Transcript 06411 Mini Nucleating Bubble Engine

06411 Mini Nucleating Bubble
Engine
Team Members
Steven Nathenson
Joseph Pawelski
Joaquin Pelaez
Andrew Pionessa
Brian Thomson
Team Coordinator
Dr. Walter
Team Mentors
Dr. Crassidis
Dr. Kandlikar
Acknowledgements
Steve and Rob in the Machine Shop
Multidisciplinary Engineering Senior Design
Project Overview
Project Description
– Creation of a mini device that transmits bubble
growth into usable motion
– Current MEMS devices use piezoelectric
membrane to convert bubble nucleation to electric.
– The project focuses on a larger device in order to
complete the analysis.
– Periodic bubble nucleation is produced a
modulated power supply putting a current through
a coiled filament.
Customer Specifications
– Keep the design within a 1 foot cube
– Maintain a budget of $500
– Dimensions within a mm scale
– Benchmark efficiency of engine
– Bubble visualization with high speed camera
– Develop mathematical models
– Run time of at least 20 seconds
– Frequency of at least 5 to 10 Hz.
Risk Assessment
– Engine parts could be too unique and small
• May result in going over budget
• May result in lack of time
– The engine design may be to similar to
current MEMS devices if a piston or piston
like design is not utilized
– Bubbles may be too small to move the
piston a significant amount for testing
Tasks
Project Number: 6411
Team Leader: Steven Nathenson
Team Members: Joe Pawelski
Joaquin Pelaez
Brian Thomson
Andy Pionessa
Project Coordinator Dr. Walters
Project Sponsor/Mentor Dr. Kandlikar
Project Sponsor/Mentor Dr. Crassidis
Team Member
Research
Research MEMS Devices
Research bubble bynamics
Research patents
Planning
Delegate tasks
Determine sponsor meeting times
Determine mentor meeting times
Determine team meeting times
Create work breakdown structure
Review and revamp WBS
Create Gantt chart
Reviw and revamp Gantt Chart
Mission statement
Technical requirements
Risk Assessment
Concept development
Feasibility assessment
Joaquin & Joe
Andy & Steven
Joaquin
All
All
All
All
Steven
All
Steven
All
All
All
All
All
All
Design
Electrical engineering
Controls engineering
Heat Transfer engineering
Systems engineering
Bubble dynamics
Fluid engineering
Mechanical engineering
Drafting
Brian
Brian
Andy & Joaquin
Steven & Joe
All
All
Steven, Joe, Andy, Joaquin
Joaqin
Production & Assembly
Manufacturing engineering
Manufacturing
Assembly
All
Joaquin & Joe
Andy & Joaquin
Gantt Chart
Week 1
Week 2
Week 3
break 1
Winter Quarter
break 2 break3
Week 4
Week 5
Week 6
Week 7
Week 8
Week 9
Week 10 Tasks
Research
Research MEMS Devices
Research bubble bynamics
Research patents
Planning
Delegate tasks
Determine sponsor meeting times
Determine mentor meeting times
Determine team meeting times
Create work breakdown structure
Review and revamp WBS
Create Gantt chart
Reviw and revamp Gantt Chart
Mission statement
Technical requirements
Risk Assessment
Concept development
Feasibility assessment
Design
Electrical engineering
Controls engineering
Heat Transfer engineering
Systems engineering
Bubble dynamics
Fluid engineering
Mechanical engineering
Drafting
Production & Assembly
Manufacturing engineering
Assemble system
Experimental Setup, Testing, & Analysis
Experimental Setup
Initial Testing
Future Testing
Analysis
All
All
All
All
Testing
Experimental Setup
Initial Testing
Future Testing
Analysis
Reports
Peer review
PDR
