06411 Mini Nucleating Bubble Engine Steven Nathenson Joseph Pawelski Joaquin Pelaez Andrew Pionessa...
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Transcript of 06411 Mini Nucleating Bubble Engine Steven Nathenson Joseph Pawelski Joaquin Pelaez Andrew Pionessa...
06411 Mini Nucleating Bubble Engine
Steven NathensonSteven NathensonJoseph PawelskiJoseph PawelskiJoaquin PelaezJoaquin Pelaez
Andrew PionessaAndrew PionessaBrian ThomsonBrian Thomson
Project OverviewProject DescriptionProject Description
– Creation of a mini device (mm scale) that harnesses the Creation of a mini device (mm scale) that harnesses the energy from periodic vapor bubble formation (nucleation) in energy from periodic vapor bubble formation (nucleation) in a fluid resulting from heatinga fluid resulting from heating
– Current research MEMS devices use a micro scale (Current research MEMS devices use a micro scale (m) m) piezoelectric membrane to convert mechanical oscillations piezoelectric membrane to convert mechanical oscillations from bubble nucleation directly to electrical current.from bubble nucleation directly to electrical current.
– Project focuses on the development of a slightly larger (mini) Project focuses on the development of a slightly larger (mini) scale engine permitting greater experimental analysis scale engine permitting greater experimental analysis capability in addition to implementation in applications capability in addition to implementation in applications requiring mechanical energy.requiring mechanical energy.
– Periodic bubble nucleation is produced by a mini heater Periodic bubble nucleation is produced by a mini heater powered by a modulated power supply.powered by a modulated power supply.
Needs Assessment• Design ObjectivesDesign Objectives
– Size limitations – 1 ftSize limitations – 1 ft33 – Cost Cost – mm scalemm scale– Regulate the heater via a control systemRegulate the heater via a control system– Battery or power supply operatedBattery or power supply operated
• Standard sized batteryStandard sized battery• Voltage and amperage based upon the power Voltage and amperage based upon the power
requirements of heaterrequirements of heater– What type of fluid allows for the best bubble growth?What type of fluid allows for the best bubble growth?– Create a light weight systemCreate a light weight system– Successfully test deviceSuccessfully test device– Benchmark efficiency of engineBenchmark efficiency of engine– Bubble visualization with high speed cameraBubble visualization with high speed camera
• Develop Theoretical ModelDevelop Theoretical Model– System modelsSystem models
Technical Requirements• Performance RequirementsPerformance Requirements
– Mechanical oscillation greater than 5-10 HzMechanical oscillation greater than 5-10 Hz– Run time of 20 seconds or moreRun time of 20 seconds or more
• Functional RequirementsFunctional Requirements– Bulk fluid temperatureBulk fluid temperature
– Bubble growth surfaceBubble growth surface
• Yield the appropriate amount of bubbles from the heating Yield the appropriate amount of bubbles from the heating surfacesurface
– Minimize friction toMinimize friction to • Increase efficiencyIncrease efficiency
• Accurate bubble modelAccurate bubble model
Risk AssessmentMajor Project RisksMajor Project Risks
– Engine parts could be too unique and smallEngine parts could be too unique and small• May result in going over budgetMay result in going over budget• May result in lack of timeMay result in lack of time
– The engine design may be to similar to The engine design may be to similar to current MEMS devices if a piston or piston current MEMS devices if a piston or piston like design is not utilizedlike design is not utilized
– Bubbles may be too small to move the Bubbles may be too small to move the piston a significant amount for testingpiston a significant amount for testing
Gantt Chart
Attribute Option 1 Option 2 Option 3 Option 4 Option 5 Option 6
Engine Type Buoyant pistonPartially
Submergedpiston
Submergedcantilever beam
Non-submergedcantilever beam
Rotary w/ ndent
Rotary w/Volumechange
Liquid TypeDe-ionized
waterAlcohol Other ------------- ------------ ------------
Impact Plate Resistant wire Protective plate Other ------------- ------------ ------------
Power SupplyDC power
supplyDC battery AC power supply ------------- ------------ ------------
