railtech pdr
DESCRIPTION
RailTech PDR. Group Members: Mike Oertli Jonathan Karnuth Jason Rancier September 11, 2008. Project Overview. Linear accelerator Voltage applied to rails Projectile shorts out rails creating EM field Pneumatic kick-start Projectile accelerates forward. Basic Design. - PowerPoint PPT PresentationTRANSCRIPT
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Group Members:Mike Oertli
Jonathan KarnuthJason Rancier
September 11, 2008
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Project OverviewLinear acceleratorVoltage applied to railsProjectile shorts out rails creating EM fieldPneumatic kick-startProjectile accelerates forward
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Basic DesignConducting rails mounted to non-conducting
surfaceCapacitor arrayPCB, logic, and UIConducting metallic projectile
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ObjectivesSafety!!!Adjustable voltage from capacitor bankUser interface
Keypad and LCDSensor dataVelocity calculationsRemote/Hands off (Safety!)
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Approach Split into 3 main areas
1. Railgun2. Control system3. User interface
Each person focus on one area
Communication and compatibility is key
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Power SupplyBrute Force discharge
Basic supply, dumps a lot of current directly on rails
Simple to design, overkill on capacitanceInefficient, back EMF problems
Recharger SupplyComplex LC timing based on railsProne to failure with bad designRequires more capacitors (if polarized are used)Much more efficientFast recharging
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Capacitors Capacitance: 610,000µFVoltage: 20VDC
30VDC surgeESR: 2.1mΩ maxType: ElectrolyticNumber used: ~20Cost: ~ $400
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Capacitor ArrayMounted capacitors
Connected by switches controlled by logic based on input voltage from user
Logic will be based on test shotsIn enclosed case (Safety)
Other possibilities:Manual switchesSwitch mode power supply
Input inductor between array and railsRamps current to railsAvoid discharging capacitors too fast
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Rail typesCylindrical
Easier to fabricateFewer piecesStronger using less material
RectangularEasier to mountBetter electrical properties, distributed current
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Example of rail
Conducting rails
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MaterialsRails: BrassProjectile: AluminumBase: Garolite & TeflonCapacitors: 20x 0.6F 20 v ElectrolyticMicrocontroller: MSP430 family - 16 bitPCBPower supplySensors (EM, voltage)Keypad and LCD
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Brass RailsComposite: ~70% Copper, ~.07% Lead,
~.05% Iron, Remainder ZincElectrical Conductivity: 28% IACSElectrical Resistance: 6.2µΩ/cmFriction: Very low with Most metalsMelting Point: 910oCInner/Outer Diameter: 0.87”/1”Cost: $58.68 for 36”
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ProjectileMetal: Aluminum
Composite: 2011Temper: T3Part #: 88615K411
Melting point: 540oC Electrical Conductivity: 45% IACSElectrical Resistivity: 3.8µΩ/cmDiameter: 7/8”Length: ~1”Cost: $17.41/foot
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Pneumatic Kick-start Avoids spot welding projectileAdded kinetic energyEliminates static friction coefficientsCompressed Air/CO2 system
Activated by Microcontroller post safety checks
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Chassis SpecsInner Support Outer Sheath
Composite Teflon PTFE Grade G-10/FR4
Crosswise Tensile Strength
3,900 PSI 35,000 PSI
Melting Point 335oC ~384oC Max Temp
Dielectric Strength 19.7MV/m 15.7MV/m
Inner/Outer Diameter
.875”/1” 1”/1.375”
Cost $9.21 per 12” $92.16 for 39”
Part # 8547K29 8668K49
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Safety FeaturesVoltage sensors on rails, cap bank, & source
Kill power if out of expected rangeEM Field Sensor
Faraday cage if EM field great enoughPlexiglas casing
Keep user isolated from high voltages and short circuited rails
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Block Diagram
MSP430xxxx
Power Supply
Keypad
LCD
RailsCapacitor Array
KillSwitch
LEDs
Inductor
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MicrocontrollerMSP430xxxx family
Testing on MSP430F16916-bit for accurate calculation of sensor dataControl safety logic based on sensor values
Disconnect switches from caps to railsDisplay values on LCD
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Software EngineeringInterface with Matlab
Import sensor dataStatistical analysisDisplay results to user as graphs and tablesMaintain records
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PCB ElementsPower supplyMSP430 FamilyDebug/information LEDsLCD (3 or 4 rows)Keypad inputCommunication with sensors(A/D)
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SensorMeasure voltage at high sample rateUsed for analysis and safety logicImplementation:
Voltage transducerSample @ 10 MHz +Response time < 50μs
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User InterfaceBasic keypad
Input desired voltage to apply to rails3 or 4 line LCD on PCB
Output sensor data and statisticsBasic input user interface
If time:Keyboard inputComputer monitor with GUIMatlab sensor data analysis
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ExpensesItem # Needed Cost per Total Cost
Rails 2x36” $58.68 $117.36
Garolite 2x42” $46.53 $120
Capacitors 20 $20 $400
Projectiles 1’ $17.41 $17.41
PCB 2 $30 $60.00
Controller 3 (donated) $0
Misc/Sensors $300
Estimated Total ~$1014.77
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Division of LaborJonathan Mike Jason
Primary Responsibility
Rail fabrication &Safety
Microcontroller& Safety
Power systems &Safety
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Schedule
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“Real World” ApplicationControl System for other high voltage
applicationsAccelerator for fun, military, other scientific
researchCapacitor array for high current burst power
systemsSensor to Matlab interface
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RealizationStay under budget by getting donationsEstablish primary goals/reasonable
functionalityOperate within these
Add incremental levels of difficulty based on time
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Plan BRisk:
Projectile fuses to rails Discontinuities in the rails and base Arcing- heat/damage to rails
Unfamiliarity Sensing systems Matlab interface
Recovery Ask for help! Use heavier duty components RTFM Have extra rails and projectiles ready
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Questions?