P12463 : Hydrodynamic Kite Model System Design Review Team Members: Mark Negro Adam Dunn Andrew Garland Michelle Wang Vulf Kirman

Contents Desired Outcomes of System Design Review (SDR) P12463 SDR Contents Desired Outcomes of System Design Review (SDR) Project Background and Key Objectives Team Member Roles Responsibilities System Architecture and Diagrams Customer Needs Customer Specifications Concept Selection Process Feasibility Analysis Schedule for MSD 1 + 2 Risks

Desired Outcomes Guidance Verify method of approach P12463 SDR Desired Outcomes Guidance Verify method of approach Reveal any unexplored areas of study from customer and guests Inform guide and customer of progress Approval to start detailed design

Project Background / Key Objectives P12463 SDR Project Background / Key Objectives The goals of the project: Design vertically mounted hydrofoil system for testing Will replicate a simplified model of a tethered kite system Data collected will be used to verify or improve an existing model simulation. Calculate power output created when the hydrofoil is attached to a freely pivoting boom Done by measuring angular velocity of moving boom arm Interface with tow rig platform designed by P12462.

Member Responsibilities P12463 SDR Member Responsibilities

Functional Decomposition P12463 SDR Functional Decomposition

System Overview Input Output Input Output Tethered Hydrofoil Model P12463 SDR Tethered Hydrofoil Model Power generated Input Output Current boom angle Current hydrofoil angle Digital video of surface interaction Boom length Aspect ratio Hydrofoil flip locations Controls / Data Acquisition Input Output Resistive torque Hydrofoil flip angles Tow Rig Input Output “Flow” velocity Hydrofoil flip locations Real-time visual representation of model motion Resistive torque Current hydrofoil angle Hydrofoil flip angles Current boom angle “Flow” velocity Net power

Control System Architecture P12463 SDR Control System Architecture Symbol Device Function 1 Strain Gage Measure torque, τ 2 Potentiometer Measure ϴ 3 Video Camera Capture high-speed _video of foil 4 Actuator Control Ф 1 3 Φ 4 2

Actuator Linkage Boom User Interface Support/Linkage Dump Load Hydrofoil Tow Rig Actuator Control flip orientation of hydrofoil Angular Position Monitor Output angular position of hydrofoil Linkage Power Source/ Regulator Data Acquisition Computer Boom Output angular position of boom Angular Position Monitor User input (if desired) User Interface Generator Station Support/Linkage Key: - Physical connection - Data connection - Power connection Digital Video Camera Input resistive torque delivered by dump load Dump Load P12463 SDR

Functional Diagram P12463 SDR Physical interface with tow rig platform (bolted flange connection Dump load (constant torque; power generation) Digital video camera Hydrofoil actuation (pneumatic or electric servo motor?) Coupled shafts Boom angle (hollow shaft potentiometer) Hydrofoil angle (hollow shaft potentiometer) Boom support / free rotation (roller bearing) Controls / Data collection

Construction Assumptions for SDR P12463 SDR Construction Assumptions for SDR Boom length and hydrofoil aspect ratio will be changed manually Hydrofoil flip location, hydrofoil flip angle, platform velocity and dump load torque will be controlled via Labview Rather than directly measuring torque, we will be calculating it as a function of angular acceleration and moment of inertia Potentiometers will be used to measure angular position of both the boom and the hydrofoil relative to the boom The linkage between the dump load and the boom will consist of coupled shafts and a bearing (roller or ball) that is capable of supporting axial loading We will be using a laptop for controlling our system and collecting data Hydrofoil actuation has not been determined; choice is between pneumatic/hydraulic actuation and an electric servo motor Digital video camera will neither receive nor transmit data or power to the rest of the system

Customer Needs P12463 SDR

Engineering Specifications P12463 SDR Engineering Specifications

Decision Criteria Functions: Attach Tow Rig Multiple Boom Lengths P12463 SDR Decision Criteria Functions: Attach Tow Rig Multiple Boom Lengths Hold Hydrofoil Position Constant Relative to Boom Flip Hydrofoil Measure Angular Position of Boom Connect Hydrofoil to Boom Allow Rotation of Boom/Types of Dump Loads Measure Torque of Boom Change when Hydrofoil Flips in Cycle

