AAT Injector Nozzle Test Chamber P15681 Calibration Fluid Exhaust System Zach Huston, Hayden Cummings, Adam Farnung, Tim Nichols, Robert Moshier, Andrew Heuser

Agenda Project Background Updated Requirements Chamber design Measurement System Risk Assessment Fluid removal system Action Items

Background - AAT Advanced Atomization Technologies (AAT) Joint venture between General Electric Aviation and Parker Aerospace Specializes in manufacturing and testing fuel nozzles for gas turbine engines

Background - Project Fuel Injection Nozzle Testing System Qualifying fuel injection nozzles Specialized calibration equipment Expensive, odorous calibration fluid Problems with system Offensive odor permeates entire building Loss of expensive calibration fluid

Problem Definition All commercial aircraft nozzles must undergo a flow test to assure that requirements are met for spray angle. This test uses Stoddart Solvent (MIL-PRF-7024F Type II) Petroleum derived, clear, transparent liquid. The fluid is very expensive and has an offensive odor The current exhaust system is ineffective at both containing containing the odor and recovering the atomized fluid for reuse.

Project Schedule Represents Critical items

Customer Requirements

Engineering Requirements

Subsystem Risk Flow

Chamber Design Components: -Nozzle Fixture (Integration of both tests in one location, constrain and attach nozzle) -Airlock (Test location, isolation, purge) -Gloves (Correct Material, ergonomics, attachment) -Containment Chamber (Collection and containment of liquid calibration fluid)

Full Chamber

Ergonomic Analysis System must accommodate operator heights from 62” – 76” Shoulder width range: 16.1” – 17.7” Center to center glove separation 14” Range of distance from shoulder to ground: 50.7” – 62.17” Chamber will require 1 foot of adjustable vertical travel *For details on the anthropometric analysis reference System Level Design Documents on EDGE

Ergonomic Analysis 46” 62” To accommodate all operators and be safe to operate from the top and in the gloves the chamber requires 16” of travel

Nozzle fixture Overview: -Combines flow and angle testing in one location -Incorporates both nozzle block- offs for flow testing and measurement system for angle testing Roles in Engineering Requirements: - S4: “Elapsed Time”: does not add significant cycle time

Upper Door Overview: -Provides access to the nozzle fixture inside of the airlock -O-Ring sealed, solenoid locked (to be integrated into controls system) Roles in Engineering Requirements: -S1: “Air Quality”: Contains Calibration Fluid -S2: “Air Particle Removal”: Provides Seal for Vacuum -S8: “Calibration Fluid Leak”: Contains Calibration Fluid -S9: “Door Sealed During Operation” -S11: “Accessibility”: Easy Access for operator to Test Block

Gloves Overview: -‘Blast Chamber’ Style gloves -Allow operator access without exposure to fluid Roles in Engineering Requirements: -S1: “Air Quality”: Fluid does not leave chamber during operator interaction -S8: “Calibration Fluid Leak”: Calibration Fluid does not escape during operator interaction -S11: “Accessibility”: Easy Access for operator to Dual Block-off

Mid Chamber Valves Overview: -Ball valve interface between top and bottom chamber -Allows for separation of Air Lock from collected calibration fluid and smaller evacuation chamber Roles in Engineering Requirements: -S1: “Air Quality”: Liquid Cal fluid is isolated to completely closed portion of chamber -S3: “Liquid Drain Rate”: Easy Access for operator to Dual Block-off

Chamber Design Testing -Glove Pressure Testing: Several gloves samples were subjected to an air pressure of approximately 14.7 psi to test their structural stability to maximum internal chamber pressure. (Please see: subsystem testing, glove pressure test videos for more information)

Chamber Design Testing Glove Material Exposure Testing: Samples of the same glove materials were exposed to the calibration fluid for two spans of time. Tests were performed on the samples post- exposure to record data for effects of the fluid on the materials. (Please see: subsystem testing, “Test Procedure Sheet (glove test).docx” for more information)

Chamber Design Testing

Bottom Chamber Overview: -Provides space for liquid calibration fluid to collect, separate from the air lock -Drain in bottom for line to fluid collection tank, recycled back into system Roles in Engineering Requirements: -S1: “Air Quality”: Liquid Cal fluid is isolated to completely closed portion of chamber -S3: “Liquid Drain Rate ”: Easy Access for operator to Dual Block-off -S8: “Calibration Fluid Leak”: Liquid Calibration Fluid is kept separate from rest of chamber, away from main openeing

Measurement Individual motorized control of probes Precision probe control to 0.5 thousandths of an inch* Cameras provide easy view LEDs increase visibility *For details on the measurement analysis reference Systems Level Design Documents on EDGE