Heating Element
Straight wire Square wire Circular wire Concentric wire Metal plate ------------
Control System
Stampcontroller
ASIC chipOther
programmable chip------------- ------------ ------------
Cooling System
None Fluid reservoir Heat exchanger ------------- ------------ ------------
Movement Causality
Bubble ImpactBoiling &
Condensation----------------- ------------- ------------ ------------
Electrical System
Pulse widthModulator
(PWM)
AC circuitdesign
DC circuit design ------------- ------------ ------------
Morphological Chart
Concept Feasibility Relative
weight Concept
1 Concept
3 Concept
4 Concept
5 Concept
6 Be Portable 0.079 3 3 3 3 3 Utilize a miniature heating element
0.096 3 3 3 3 3
Be Under Budget 0.011 3 2 2 1 1 Utilize a power supply or a battery
0.073 3 3 3 3 3
Produce a mechanical oscillation
0.084 3 3 3 1 1
Create a millimeter sized engine
0.079 3 2 2 2 2
Protect the heating element
0.118 3 3 3 3 3
Control bubble growth via a control system
0.112 3 3 3 3 3
The liquid reservoir should be cooled
0 3 3 3 3 3
Theoretically prove engine design
0.107 3 3 3 1 1
Create a working engine 0.096 3 2 2 1 1 Test the engine 0.084 3 3 3 3 3 Create a lightweight design
0.062 3 3 3 3 3
Alleviate friction between piston and casing
0.082 3 4 4 4 4
Raw score ---------- 3.249 3.145 3.145 2.656 2.656 Normalized score ---------- 1 0.968 0.968 0.817 0.817
Weighted Average Analysis
Design Overview• Buoyant Piston DesignBuoyant Piston Design
– Expanding bubbles in the water cause Expanding bubbles in the water cause piston to move piston to move
– Piston-cylinder configurationsPiston-cylinder configurations • Simple to machineSimple to machine• One moving partOne moving part
– Movement of piston easily measuredMovement of piston easily measured
– Piston is buoyantPiston is buoyant• Seal is not crucial and may leak slightlySeal is not crucial and may leak slightly• Friction is reducedFriction is reduced
Detailed DesignMaterial SelectionMaterial Selection• Piston CasingPiston Casing
– Boroscilicate Glass (Pyrex)Boroscilicate Glass (Pyrex)– Stock part at McMaster - CarrStock part at McMaster - Carr– Machining - glass department is able to cutMachining - glass department is able to cut
• Piston BasePiston Base– Glass Mica Ceramic – high temp Glass Mica Ceramic – high temp – Machining - Mechanical engineering machine shopMachining - Mechanical engineering machine shop
• PistonPiston– Low Density Polyethylene (LDPE)Low Density Polyethylene (LDPE)– Less dense than waterLess dense than water– Core center to promote floatationCore center to promote floatation– Machining - Mechanical Engineering machine shopMachining - Mechanical Engineering machine shop
• ElectrodesElectrodes– Copper Wire - Stock item at McMaster-CarrCopper Wire - Stock item at McMaster-Carr
• Heater ElementHeater Element– Option 1Option 1
• Platinum wire and soldered electrodesPlatinum wire and soldered electrodes– Option 2Option 2
• Manufactured heating elements provided by Dr. KandlikarManufactured heating elements provided by Dr. Kandlikar
Pyrex Glass Casing
Ceramic Mica Base
LDPE Piston
Platinum Wire
Copper Electrodes
Piston Design
mD
mh
wp
pi 0052.0
42
37
322
3 3504.159tan3
2mE
rhrhrV bbbpp
WM
WT
TCS
VV
VtRRtHtA
max,
max,22 0))])(()([(Piston ConsiderationsPiston Considerations
–Max volume of piston Max volume of piston given density of water & given density of water & piston materialpiston material
–Obtain wall thicknessObtain wall thickness
–Obtain true piston Obtain true piston volume given drill bit volume given drill bit dimensionsdimensions
–Verify that the piston Verify that the piston still floats at appropriate still floats at appropriate heightheight
Budget
$500$500– PistonPiston– CasingCasing– BaseBase– Heater Heater – Electrical ControlsElectrical Controls
Part # Name Description Quantity Unit Cost Total Cost
1 PistonLow density Polyethelyne, 0.25" OD ± 0.018" x 8 ft., McMaster Carr
#8754K12 8 $0.67 $5.36
2 CasingPyrex tubing, 0.375" ± 0.012" x 0.218" ± 0.028" x 1 ft., McMaster Carr
#8729K33 1 $4.16 $4.163 Base Glass Mica Ceramics, 1/2" OD x 3", McMaster Carr #8499K618 1 $26.35 $26.354 Electrodes Copper wire - .032" (78 ft) (8873K17) Mcmaster-Carr 1 $3.13 $3.135 Heating Element Platinum Wire, 0.008" OD x 0.16437" 1 $0.00 $0.00
$39
Theoretical Models
Navier StokesNavier Stokes– Parallel Plates with Parallel Plates with
