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P15318: Gaseous Mass Flow Rate Controller

P15318: Gaseous Mass Flow Rate Controller. Brian Church, Anthony Salmin, Tyler Breitung, Ross Bluth, Michael Oplinger, Stephen Mroz. Week 6 System Level Design Review - 10/2/14. Agenda. Background Problem Statement Customer Requirements Engineering Requirements House of Quality

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P15318: Gaseous Mass Flow Rate Controller

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  1. P15318: Gaseous Mass Flow Rate Controller Brian Church, Anthony Salmin, Tyler Breitung, Ross Bluth, Michael Oplinger, Stephen Mroz Week 6 System Level Design Review - 10/2/14

  2. Agenda • Background • Problem Statement • Customer Requirements • Engineering Requirements • House of Quality • Functional Decomposition • Concept Development • Feasibility Analysis • Risk Assessment • Test Plan • Project Plan Week 6 System Level Design Review - 10/2/14

  3. Current Prototype Dynamic range of flow of 100:1 No means of flow rate control Not ready for use in an automotive environment Week 6 System Level Design Review - 10/2/14

  4. Problem Statement: Desired State Increase the flow rate accuracy to ± 0.5% A distribution plate for mixing CNG and air Smaller and lighter than current prototype A Proportional-Integral-Derivative (PID) actuator control algorithm to increase flow rate accuracy Week 6 System Level Design Review - 10/2/14

  5. Problem Statement: Project Deliverables Fully operational prototype that can be tested and verified with compressed air Complete technical design documentation Comprehensive system operation instruction manual Documentation of failure modes Demonstration at Imagine RIT Week 6 System Level Design Review - 10/2/14

  6. Problem Statement: Constraints Low cost Simple installation Small and lightweight Design for manufacturability Electrical/Mechanical packaging for an automotive environment Week 6 System Level Design Review - 10/2/14

  7. Customer Requirements: Last Time Week 6 System Level Design Review - 10/2/14

  8. Customer Requirements: Changes 3 Constraint 1 Constraint Week 6 System Level Design Review - 10/2/14

  9. Customer Requirements: Now Week 6 System Level Design Review - 10/2/14

  10. Engineering Requirements: Last Time Week 6 System Level Design Review - 10/2/14

  11. Engineering Requirements: Changes mass flow rate control 3 1 Week 6 System Level Design Review - 10/2/14

  12. Engineering Requirements: Now Week 6 System Level Design Review - 10/2/14

  13. House Of Quality: Then Week 6 System Level Design Review - 10/2/14

  14. House Of Quality: Now Week 6 System Level Design Review - 10/2/14

  15. Open Items from Last Review • Issues • How are we going to allocate the flow rate accuracy and response time between the systems? • Actions Taken • Accuracy (± 1%) • 80% Actuator/Valve • 10% A/D converter • 10% Leakage • Response time (50 ms) • 80% Mechanical movement • 20% Computations • Current Status • Take allocations into account during detailed design phase Week 6 System Level Design Review - 10/2/14

  16. System Architecture Week 6 System Level Design Review - 10/2/14

  17. Functional Decomposition Week 6 System Level Design Review - 10/2/14

  18. Functional Decomposition: Receive Fuel Week 6 System Level Design Review - 10/2/14

  19. Functional Decomposition: Regulate Flow Week 6 System Level Design Review - 10/2/14

  20. Functional Decomposition: Delivering Fuel Week 6 System Level Design Review - 10/2/14

  21. Functional Decomposition: Ensure Safety Week 6 System Level Design Review - 10/2/14

  22. Morphological Chart Week 6 System Level Design Review - 10/2/14

  23. Morphological Chart Continued Week 6 System Level Design Review - 10/2/14

  24. ConceptGeneration • Four concepts generated • Prototype • Modified Prototype • Cost Effective • High-Tech (Expensive) Week 6 System Level Design Review - 10/2/14

  25. Pugh Evaluation Week 6 System Level Design Review - 10/2/14

  26. Pugh Evaluation Continued Week 6 System Level Design Review - 10/2/14

  27. Pugh Evaluation Continued Week 6 System Level Design Review - 10/2/14

  28. Pugh Evaluation Continued Week 6 System Level Design Review - 10/2/14

  29. Selected Concept • The Modified Prototype was ranked 1st in the Pugh Evaluation • However, we still have to evaluate several component alternatives to meet the accuracy and cost deliverables Week 6 System Level Design Review - 10/2/14

