1. Growth Innovations Kite Group Final Project Presentation 6 April 2006 Chris Boven Trever Carnes Brandon Henley Emmanuel Zoubovsky

2. Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Design a System to Control a Traction Kite for Sailing Applications

3. Kite Background Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Upper Level Winds More Stable 3 Lines  Sides: Turning  Middle: Pitch Each Line Controlled by a Crewmember

4. Specifications Line Speed: 5 ft/sec (turning) Line Loads: 1500 pounds Section Weight: < 200 lb Power Source: 12-volt batteries Controlled using one hand Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work

5. Concepts Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Ideas  Electric Capstans  Hydraulic Motors  Individual Gearboxes  Planetary Systems Why Planetary Systems?  Collective Control  Turning Advantage  Stress Distribution

6. Calculations Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Gear Selection  Turning Line Speed: 5.1 ft/sec  Gear Stresses: 1.2 Factor of Safety Power Consumption  In/Out: 10.6 HP  Pitch: 2.1 HP  Does Not Consider Friction

7. Final Design - Gears Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Planetary Gearsets  Multiple Inputs Sun Gear Outer Ring  Single Output Planet Carrier Worm Gears  Speed Reduction  Backfeed Prevention

8. Final Design - Gears Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Inputs  Turning Differential  Pitch Angle of Attack  In/Out Kite Orientation Unchanged

9. Final Design - Frame Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Welded Steel Frame Angular Members  Prevent Collapse  Allow Motor Access Larger Members  Support Main System

10. Final Design - Electronics Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Off-the-Shelf Components  RC Transmitter  RC Receiver  RC Interface  Motor Controller  Motor

11. Manufacturing - Lathe Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Turned on Lathe  11 Shafts  3 Spools  15 Round Plates  36 Spacers

12. Manufacturing - Mill Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Machined on Mill  30 Plates  3 Keyways  31 Gear Mods

13. Manufacturing - Welding Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Total Shop Time: 590 Hours

14. Assembly Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Used: 400+ Fasteners Broke: 20+ Allen Wrenches Time Spent: 60 Hours

15. Testing – Fit Testing Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Fit Shafts in Bearings Size Spacers to System Align Bearings Adjust for Oversized Material Compensate for Bowed Plates File Damaged Gear Teeth

16. Testing – No-Load Testing Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work All Motors Running  Line Speed of ~5 ft/sec in Turning  In/Out Caused Slight Backfeed RC Interfaces Ceased to Function

17. Testing – Loaded Testing Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work This Page is Under Construction. Please check back at a later date!

18. Future Work Introduction Kite Background Specifications Concepts Calculations Final Design Gears Frame Electronics Manufacturing Lathe Mill Welding Assembly Testing Fit No-Load Loaded Future Work Possible Future Projects  Lighten the System  Make System More Modular  Scale Down System Size  Make Corrosion Resistant

19. Questions