William Lentlie – Project Leader (ME)Tim Buckner – Lead Engineer (ME)Hope Alm – Mechanical Engineer

Shauna Traxler – Mechanical EngineerAndres Santizo Matheu – Industrial Engineer

P-12462 TOW TANK FOR TETHERED

HYDROFOIL

Faculty Guide: Ed HanzlikSponsors: Dr. Mario Gomes

EPA P3

• Project overview• System design• Actual design summary• Testing• Conclusions• Recommendations• Questions

AGENDA

http://www.cityofsouthlake.com/waterconservation

• To build a small scaled version of tethered hydrofoil to compare with a simulation provided by Dr. Mario Gomes in MATLAB.

• Create a tow tank capable of moving a platform at a constant specified speed over the top of a stationary body of water in order to recreate a river flow passing over a hydrofoil.

OBJECTIVE

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CUSTOMER NEEDSImportance Description How its being Accomplished

9Tow tank must be able to tow a platform above the surface of a stationary body of water at a

constant speed

Tank size meets specification

Motor Speed controlled with driver

Driver has different speed ranges

Calculated from F=ma+Fdrag

3The platform must allow an attachment of two

different instrumented systems, a set of stationary hydrofoils and a model of a translating

hydrofoil system

Tank size meets specification

Tank weight is below required by floor

Interface allows for different attachments

9 Tow length needs to be large enough to achieve steady state

Tank size meets specificationTank length = 16ft

Driver will control speed and accel/decel can be set for 0-30sec

9 System size should allow for appropriately scaled model testing

Tank size meets specification

Total approximate weight = 150lbs

Calculated from F=ma+Fdrag

3 Platform should be above or to the side of the water with no moving parts under water Cart has multiple attachment points

CUSTOMER NEEDSImportance Description How its being Accomplished

9Platform must allow for bolting of the

instrumented model away from the wall of the tank

Cart has multiple attachment points

9Measurements should be of high quality and

should be made with appropriate sampling rates and resolution

Encoder, DC driver speed sensor

Deflection calculations performed in ANSYS

Measurement device should match specification

DC drive accuracy ± 1/2 rpm, encoder mounted

Measurement device should match specification

Measurement device should match specification

Timed in Labview

9 The tank must be safe for the operator and those around them

Ergonomics was considered in the height of tank

9 The tank must not damage the surroundings Membrane or sealant will be used to stop leaks

3 The tank must be cost effective Cost meets budget

3 Easy to use and to train new usersLabview useability will be a priority

Users Manual / Video will be provided

9 Tank should not interfere with operation of models P12463 is aware of the size constraints

ENGINEERING SPECSSpecification Value

Size <= 19ft in length and 50in in width

Weight 300 lbf/ft^2System Cost < $2000

Distance Cart Travels 16ft

Velocity of Cart 3.28 ft/sTowing Velocity Variation 0-3.28 ft/s

Towing Force 60lbsMax Sideways Deflection of Rail System 1/32" Center of Platform From Edge of Tank 1 <= 8 in

Data Sampling Rates 500 HzResolution of Velocity Data (0.032 +/- 0.164) ft/s

Resolution of Force Data (.1 +/- .2) lbf Resolution of Distance Data (3/8 +/- 1 7/8) in

Resolution of Time Data (0.001 +/- 0.01 s)

Setup Time (By User) < 30 min

Can Test Different Models and Hydrofoil Sets > 2 sets

Compliance with Accepted Safety Protocols and Regulations In Compliance with All Standards

Tank is Designed so Model is Not Restricted in its Motion

Tank does not Interfere with Model

Tank assembly does not damage its surroundings Tank causes no Damage

Training Time (1st Time) < 60 min http://engineeringmyfuture.webs.com/

PROJECT TIMELINESept 11

• Planning: Customer Needs & Engineer Specs

Sept 11• Concept Development: Brainstorm, Concept Evaluation

Oct 11• System Review: Pool vs. Tank, System Architecture

Nov 11• Detail Design Review: BOM, Feasibility Analysis

Dec 11Jan 12

• Manufacturing: Mini-Tank, Full Scale Tank

Feb 12• Testing: Functionality, System Interaction

Feb 12• Final Product: Delivery, Final Presentation

Proposed concepts for the tank materials.• Wood structure and

wood panels• Steel structure and

wood panels• Steel structure and steel

panelsProposed concepts for rails and cart• Angle iron rails and skate

bearings• 80/20 linear motion

system• Machined bottom

supported rail

CONCEPT GENERATION

ANALYSISForces applied

• Hydrostatic Force at maximum height

• Point load of 200 lbf (889.64 N)

Constraints• Deflection: 1/32”

(7.94e-4 m)• Yield Stress: 50 ksi

(345 Mpa)

Dimensions [in] FOS Stress FOS DeflectionAngle Iron 2x2x.125 (Length) 6.42 2.25

Length with -100lbf point load 0.67 0.28Length with +100lbf point load 0.83 0.37

Angle Iron 2x2x.375 with 2x2x.25 20.45 9.64Length with -100lbf point load 4.39 1.93Length with +100lbf point load 6.34 3.09Length with -200lbf point load 2.38 1.06Length with +200lbf point load 2.85 1.34

FINAL DESIGN• 3/8 in (9.525 mm) thick, 2” SQ. (5.080 cm)

Angle iron• 1/4 in (6.350 mm) thick, 2” SQ. (5.080 cm)

Angle iron• 3/4 in (19.050 mm) thick Plywood• 16 feet (4.877 m) long 80/20 Aluminum • 3/4 hp (559.270 w) Motor• 1/16 in (1.588 mm) diameter Aircraft Cable• 6 in (15.240 cm) diameter Pulleys

• Tanks dimensions: 16 feet (4.877 m) long, 2.5 feet (0.762 m) wide, and 2 feet (0.610 m) high.

