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Published byAllan Norris Modified over 9 years ago
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CDR October 9, 2008 Mike Oertli Jonathan Karnuth Jason Rancier
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Division of Labor Mike O. Program MCU Matlab interface Jonathan K. Construct rails Assist in control system design and coding Jason R. Construct capacitor array Design voltage sensors
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Block Diagram MSP430F169 Power Supply Keypad LCD Railgun Capacitor Array Kill Switch LEDs Inductor Voltage Sensor Pneumatic Starter System Encoder
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Budget ItemQty. NeededCost PerTotal for item Brass Rails (36")258.68117.36 Garolite G-10 (39")192.16 Teflon (12")69.2155.26 Aluminum (12")217.4134.82 Capacitors50Donated0.00 PCB233.0066.00 Microcontroller20.00 Air compressor156.10 Air tank162.00 Solenoid Valve1170.00 Pressure Regulator135.00 Transformer1100.00 Plastic housing150.00 Sensors/Miscellaneous200.00 Grand Total1,038.70
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Safety Features Voltage sensors on rails, cap bank, & source Kill power if out of expected range Plexiglas casing o Keep user isolated from high voltages and short circuited rails Pressure Regulator o Added ability to safely release tank pressure
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Power System Diagram
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Capacitor Battery 50x 450V 3.7mF Capacitor Donated by CDE Array of 3 banks of 16 in parallel Overall: 1350V ~ 20mF
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Capacitor Battery
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Basic Charger
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Power Parts 2x 200KOmh @ 3W 1x 800Omh @.25 W 50x 100kOmh @ 3 W 3x 22KOmh @ 50 W 1x 120V 15 Amp AC switch 1x Fuse Holder 120VAC 1x 1600v Power Diode 2x High Voltage Switch(1000V) 1x Microwave Transformer 1x Variac Variable Transformer Copper Plate Plexiglass Box
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Cylindrical Rail Design Design Difficulties Material Tolerances Material Loss Toxic materials Difficult to machine at desired barrel length Efficient Design method Maintain physical contact despite material disintegration
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Machined & Fabricated Parts
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Compressed Air Injector Adapter
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Injector Adapter Drawing
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Brass Rails Composite: ~70% Copper, ~.07% Lead, ~.05% Iron, Remainder Zinc Electrical Conductivity: 28% IACS Electrical Resistance: 6.2µΩ/cm Friction: Very low with Most metals Melting Point: 910 o C Inner/Outer Diameter: 0.87”/1”
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Projectile Metal: Aluminum Composite: 2011 Temper: T3 Part #: 88615K411 Melting point: 540 o C Electrical Conductivity: 45% IACS Electrical Resistivity: 3.8µΩ/cm Diameter: 7/8” Length: ~1”
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Pneumatic Kick-start Avoids spot welding projectile Added kinetic energy Eliminates static friction coefficients Compressed Air system Activated by Microcontroller post safety checks Additional safety with inclusion of Pressure Regulator
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Injection System
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Complete System Compressed Air Tank Compressor Solenoid Valve Ball Valve Pressure Regulator Manufactured Parts Railgun Adapter Tank Adapter Compressor Adapter
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Electromagnetic Solenoid Valve
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Pressure Regulator Features High Pressure capabilities Very Low Flow 1/150 Flow of the Solenoid (.06 Cv) Adjustable Pressure Range Low leakage Value 3600 Psi Capabilities
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Chassis Specs Inner SupportOuter Sheath CompositeTeflon PTFEGrade G-10/FR4 Crosswise Tensile Strength 3,900 PSI35,000 PSI Melting Point 335 o C ~384 o C Max Temp Dielectric Strength19.7MV/m15.7MV/m Inner/Outer Diameter.875”/1”1”/1.375” Cost$9.21 per 12”$92.16 for 39” Part #8547K298668K49
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Parts List- Control System Voltage Sensor MM74C922 16 key encoder Keypad, 3-line LCD Master kill switch “Hot” switch
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Parts List- MCU MSP430F169 2 ADC 1 RS232 Voltage regulator LEDs
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Interfaces MSP430F169Matlab RS232 Key EncoderKeypadMSP430F169 Wire-wrap/Solder MSP430F169 P6 I/O (ADC) Voltage Sensor 3-Line LCDMSP430F169 Wire-wrap/Solder
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Keypad Pin Layout 1234567 141312111098
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Key Encoder MM74C922 16 Key Debounce Continuous row scan
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Keypad & Encoder Schematic
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Keypad Demo
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Software- MCU Language: C++ Inputs: Keypad (via encoder chip on P1), voltage sensors (1 on ADC on P6, 2 nd via off board ADC), power (6V) Outputs: 3-line LCD (P2), Matlab (RS232), capacitor charging control (switch based on sensors), safety/kill switch
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MCU Logic
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Software- Matlab Plot time domain analysis of sensor readings Keep test-run information Inputs: Data from MSP Outputs: GUI showing data Interface: RS232
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Questions?
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