MEDUSA Methane Engine Design for Unmanned Small Aircraft Manufacturing Status Review University of Colorado at Boulder 02/03/2015 Good afternoon everyone, we are the MEDUSA team. Thank you for joining our pdr review Customer: Dr. Ryan Starkey Advisor: Dr. Jelliffe Jackson Team Daniel Frazier Nathan Genrich Abram Jorgenson Christopher Jirucha Crawford Leeds Huikang Ma Alexander Truskowski Carlos Torres Corey Wilson

Outline Overview Manufacturing Budget Schedule Mechanical Electrical Software Budget Project Overview and Schedule Christopher Jirucha Mechanical Alexander Truskowski Electronics Nathan Genrich Software Crawford Leeds Budget I will start this presentation with the project description and baseline design. I will then pass it off to my colleagues to discuss the feasibility analysis for each of the critical element which including engine control unit, fuel delivery system and combustion can. I will then finish by providing a project summary Project Overview Mechanical Electrical Software Budget

Functional Requirements 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 Requirements Engine Control Unit (ECU) Start, run, and shut down engine Maintain JetCat recommended safe operation conditions Log data Fuel Delivery System (FDS) Deliver up to 4.2g/s of methane to combustion can Deliver kerosene/oil mix to bearings at stock rates Project Overview Mechanical Electrical Software Budget

Project CONOPS and Objective RC Signal RC Receiver Current Stock Engine: JetCat P90-RXI JetCat ECU Commands to pump/solenoids RPM and Temperature from Engine Sensor Board Injection point RPM < 130,000 Shaft Lubrication Line Exhaust Temp < 700oC Kerosene Fuel/Lubricant

Project CONOPS and Objective Mass Flow Controller Safety Valves Pressure Regulator Commands to Controller Methane Tank Student ECU Fuel Manifold Commands to pump/solenoids RPM and Temperature from Engine Sensor Board RPM < 130,000 Student Engine Board Six Student injectors Exhaust Temp < 700oC

Differential Amplifier Fuel System Key Physical Contact Electrical Signal Data Provided Purchased Designed RC Controller Methane Tank (175 ft3) Mass Flow Controller 0.9 - 4.2 g/s Startup Command Thrust Command Fuel Pump Kerosene Tank Shut down Command Lubrication System Throttle Start Stop PWM Lubrication Solenoid ECU Engine Injectors Input Receivers Starter Motor Combustion Can Compressor Bearings Turbine Nozzle Data Logging Injectors Logic Algorithms 0-12V 9.9V, PWM T5 < 700oC 0-2500 Hz Square Wave Differential Amplifier Command Outputs 3.6V, 14.4 W Cold Junction Compensation Amplification 0-3.3V

SCHEDULE This is our baseline design

MEDUSA Original Work Plan (CDR) Where We Are Week 1 Week 10 Week 15 Original ECU phase I plan: Electronics: Prototype finished during break Software: Coding finished during break Electronic and software testing begins right after break Current Plan: Move two weeks from “Modified Engine Integration and Testing” to ECU phase I ECU phase I ECU FDS Engine Integration Engine Repair Milestone Uncertainty MSR TRR SFR

MEDUSA Current Work Plan Where We Are Week 6 Week 10 Week 12 Week 14 Final System Test: Modified engine integration completed Modified engine test completed and requirements verified FDS Phase II: FDS component tests completed and requirements verified Lubrication experimental test completed and lubrication data collection completed ECU Phase I: ECU & ESB: Prototype manufactured and tested individually Software: All code completed and tested individually LabVIEW: LabVIEW code completed and tested individually FDS Phase I: FDS components ordered and received FDS components manufactured 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 engine ECU phase I Spring Break ECU phase III ECU phase II Electrical Software Labview ECU Integration Fuel Delivery Lubrication Engine Integration FDS phase I MSR TRR Final system Test FDS phase II SFR

MECHANICAL SYSTEMS This is our baseline design

Mechanical: Design Overview Piping system with control valves Deliver methane to injectors Wood test stand will be rebuilt New rear mounted fuel injectors Deliver methane to combustion chamber On the right is a picture of the full mechanical set up. This includes the pipes and valves on the methane cylinder stand as well as the new fuel injectors that are mounted on the rear of the engine. Project Overview Mechanical Electrical Software Budget

Mechanical- FDS Test Stand Status Item Status Pressure Regulator Purchased Pressure Relief Valve Received Mass Flow Controller Fuel Manifold Check Valve Shutoff Solenoid Wood Test Stand Parts Purchased Pipes and fittings Methane Local and in stock Deadline Feb 12 5 Hours Remaining Project Overview Mechanical Electrical Software Budget

Mechanical- Fuel Injectors Status Mounted Injector Item Status 1mm Tubing Purchased Internal Nut CAM Designed for manufacture Washer Manufactured Prototype Nozzle Stainless Steel Elbow/Adaptor Deadline Feb 22 30 Hours Remaining Project Overview Mechanical Electrical Software Budget