Measurement Cameras capture ideal vantage point for angle test Live video displayed above probe controls Logitech C310 HD Webcam -720p HD Video -Easy interface with Windows -5 MP Photos

Measurement Cameras provide excellent visibility of spray and probes Visibility with camera of drops through mist confirmed by testing* Visibility with camera through LED glare confirmed by testing* Visibility with mist, no LEDs Visibility with LED glare *For details on the measurement tests reference Systems Level Design Documents on EDGE

Eyedropper Test LED Interference Test at 110 o LED Interference Test at 180 o Mist Interference Test

Drop Test Results SME – Rachel Silvastrini

Mist Interference Test Materials: -12 Volt Car Battery -Jumper Cables -GE90 Nozzle -Water -Camera -Laptop -Dropper Results: Mist interference with the camera visibility is minimal to the point of unnoticeable.

Fluids Subsystem Mist evacuation is needed to maintain visibility during test. The amount of air pulled from the system must be adjustable. Evacuating mist cannot influence the testing procedure. A two speed system combines low speed for visibility during test with high speed for fast mist evacuation at the end of the test.

Subsystem Flow By keeping the entire system sealed, no calibration fluid is allowed to escape. All aspects of the system are sealed including chamber doors, chamber drain, drain tank, mist collector system and mist collector drain. The test chamber will be automatically purged before allowing the chamber doors to be opened, eliminating the chance for an operator to come in contact with the atomized while also not allowing the atomized fluid to escape. Fluid that is pulled through the mist collector is returned to the drain tank. System is automated to reduce operator error.

Fluids Subsystem - Heart The heart of the subsystem is the AER Control System CM300. This unit is able to pull 300 cfm from the test chamber to quickly purge the system, while being throttled back during testing in order to not effect test results. Custom built unit will feature aluminum rotating drum to eliminate spark risk. Unit will be fitted with an activated carbon after filter to reduce any remaining odor. Filter can be replaced with ordinary activated carbon which is inexpensive and easily procured. Fluid removed via the collector will be returned to the drain tank.

Spray Angle Testing Engineering requirement S10 states that the test system cannot influence the test results. Test designed to mitigate risk of the system influencing test results (spray angle). Miniature test chamber built with ability to alter test chamber pressure as well as spray fluid through GE90 nozzle. Test chamber was tested at atmospheric and negative pressures. Result of test at atmospheric pressure can be seen at the left and demonstrates the control.

Spray Angle Testing Result of test at 0.5 atmosphere can be seen at the left and demonstrates the spray angle while under vacuum. Results show that testing under a mild vacuum greatly alters test results. Testing needs to be done at near atmospheric pressure levels in order to not influence test results.

Odor Testing An activated carbon filter will serve as the last line of defense to keep any odors from escaping the test chamber. The experimental chamber was setup with cal fluid and a small fan to mimic odor escaping. The escaping air was then tested for odor and recorded. A carbon/charcoal filter was then fitted to the air exit. The fan was run and the escaping air was again tested for odor. Cal fluid odor was greatly reduced with the addition of the filter.

Controls Doors lock during testing Two solenoids lock outside chamber door Automated ball valves between upper and lower chambers Prevents odor-filled air from leaving chamber

Controls Automated air purge sequence 1.Closes ball valves sealing upper chamber 2.Runs pump for air purge 3.Unlocks chamber door

Controls Precision variable-speed probe control Precision of ” Minimum speed of in/sec Maximum speed of 0.5 in/sec *For details on the measurement analysis reference Systems Level Design Documents on EDGE

Integration Cycle time analysis Cycle time reduced by 3.5 minutes from current New cycle time of ~8.2 minutes Major time savings: fewer nozzle connections and movements due to one test location, fewer X opening door Time additions: putting on and removing gloves

Risk Assessment

Remaining Risks RiskImportancePlan for MitigationCompletion Date Air / Fluid Leaks(27)(9)Test plan available on Edge under “Subsystem Test plans” ‘Test for Air Leaks in Chamber’ MSD II (Week 3-5) Nozzle Detaches27 Run test with different fittings to see which forms the best connection and is the easiest to install Week 14 Inability to interact with control system 9Determine I/O capabilities of test pressure control system Week15 Subsystem integration fail27Continue weekly updatesOngoing

Bill of Materials Subsystem: Chamber$1, Measurement$ Fluid Control$5, Controls/Integration$ Total $6,765.81

MSD II Project Plan

Action Items Design Signed off by Jim Complete drawing package Make appointment with operators to perform glove simulation Compile purchase orders MSD II Risk Assessment

Appendix BOM - Chamber

Appendix BOM – Fluid Control

Appendix BOM – Measurement / Controls