  30. Feasibility • Question: Will the valve design have an impact on the flow rate accuracy? • Ball valve • Needs to be designed from scratch, low accuracy • Gate valve • Needs to be designed from scratch, low accuracy • Cam/ball • Already implemented in a prototype, high accuracy • Rotating disk • Already implemented in a prototype, high accuracy Week 6 System Level Design Review - 10/2/14

  31. Feasibility Snail Egg Dwell • Question: Will the valve design have an impact on the flow rate accuracy? • Cam/ball • Snail • Egg • Dwell Week 6 System Level Design Review - 10/2/14

  32. Feasibility OpenClosed • Question: Will the valve design have an impact on the flow rate accuracy? Week 6 System Level Design Review - 10/2/14

  33. Feasibility • Question: Will the valve design have an impact on the flow rate accuracy? Week 6 System Level Design Review - 10/2/14

  34. Feasibility • Question: Will the valve design have an impact on the flow rate accuracy? • Rotating disk Open Closed Week 6 System Level Design Review - 10/2/14

  35. Feasibility • Question: Will the valve design have an impact on the flow rate accuracy? Week 6 System Level Design Review - 10/2/14

  36. Feasibility • Question: Will the valve design have an impact on the flow rate accuracy? • Answer: Yes! • Current status • Need to develop equations/models • Cam profiles • Slots in rotating disks • Need to relate angular rotation of actuator to flow rate Week 6 System Level Design Review - 10/2/14

  37. Feasibility • Question: Will changes in pressure and temperature affect the mass flow rate? • m – Mass flow rate • A – Area of valve opening • P – Pressure • T – Temperature • γ – Specific Heat Ratio • R – Gas Constant Week 6 System Level Design Review - 10/2/14

  38. Feasibility • Question: Will changes in pressure and temperature affect the mass flow rate? • Volume remains constant in chamber • As temperature increases, pressure increases due to basic thermodynamics 7.07% > 3.0% • Answer: Theory shows that we will need pressure and temperature sensors to have accurate flow. Week 6 System Level Design Review - 10/2/14

  39. Feasibility • Question: Is it feasible to use a thermocouple, RTD, or thermistor for our temperature measurements? Week 6 System Level Design Review - 10/2/14

  40. Feasibility • Question: Is it feasible to use a general purpose, flush diaphragm, or PCB mountable pressure transducer? Week 6 System Level Design Review - 10/2/14

  41. Feasibility • Question: Can a microcontroller can be used to control GMFRC? • Expecting shock and vibrations over extended period • Temperatures in engine compartment can reach 85°C • Needs to read raw sensor data, convert to digital data, determine necessary actuator position, and control actuator position • Want ± 1% accuracy • Actuator needs to go from fully closed to fully open in 50 ms • Microcontroller costs needs to be within budget Week 6 System Level Design Review - 10/2/14

  42. Feasibility Question: Can a microcontroller can be used to control GMFRC? Week 6 System Level Design Review - 10/2/14

  43. Feasibility • Question: How much power will our system draw? Week 6 System Level Design Review - 10/2/14

  44. Feasibility • Question: Do we need to add a cooling method to prevent overheating? • Answer: If we can use Electronics with a high enough temperature resistance….No Week 6 System Level Design Review - 10/2/14

  45. Feasibility • Question: Will we be able to meet our budget requirements? Week 6 System Level Design Review - 10/2/14

  46. Proposed Test Setup Week 6 System Level Design Review - 10/2/14

  47. Test Plan • Test fuel mixing • Use CFD analysis to confirm distribution plate mixes fuel and air • Test valve • Run compressed air through device and open and close valve • Test microcontroller • Generate values to simulate varying sensor readings • Test response time • Have microcontroller open and close actuator • Test with installed sensors • Vary sensor variables to test microcontroller response • Test voltage regulator • Vary input voltage • Test leakage • Pressurize system and measure amount lost due to leakage • Test flow rate accuracy and repeatability • Connect device to compressed air tank and measure output Week 6 System Level Design Review - 10/2/14

  48. RISK Week 6 System Level Design Review - 10/2/14

  49. RISK Continued Week 6 System Level Design Review - 10/2/14

  50. RISK Continued Week 6 System Level Design Review - 10/2/14

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