Mechanical: Work Overview Component Action Item Start Status Deadline Fuel Delivery Purchase pipes and valves 1/1 2/2 Purchase materials for wood test stand Build wood test stand 1/20 2/7 Assemble test stand and mount controllers and piping 2/1 Full FDS and fuel inject integration Fuel Injectors Internal nut prototype 3/1 Washer prototype 2/20 Nozzle prototype Braze 1mm tubing to nozzle Complete Complete 3 Hours Remaining 10 Hours Remaining 2 Hours Remaining 10 Hours Remaining 3 Hours Remaining 8 Hours Remaining 4 Hours Remaining Where we are 2/20 3/1 3/22 4/19 1/1 Purchasing Assembly & Manufacture All Manufacturing Complete All Testing Complete Project Overview Mechanical Electrical Software Budget

ELECTRICAL SYSTEMS Project Overview Mechanical Electrical Software This is our baseline design Project Overview Mechanical Electrical Software Budget

Electrical: Design Requirement Engine Control Unit ECU Board Receives signals from sensor board Commands Mass Flow Controller Sends signals to pump and solenoid Project Overview Mechanical Electrical Software Budget

Electrical: ECU Board Status LED’s Dual Comparator Component Assembly Isolated Testing Full Load Testing LED Drivers Complete Not Started RS232 Drivers RS232 Receivers Compete RS232 Connector RS422 Drivers RS422 Receivers Dual Comparator RS422 Drivers LED Drivers RS-232 Driver/ Receiver DELETE RS422 Receivers Jan 1 5 Hours Remaining Feb 22 Microcontroller Project Overview Mechanical Electrical Software Budget

Electrical: Design Requirement Engine Sensor Board Reads thermocouple and RPM Sensors Sends signals to ECU Engine Sensor Board Project Overview Mechanical Electrical Software Budget

Electrical: ESB Board Status Engine Sensor Board: LDO Regulators High Side Drivers Component Assembly Isolated Testing Full Load Testing Thermocouple IC Complete Not Started LDO Regulators RS 422 Drivers Compete RS 422 Receivers Duel Comparator High Side Drivers Differential Amplifier RS422 Receivers Comparator Thermocouple IC RS422 Drivers High Side Drivers RS422 Receiver Jan 1 5 Hours Remaining Feb 22 Project Overview Mechanical Electrical Software Budget

Electrical: Work Overview Action Item Start Status Deadline Concerns Breadboard Assembly 1/1 2/1 Individual Component Tests 2/5 Isolated Full Load Test 2/6 2/22 Most bugs will occur here Integrate ECU and ESB 2/23 3/15 Manufacture PCB Boards 3/22 Integrate With Engine Controls PCB Boards Rev 2 3/29 Run with MatLab Simulator 4/5 Software must be done Run with actual Engine 4/19 Difficulty just running on kerosene Complete Complete 15 Hours Remain 10 Hours Remain 1 Week Turnaround 15 Hours Remain 1 Week Turnaround 15 Hours Remain 15 Hours Remain Where we are 2/22 3/15 3/22 4/5 4/19 1/1 Breadboard Full Load ECU& ESB Controls Simulation Engine Testing Project Overview Mechanical Electrical Software Budget

SOFTWARE This is our baseline design

ECU Software: Overall Design 5 Critical routines – same as CDR Engine Maintenance (CR.1) Check for extremes Engine Start Up (CR.2) Start the engine from user input Engine Shut Down (CR.3) Shut down the engine from user input Engine Running (CR.4) Allow throttle control Emergency Shut Down (CR.5) Shut down engine in case of extreme Project Overview Mechanical Electrical Software Budget

ECU Software: Status Where we are 2/20 3/7 3/22 1/25 4/19 1/1 Item Start Status Deadline Concerns & Notes Familiarize with IDE 1/1 1/20 Longer than expected. 2 weeks behind CDR expectation. Program the Chip 1/15 1/25 Basic I/O (LED Blink) Interrupt Modules 2/20 High Risk Logic Template 2/1 Compartmentalized Testing Integrate Software 2/22 3/7 Minimal Simulator Testing 3/8 3/22 Software Bugs Test Review 4/19 Glitches during full engine test Complete Complete Complete 40 Hours Remain 10 Hours Remain 20 Hours Remain 20 Hours Remain 10 Hours Remain N/A Where we are 2/20 3/7 3/22 4/19 1/1 1/25 Familiarization Individual Modules Integration Simulation Engine Testing Project Overview Mechanical Electrical Software Budget

BUDGET Project Overview Mechanical Electrical Software Budget This is our baseline design Project Overview Mechanical Electrical Software Budget

MEDUSA Budget Testing Shipping & Other Remainder FDS Margin FDS Unspent Remainder ECU ECU Total used = $ 3223.25 Total remainder = $ 1776.75 Margin = $726.75 Project Overview Mechanical Electrical Software Budget