• Max cart towing velocity: 3.21 ± 0.10 ft/s (0.950 ± 0.025 m/s)• Max volume of water: 599 US gallons (2,265 L)• 2 modular pieces, capable of being disassembled, moved, and

reassembled by 2 people

FINAL PRODUCT

• Velocity Range• Distance Accuracy• Start Up Transients• Cable Wear

TESTING TECHNIQUES & DIFFICULTIES

TESTING RESULTS

BUDGET

http://shannonpenrod.wordpress.com/2010/06/29/money-makes-the-world-go-around/

Tank QTY COST Tank Walls 23/32" Plywood - 4' x 8' Sheets 4 $87.48 Tank Walls 23/32" Plywood - 4' x 8' Sheets - Mini-Tank Design 1 $21.87 Tank Walls #10 x 1in. Flat Head Phillips Drive Wood Screw (100 pcs) 1 $21.87 Tank Support 2" x 2" x 1/4" Steel Angle - 22-7/8" LG. - Mini Tank & Large Tank 4 $87.48 Tank Support 2" x 2" x 1/4" Steel Angle - 25-3/4" LG. 2 $43.74Motor DC Motor Motion Transfer from Motor 1 $0.00 DC Drive Speed control and Power Supply 1 $0.00 Speed Sensor Feedback loop to DC driver 1 $0.00Motion System 1/16" Cable Wire Rope - Aircraft Cable 1/16", 7x7, by the foot 100 $13.00 Drive Pulley Transfers Motion 1 $9.16 Pulley Pulley with plain bronze bearings 1 $10.50Rail and Platform Length Rails 1" x 1" T-Slotted Extrusion 2 $64.88

Width Rails and Supports 1" x 1" T-Slotted Extrusion-97" 1 $29.08

Initial Budget: $2,000Expanded Budget: $2,500

Final Expenses: $2,169.05

• Waterproofing plywood

• Liner management

• Leak detection

• Tow cable management

• Safety

CHALLENGES

CONCLUSIONS

Customer Needs and Objectives

Importance Description How its being Accomplished Comments

Tank size meets specificationMotor Speed controlled with driverDriver has different speed ranges

Calculated from F=ma+Fdrag Need was removed by customerTank size meets specification

Tank weight is below required by floorInterface allows for different attachments

Tank size meets specification

Tank length = 16ftCart cannot travel full 16 ft, because of

boom arm lengthDriver will control speed and accel/decel

can be set for 0-30secTank size meets specification

Total approximate weight = 150lbsCalculated from F=ma+Fdrag

CN5 3Platform should be above or to the side of the water with no

moving parts under waterCart has multiple attachment points

CN6 9Platform must allow for bolting of

the instrumented model away from the wall of the tank

Cart has multiple attachment points

Encoder, DC driver speed sensor Labview motor control needs attention

Deflection calculations performed in ANSYS

Measurement device should match specification

DC drive accuracy ± 1/2 rpm, encoder mounted

Measurement device should match specification

Measurement device should match specification

Timed in Labview

CN8 9The tank must be safe for the

operator and those around themErgonomics was considered in the height of

tank

CN9 9The tank must not damage the

surroundingsMembrane or sealant will be used to stop

leaksLiner does not satisfy concerns on leak

prevention

CN10 3 The tank must be cost effective Cost meets budgetWent over initial budget of $2000, but

stayed well under secondary budget of $2500

Labview useability will be a priorityIn process of creating Labview

DirectionsUsers Manual / Video will be provided

CN12 9Tank should not interfere with

operation of modelsP12463 is aware of the size constraints

Needs were removed by customer

CN7 9

Measurements should be of high quality and should be made with appropriate sampling rates and

resolution

CN11 3 Easy to use and to train new users

CN3 9Tow length needs to be large

enough to achieve steady state

CN4 9System size should allow for appropriately scaled model

testing

CN1 9

Tow tank must be able to tow a platform above the surface of a

stationary body of water at a constant speed

CN2 3The platform must allow an attachment of two different

instrumented systems, a set of

http://flowers.cdd5.com/showthread.php/amigo-semaforo/

1) Upgrade the plastic liner to a more durable material.2) Upgrade tow cable and/or drive pulley.3) Place windows in the tank walls to allow in water visibility. 4) Upgrade the plywood panels (walls) to sheet metal panels or glass panels5) Improve rail mounting to tank

FUTURE UPGRADES

http://www.pondlineronline.co.uk/

• EPA P3• Dr. Mario Gomes• Prof. Ed Hanzlik• Prof. John D. Wellin• Dr. Steven Day• Kelsey McConnaghy• Rob Kraynik• Jan Maneti• Dave Hathaway• FMS• Mahany Welding Supply

ACKNOWLEDGEMENTS

QUESTIONS

http://fhalosangeles.net/first-time-buyer-questions/