Feasibility Analysis: Boom Arm & Hydrofoil (Maximum) P12463 SDR Feasibility Analysis: Boom Arm & Hydrofoil (Maximum) Milestones Reached Created an excel spreadsheet which would take a set of inputs on dimensions of boom and other factors to determine the bending stress on the boom at different boom angles and angles of attack based on the data retrieved from the MATLAB simulation. Brainstormed the possible worst case scenarios for the system as far as bending stress and stall were concerned. Some of the assumptions that were made during the brainstorming session are as follows: Static Equilibrium Angular velocity of the boom arm is 0 rad/s Hydrofoil chord length is perpendicular to the direction of the flow velocity The brainstorming session was verified by altering some of the values in the MATLAB simulation to mimic our setup.   Milestone that have yet to be reached Must get the MATLAB code to output lift forces in order to change the moment equation in the excel spreadsheet to account for bending based on both drag and lift. Need to test out a set of worst case scenarios for both the hydrofoil and boom arm (for bending stress) to be able to see which set of boom and hydrofoil dimensions fit best for both the tank team and our team.

Feasibility Analysis: Hydrofoil (Minimum) P12463 SDR Feasibility Analysis: Hydrofoil (Minimum) Minimum hydrofoil size is limited by manufacturing methods and precision of instrumentation. The team will be contacting a manufacturer of hollow shaft potentiometers to, hopefully, determine the accuracy of this device when monitoring angular position

Feasibility Analysis: Tank Width and Boom Arm P12463 SDR Feasibility Analysis: Tank Width and Boom Arm Option 1: Boom is in middle of tank Assumptions: -assume 90 degrees total rotation. Rotation is equal on both sides of platform (45 degrees) Option 2: Boom is at side of tank. Boundary layer is less than Wph -platform against tank wall -90 degrees maximum rotation -rotation starts parallel to length of tank wall Option 1 Chord Length [inches]: 4 Tank size [inches] 60 Boundary Layer thickness (1 side) [inches] 16 Usable Tank Width [inches] 28 Length of Boom [inches] 19.8 Option 2 Chord Length [inches] 4 Tank Size [inches] 30 Boundary Layer [inches] 8 Wph [inches] 10 Usable Tank Width [inches] 12 Length of Boom [inches]

Feasibility Analysis: Tank Width (cont.) P12463 SDR Feasibility Analysis: Tank Width (cont.) Option 3: Boom is at side of tank. Boundary layer is greater than Wph Assumptions: -platform against tank wall -start of cycle outside of boundary layer Option 3   Chord Length 4 Tank Size [inches] 30 Boundary Layer [inches] 8 Wph [inches] Length of Boom 18

Feasibility Analysis: Tank Size and Cycle Time P12463 SDR Feasibility Analysis: Tank Size and Cycle Time Parameter Symbol Unit Control Value Parameter Variation Mass of kite mk kg 0.05 Mass of boom mb 0.25 Length of boom l m 0.45 Angle of foil to boom beta rad 70 Value of braking torque K Nms 0.5 0.1 0.3 0.7 0.9 Span of foil in water r_dep in 14 Chord Length chord 1.4 River velocity vinf m/s 1 Initial angle of boom Y0(1) 5 Initial angular velocity of boom Y0(2) rad/s 60 Angular position limits theta >90,<5 Angular velocity limits thetadot <2 Return Angle -70 Cycle Time   s/cyc 1.78 1.26 1.58 2.02 2.29

Feasibility Analysis: Tank Size and Cycle Time (cont.) P12463 SDR Feasibility Analysis: Tank Size and Cycle Time (cont.)

