpose:Acquire stock lubrication rates

Concept

Run engine with two flowmeters

Use difference in measurements

Fuel Solenoid

Flowmeter

Lube Solenoid

Pump

Flowmeter

32Slide33

ECU Verification & Validation Overview Purpose:Verify the student built ECU behaves as expected based on ECU requirementsEquipment Needed:Engine Simulator: Provide simulated engine data to the ECU.LabVIEW: Monitoring the output signals and verify the data rateMatlab: Provide digital data for

engine simulator and data analysis Engine SimulatorLabVIEW Based

Student Build ECU LABVIEWVerify Command OutputLABVIEWVerify Data Rate

1. Exhaust Temp 2. RPM Data

1. Starter Signal

2. Glow Plug Signal

3. Flow Controller Signal

4. Lubrication Signal

1. Exhaust Temp

2. RPM Data

Spektrum DX7 Controller

Send Commands

1. ON/OFF Commands

2. Throttle Level

Input

Output

59Slide34

ECU V&V: ECU Commanding TestPurpose:CPE 5, 6, 7: Verify student build ECU can receive intended commands from RC controller and send intended commands to different engine componentsVerify ECU sends intended commands to engine components with LabVIEWStarter signal: 0 - 10VGlow plug signal: 0 - 10 VMass Flow Controller Signal: RS232

Pump signal: PWMLub. Solenoid signal: Variable Frequency SignalSpektrum DX7 ControllerSend Commands

Student Build ECU LABVIEWVerify Command Output

1. ON/OFF commands

2. Throttle Level

1. Starter Signal

2. Glow Plug Signal

3. Mass Flow Controller Signal

4. Lubrication signal

60Slide35

ECU V&V: Data Collection TestPurpose:CPE 8: Verify student build ECU can collect and store the data at intended data rateUsing Engine simulator to provide simulated engine data to the ECUMeasure data stored,

Verify recording rate RPM desired data rate = 475 HzThermocouple desired data rate = 11.37 HzEngine SimulatorLabVIEW Based

Student Build ECU 1. Simulated Exhaust Temp 2. Simulated RPM dataUSB

LABVIEW

Verify Data Rate

1. Digital Exhaust Temp 2. Digital RPM data

61Slide36

ECU Software: Detailed StatusInterrupt/PWM Based ModulesRPM Sensor ReadPump Motor Driver

RC Controller InputDigital I/O ModulesLubrication SolenoidStarter Motor

Glow PlugStart/Stop ButtonAsynchronous Serial CommRS-232 to Mass Flow ControllerRS-232 to Computer (testing only)

40 man hours total before 2/20/2015

36Slide37

Project CONOPS and Objective