CDR
All
All
All
Reports
Peer review
PDR
CDR
Morphological Chart
Attribute
Option 1
Option 2
Option 3
Engine Type
Buoyant piston
Partially
Submerged
piston
Submerged
cantilever beam
Liquid Type
De-ionized
water
Alcohol
Other
Impact Plate
Resistant wire
Protective plate
Power Supply
DC power
supply
Heating
Element
Option 4
Option 5
Option 6
Rotary w/
ndent
Rotary w/
Volume
change
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Other
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DC battery
AC power supply
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Straight wire
Square wire
Circular wire
Concentric wire
Metal plate
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Control
System
Stamp
controller
ASIC chip
Other
programmable chip
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Cooling
System
None
Fluid reservoir
Heat exchanger
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Movement
Causality
Bubble Impact
Boiling &
Condensation
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Electrical
System
Pulse width
Modulator
(PWM)
AC circuit
design
DC circuit design
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Non-submerged
cantilever beam
Concept Feasibility
Weighted Average Analysis
Be Portable
Utilize a miniature
heating element
Be Under Budget
Utilize a power supply or
a battery
Produce a mechanical
oscillation
Create a millimeter sized
engine
Protect the heating
element
Control bubble growth
via a control system
The liquid reservoir
should be cooled
Theoretically prove
engine design
Create a working engine
Test the engine
Create a lightweight
design
Alleviate friction between
piston and casing
Raw score
Normalized score
Relative
weight
0.079
Concept
1
3
Concept
3
3
Concept
4
3
Concept
5
3
Concept
6
3
0.096
3
3
3
3
3
0.011
3
2
2
1
1
0.073
3
3
3
3
3
0.084
3
3
3
1
1
0.079
3
2
2
2
2
0.118
3
3
3
3
3
0.112
3
3
3
3
3
0
3
3
3
3
3
0.107
3
3
3
1
1
0.096
0.084
3
3
2
3
2
3
1
3
1
3
0.062
3
3
3
3
3
0.082
3
4
4
4
4
-------------------
3.249
1
3.145
0.968
3.145
0.968
2.656
0.817
2.656
0.817
Detailed Design
LDPE Piston
Material Selection
• Piston Casing
–
–
–
Boroscilicate Glass (Pyrex)
Stock part at McMaster - Carr
Machining - glass department is able to cut
• Piston Base
–
–
Glass Mica Ceramic – high temp
Machining - Mechanical engineering machine shop
• Piston
Pyrex Glass Casing
Platinum Wire
–
–
–
–
Low Density Polyethylene (LDPE)
Less dense than water
Core center to promote floatation
Machining - Mechanical Engineering machine shop
• Electrodes
Ceramic Mica Base
–
• Heater Element
–
Copper Electrodes
Copper Wire - Stock item at McMaster-Carr
Option 1
•
–
Platinum wire and soldered electrodes
Option 2
•
Manufactured heating elements provided by Dr. Kandlikar
Budget
$500
–
–
–
–
–
Piston
Casing
Base
Heater
Electrical Controls
Part #
Name
1
Piston
2
3
4
5
Casing
Base
Electrodes
Heating Element
Description
Low density Polyethelyne, 0.25" OD ± 0.018" x 8 ft., McMaster Carr
#8754K12
Pyrex tubing, 0.375" ± 0.012" x 0.218" ± 0.028" x 1 ft., McMaster Carr
#8729K33
Glass Mica Ceramics, 1/2" OD x 3", McMaster Carr #8499K618
Copper wire - .032" (78 ft) (8873K17) Mcmaster-Carr
Platinum Wire, 0.008" OD x 0.16437"
Quantity Unit Cost Total Cost
8
$0.67
$5.36
1
1
1
1
$4.16
$26.35
$3.13
$0.00
$4.16
$26.35
$3.13
$0.00
$39
Theoretical Models
Navier Stokes
– Parallel Plates with
Gravity
u  μu max
 P
 y 1 
τμ