Feasibility Analysis: Flipping Mechanism P12463 SDR Feasibility Analysis: Flipping Mechanism Timing Input   Comments Desired Cycles, n 3 Usable tank length (meters) 4.3 Minimum cycle time (m/cycle) 1.43 Eqn = desired cycle time/n Flow velocity, v (m/s) 0.5 Attainable cycle time (m/cycle) 1.2 Output Number of flips 5 Eqn = (n*2)-1 Allowable time to flip (s/flip) 0.28 Eqn = (((Minimum-attainable)*n)/v)/# of flips Comparison   Servo Hydraulic Weight >50 g Heavy Speed 0.08 s/60°* Torque 12 kg-cm Lots Cost to $70 Hundreds * At 6V Available in high resolution sampling ranges. Don't know if torque is sufficient to keep foil from slipping. High-torque models available ^ Not practical for our use. Will consult with Wellin about his thoughts on hydraulics. Let's move forward with Servo.

Budget: Estimations P12463 Budget: $2,000 P12463 SDR   $2,000 Expense Description Qty Unit Cost Cost Hydrofoil Materials 5 $8 $40 Dump Loads 1 $600 Hollow-shaft Potentiometer 2 $10 $20 Flipping Mechanism $100 Boom Materials 3 $50 $150 Camera $0 Bearing for Boom Shaft Coupling Attachment Rig Material Laptop $300 Environmental Protection ? Cables and Wires Remainder: $440

Schedule for MSD 1 P12463 SDR Task Name Duration Start Finish Predecessors Brainstorming 2 days Mon 10/3/11 Thu 10/6/11 Risk Assessment 3 days Sun 10/2/11 Tue 10/4/11 Send Preview of System Design Review 0 days System Design Review Calculations 5 days Design Review "Check" Make Changes from Design Review "Check" Wed 10/5/11 5 Send SDR Presentation to Attendees 6 Decide methods to fulfill functions 16 days Tue 10/25/11 System Design Review Fri 10/7/11 Detailed Calculations on Hydrofoil Loads 6 days Fri 10/14/11 Design Boom Arm Mon 10/10/11 Mon 10/17/11 Detailed Calculations for Boom Connections 10 days Fri 10/21/11 Identify Parts Needed to Acquire Wed 10/12/11 Wed 11/2/11 Prepare for Detailed Design Review 4 days Mon 10/31/11 Thu 11/3/11 Detailed Design Review 14,10,11,12,13 Additional Detailed Design Based on Review 8 days Tue 11/8/11 Thu 11/17/11 15 Order Long Lead Time Parts 14 days Prepare for MSD I Review Mon 11/14/11 MSD I-Final Design Review 18 Thanksgiving Break Sat 11/19/11 Sun 11/27/11

Schedule for MSD 2 P12463 SDR Task Name Duration Start Finish Predecessors Order/Acquire Short Lead time Parts 6 days Mon 11/28/11 Mon 12/5/11 Manufacture Hydrofoils 10 days Fri 12/9/11 Manufacture Boom 7 days Tue 12/6/11 Assemble Boom Connections Wed 12/7/11 Thu 12/15/11 23 Test Boom Connections 2 days Fri 12/16/11 Sat 12/17/11 24 LabView Programming 36 days Fri 1/13/12 Incorporate Actuation Devices 19 days Wed 12/14/11 Mon 1/9/12 Test Actuation Devices 3 days Thu 1/12/12 27 Incorporate Dump Load 4 days Tue 1/10/12 Test Dump Load Mon 1/16/12 Wed 1/18/12 29 Incorporate Instrumentation Mon 1/23/12 23,25,26 Test Instrumentation Tue 1/24/12 Thu 1/26/12 31 Protect Components Fri 1/20/12 Test Protection of Components 5 days Fri 1/27/12 33 Winter-Holiday Break 16 days Sun 1/8/12 Preliminary Integrate System With Team P14262 Mon 1/30/12 Wed 2/1/12 22,23,25,28,30,32,34 Debug After Preliminary Integration Thu 2/2/12 Tue 2/7/12 36 Preliminary Customer Demo 0 days 37 Debug per Customer Needs Thu 2/9/12 Fri 2/17/12 38 Reintegrate System with Team P14262 Mon 2/20/12 Wed 2/22/12 39 Final Customer Demo 39,40 Prepare for MSDII-Final Review 13 days Tue 2/21/12 Thu 3/8/12 MSD II-Final Review 41