MEDUSA Methane Engine Design for Unmanned Small Aircraft Manufacturing Status Review University of Colorado at Boulder 02/03/2015 Good afternoon everyone, we are the MEDUSA team. Thank you for joining our pdr review Customer: Dr. Ryan Starkey Advisor: Dr. Jelliffe Jackson Team Daniel Frazier Nathan Genrich Abram Jorgenson Christopher Jirucha Crawford Leeds Huikang Ma Alexander Truskowski Carlos Torres Corey Wilson

BACKUP SLIDES This is our baseline design

Spring Work Plan (Worst Case) Where We Are MSR TRR SFR

Verification and Validation This is our baseline design

FDS V&V: Fuel Delivery System Pressure Transducer 2L Pressure Vessel Pressure Relief Valve Pressure Relief 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 Fuel Manifold Injectors Methane Tank Pressure Regulator Shutoff Solenoid Pressure Controller Check Valve

FDS V&V: Lubrication System Purpose: CPE 4:Verify Stock lubrication conditions maintained Pump fuel and lubricant into graduated cylinders Compare with flowmeter values from engine tests Use existing hardware Determine pump voltage and current experimentally Deliver mass flow rate equivalent to the mass flow at max throttle at all times Constant over lubrication

Lubrication Test Purpose: Flowmeter Fuel Solenoid Flowmeter Pump Acquire stock lubrication rates Flowmeter Fuel Solenoid Flowmeter Lube Solenoid Pump Concept Run engine with two flowmeters Use difference in measurements

ECU Verification & Validation Overview Purpose: Verify the student built ECU behaves as expected based on ECU requirements Equipment Needed: Engine Simulator: Provide simulated engine data to the ECU. LabVIEW: Monitoring the output signals and verify the data rate Matlab: Provide digital data for engine simulator and data analysis Engine Simulator LabVIEW Based LABVIEW Verify Command Output 1. Starter Signal 2. Glow Plug Signal 3. Flow Controller Signal 4. Lubrication Signal 1. Exhaust Temp 2. RPM Data Input Student Build ECU Output 1. Exhaust Temp 2. RPM Data 1. ON/OFF Commands 2. Throttle Level LABVIEW Verify Data Rate Spektrum DX7 Controller Send Commands

ECU V&V: ECU Commanding Test Purpose: CPE 5, 6, 7: Verify student build ECU can receive intended commands from RC controller and send intended commands to different engine components Verify ECU sends intended commands to engine components with LabVIEW Starter signal: 0 - 10V Glow plug signal: 0 - 10 V Mass Flow Controller Signal: RS232 Pump signal: PWM Lub. Solenoid signal: Variable Frequency Signal LABVIEW Verify Command Output 1. Starter Signal 2. Glow Plug Signal 3. Mass Flow Controller Signal 4. Lubrication signal Student Build ECU 1. ON/OFF commands 2. Throttle Level Spektrum DX7 Controller Send Commands

ECU V&V: Data Collection Test Purpose: CPE 8: Verify student build ECU can collect and store the data at intended data rate Using Engine simulator to provide simulated engine data to the ECU Measure data stored, Verify recording rate RPM desired data rate = 475 Hz Thermocouple desired data rate = 11.37 Hz Engine Simulator LabVIEW Based 1. Simulated Exhaust Temp 2. Simulated RPM data Student Build ECU USB 1. Digital Exhaust Temp 2. Digital RPM data LABVIEW Verify Data Rate

ECU Software: Detailed Status Interrupt/PWM Based Modules RPM Sensor Read Pump Motor Driver RC Controller Input Digital I/O Modules Lubrication Solenoid Starter Motor Glow Plug Start/Stop Button Asynchronous Serial Comm RS-232 to Mass Flow Controller RS-232 to Computer (testing only) If this slide looks like a filthy mess, just run it. It is very, VERY heavily animated. 40 man hours total before 2/20/2015

Project CONOPS and Objective RC Signal RC Receiver Current Stock Engine: JetCat P90-RXI JetCat ECU Commands to pump/solenoids RPM and Temperature from Engine Sensor Board Injection point RPM < 130,000 Shaft Kerosene Fuel/Lubricant Lubrication Line Exhaust Temp < 700oC

ECU Software: Required Functionalities Digital I/O Modules Interrupt Driven Modules WORK IN PROGRESS These are the user-commanded inputs. They are required to actively control the engine. Digital Control of the Glow Plug PWM control of the Fuel Pump for Lubrication WORK IN PROGRESS These are required to run the engine safely. RPM sensor read test DONE. DONE with the ability to control the digital output of pins Digital Control of the Starter Motor Use ADC to read the Thermocouple User Control Modules Digital control of the Lubrication Solenoid PWM input: RC Controller RS-232 Control of Mass Flow Controller PWM Input: RPM Sensor If this slide looks like a filthy mess, just run it. It is very, VERY heavily animated. Digital control of the Shut-off Valve