 a   ρg x   
y  a
 x
 a 2 
• Upper plate is moving at a
constant velocity
– Pipe Flow with Gravity
v x
2vmax r
 

r
R2
Theoretical Models
System Models
– Factors taken into account
– Two model types
• Based upon geometrical relationships
• Based directly off of the Navier-Stokes equations
– 5 total models
• Some neglected forces shown to be insignificant
• Some include all forces of the system
– Verification Model
• Simplified version of the models
Theoretical Models
Systems Model 1
– Second order
approximation
– Negligible forces are
removed
– Water displacement is
known
– Water moves proportional
to the displacement of the
bubble
xp
xw
K1
Piston
B1
B4
Water
mw
B3
Mp Piston
K1

B1
Mw Water
Systems Model 2
B2
mp
xp
– First order approximation
– Neglects the viscous
shear force due to the air
on the piston
– Water moves proportional
to the displacement of the
bubble
B2
Additional Theoretical Analysis
Bubble growth rate
– Mikic’s equations
– Experimentally
determine with high
speed camera
B2R
Rt  
A
R 

tA2
t  2
B


 
3/ 2
2 
t 1  t 
3
3/ 2

1
 bTL  TSat ( pL )h fg  G 
A

 LTSat ( pL )


1/ 2
 12 Ja 2
B  
 
1/ 2



Additional Theoretical Analysis
• Heat Transfer
– Transient heat
conduction
– Semi-infinite solid
– For 12 ms pulse, 10
V and between 2 and
5 A were applied to
the entire circuit
– Power = 20 to 50 W
1
  *t 2
2* q *

"
2
   exp   x    qo x erfc x 
T x, t   T 
 4 * * t   k 
k
 2  *t 

 

"
o
T ∞ = 25 C
x
qo ”
Power  101.495W
T s = 400 C
Electrical System Requirements
Specifications
– Supply pulse signal with adjustable amplitude, duty cycle,
and frequency
– Signal must be output continuously
– 100, 72, and 60 W signal for 10, 20 and 30 ms pulse
– Implement component protection as well as operator
protection
– Design for small load resistance (~0.5 Ω)
– Flexible for different loads
Final Electrical Design
0
Vdd
V7
0
0
Vdd
Vdd
V5
D1
I
G2
V6
S2
G3
Vin
D3
D2
I
G4 M4
0
I
PL, VL Load
G1 M1
D4
PL, VL Load
Vin
Vin
S4
S1
0
M3
M2
PL, VL Load
S3
0
(a) Single NMOS
0
(b) Single PMOS
k
2
I D  VGS  VT 
2
0
0
(c) Combined
Current for saturation condition
Pulse Width,
PW [ms]
5.65
5.2
4.3
10
20
30
7.09
6.05
5.54
14.2
12.1
11.1
101
73.2
61.3
100
72
60
Percent Error
[%]
[W]
Expected Load
Power, PL [W]
Load Power, PL
Current, I [A]
[V]
Load Voltage, VL
Input Voltage,
Vin [V]
Final Electrical Design Results
0.66
1.7
2.2
Testing
Experimental Design
Experimental Design for HS Camera Analysis of a Micro Nucleating Bubble Engine
– High Speed Camera
– Scale
– A high intensity light
Equipment
• Camera: Photron Ultima
APX digital video
• Lens: Nikon AF Micro
NIKKOR 105mm 1:2.8 D
with optional 2x
magnification.
• Light: 600 watt halogen
continuous source
• Fan: High CCM 24 volt
• Scale: Stainless, + .01 mm
• Camera mount: standard
x-y mount
• Base: optics table
High Output
Light Source
Scale
Bubble
Engine
High
Capacity Fan
HS camera
X-Y axis
Base
Placement of Scale should Correspond to the CL of engine piston.
White
Backgroud
Testing
Wave Heater
Coil Heater
Customer Specifications
• Keep the design within a 1 foot cube
– Completed: The power supply was reduced in size to maintain
this size requirement
• Maintain a budget of $500
– Used less than $200
• Dimensions within a mm scale
– The inside diameter of ~5.5 mm
– The height of the piston is 25.4 mm
• Benchmark efficiency of engine
– The efficiency has been benchmarked at .07%
• Bubble visualization with high speed camera
– Video has been taken
• Develop mathematical models
• Run time of at least 20 seconds
– Greater than 20 seconds
• Frequency of at least 5 to 10 Hz.
– Approximately 20 Hz.
Results
Max displacement of 7 mm
Max displacement : 5 mm
Efficiency:
Results