Risk Assessment P12463 SDR Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Owner 1 Incorrect engineering analysis Component or total system failure, unsatisfied customer Incorrect assumptions, miscommunication 2 3 6 Double-Check Calculations, Facility Confirmation All of team Inability to hold hydrofoil angle constant relative to boom Unsatisfied customer, unable to collect data Failure of mechanism, poor integration with other function components, higher loads on hydrofoil than expected Testing, Double-check calculations Vulf/Andrew Failure for boom to rotate Inability to get correct data, safety issues, must redesign/manufacture Improper calculations and unexpected stresses, improper construction Testing, proper design, compare with other existing technologies Adam/Mark 4 Inaccurate measurements Unsatisfied customer Improper sizing of instrumentation, Improper installation of instrumentation, miscalculation of loads Double-Check Calculations, Facility Confirmation, Check Manufacturing specifications Vulf/Adam 5 Inability to connect with P12462 Must rework or reconceptulize connection Miscommunication or lack of documentation between groups Communication of current plan and changes, keep current interface document between groups Change in customer needs/priority Narrow project scope, re-evaluate functional decomposition and system design Customer decisions, Purpose of collected data changes - Mark/Customer 7 Flipping mechanism failure 8 Structural failure of hydrofoil Vulf/Mark

Risk Assessment (cont.) P12463 SDR Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Owner 9 Over budget Cannot order necessary parts Bad cost management, necessary technologies more expensive for required performance 2 4 Proper utilization of available technologies, Keep track of budget Andrew/Michelle 10 May not finish project on time Bad grades, unsatisfied customer Poor time management Compare progress to Gantt Chart to stay on track Mark/All of Team 11 Structural Failure of Boom Inability to get correct data, safety issues, must redesign/manufacture Improper calculations and unexpected stresses, improper construction 1 3 Double-Check Calculations, Facility Confirmation Michelle/Mark 12 Customer needs not met Unsatisfied customer, bad grades Improper understanding of customer needs Design to Customer Needs and Customer Specifications 13 Loss of team member Other team members must compensate for additional workload Health, family, personal reasons - All of team 14 Unable to protect system components Safety issues, damaged components, must reorder parts Improper construction, improper selection of protection, unexpected environmental conditions Check test location and conditions Adam/Vulf 15 Incorrect manufacturer specifications Must reorder, increased lead-time ? Proper Testing of product Mark/Adam 16 P12462 unsuccessful Inability to complete data collection or test functionality of project Location/space limitations, construction problems, lack of proper control system, leaks Assign System Integration engineer Adam/Mark

Risk Assessment (cont.) P12463 SDR Risk Item Effect Cause Likelihood Severity Importance Action to Minimize Owner 17 Necessary technology not available for budget allocated Concept can not be built, limited data accuracy, limited functional precision Inadequate concept assessment, limited budget, project scope to large 1 3 Adequate brainstorm and decision process to accomplish function, Consult faculty Andrew/Adam 18 Parts need to be sent out for machining Unexpected costs, increased lead-time Improper design, miscalculation, parts require hire precision the RIT capabilities Proper design and calculation Vulf/Mark 19 Unable to modify boom length Unsatisfied customer Failure of boom adjustment mechanism, poor integration with other function components 2 proper mechanical design, use system diagrams, compare with other existing solutions Adam/Mark 21 Project parts ordered too late Testing, integration delayed, miss project deadline Design analysis miscalculation, improper assumptions for calculations Use Gantt Chart to monitor progress, double check calculations Mark/Andrew 22 Inaccurate lead-time from manufacturer Parts arrive late, Testing, integration delayed, miss project deadline Shipping delays due to holidays, delays in RIT receiving Give extra time for parts to arrive, Use Gantt Chart to monitor progress 23 Team dysfunction Inability to divide out work, decreased communication, incomplete project Different ideas, strong personalities Abide by Norms and Values, Consult individuals if problem arises Mark/Project Guide 24 Project scope too large May not finish project on time Project improperly scoped Work with project guide and customer to show the efforts needed for a successful project Mark

P12463 SDR Questions? Comments?