GravityGravity • Upper plate is moving at a Upper plate is moving at a
constant velocityconstant velocity
– Pipe Flow with GravityPipe Flow with Gravity 2
max2
R
rv
r
vx
2
1
a
yρg
x
Pa
a
μu
y
uμτ x
max
Theoretical ModelsSystem ModelsSystem Models
– Factors taken into accountFactors taken into account
– Two model types Two model types • Based upon geometrical relationshipsBased upon geometrical relationships• Based directly off of the Navier-Stokes equationsBased directly off of the Navier-Stokes equations
– 5 total models5 total models• Some neglected forces shown to be insignificantSome neglected forces shown to be insignificant• Some include all forces of the systemSome include all forces of the system
– Verification ModelVerification Model• Simplified version of the modelsSimplified version of the models
xxDD
D
DD
D
a
D
xDD
D
a
hDx
DD
DDgxm
Bkxm
pc
p
pc
ppw
pc
pipw
pc
ppwpp
pp
22
2
22
2
22
2
22
2
2
4
11
B1
B2K1
xp Mp Piston
Mw Water
xDD
DDgxx
DD
D
a
Dx
a
hD
xxDD
D
DD
D
a
Dx
DD
D
a
hDWFxm
pc
ppww
pc
ppww
ipw
pc
p
pc
ppw
pc
pipwwbww
22
2
222
2
22
2
22
2
22
2
4
Systems Model 1Systems Model 1
– Second order approximationSecond order approximation– Negligible forces are Negligible forces are
removed to simplify the removed to simplify the systems modelsystems model
– Model is setup for a known Model is setup for a known water displacementwater displacement
– Model assumes that the water Model assumes that the water moves proportional to the l moves proportional to the l displacement of the bubbledisplacement of the bubble
Theoretical Models
B1
B2
B4
xp
xw
mp
mw
B3
K1
Water
Piston
1222
44
2
22
iwpwppw
ipwppwipwpp
hgaD
xgaD
xxa
D
xa
hDgmxDghDgxm
Systems Model 2Systems Model 2
– First order approximationFirst order approximation– Neglects the viscous shear Neglects the viscous shear
force due to the air on the force due to the air on the pistonpiston
– Model assumes that the water Model assumes that the water moves proportional to the l moves proportional to the l displacement of the bubbledisplacement of the bubble
Theoretical Models
Plot comparison from Simulink Models Plot comparison from Simulink Models – Negligible factors in design considerationsNegligible factors in design considerations
Theoretical Models
Additional Theoretical Analysis
Bubble growth rateBubble growth rate– Mikic’s equationsMikic’s equations– Experimentally Experimentally
determine with high determine with high speed cameraspeed camera
A
RBtR
2
113
2 2/32/3 ttR
2
2
B
tAt
2/1212
Ja
B
2/1
)(
)(
LSatL
GfgLSatL
pT
hpTTbA
Additional Theoretical Analysis
• Heat TransferHeat Transfer– Transient heat Transient heat
conductionconduction– Semi-infinite solidSemi-infinite solid
10 ms10 ms
t
xerfc
k
xq
t
x
k
tq
TtxT oo
*2**4exp
***2
,"2
2
1
"
x
qo”
T ∞ = 25 C
T s = 400 C
WPower 495.101
WPower 495.101
Electrical System Requirements
SpecificationsSpecifications– Supply pulse signal with adjustable amplitude, duty cycle, Supply pulse signal with adjustable amplitude, duty cycle,
and frequencyand frequency– Signal must be output continuouslySignal must be output continuously– 100, 72, and 60 W signal for 10, 20 and 30 ms pulse 100, 72, and 60 W signal for 10, 20 and 30 ms pulse – Implement component protection as well as operator Implement component protection as well as operator
protectionprotection– Design for small load resistance (~0.5 Ω)Design for small load resistance (~0.5 Ω)– Flexible for different loadsFlexible for different loads
Specific Electrical Requirements
Load Power, PL
[W]Pulse Width, PW
[ms]Input Voltage,
Vin [V]Current, I [A]
100 10 7.18 14.142
72 20 6.09 12
60 30 5.56 10.956
Electrical System Concepts
Power Supply
ControlSystem
MeasureVoltage,
Current, Power
HeaterSystem
Power Supplied to
System
Power lostdue to Thermal
Resistances Pulse
AmplitudeControl
FrequencyControl
Duty CycleControl
MeasureVoltage,
Current, Power
CreatePulse Signal
Final Electrical Design
M1
Vin
0 0
Load
G1
S1
D1
D2
D4
V 5Vdd
0
D3G2
G4
G3S2
Vin
0
V 6Vdd
0
S4
S3
Load
0
M2
0
V 7
Vdd
Load
M3
M4
Vin
0 0
I
PL, VL
PL, VL
I
I
PL, VL
(a) Single NMOS (b) Single PMOS (c) Combined
22 TGSD VVk
I Current for saturation condition
Final Electrical Design Results
Input Voltage, Vin [V]
Pulse Width,
PW [ms]
Load Voltage, VL [V]
Current, I [A]
Load Power, PL [W]
Expected Load
Power, PL [W]
Percent Error [%]
5.65 10 7.0943 14.189 100.658 100 .658
5.2 20 6.0509 12.102 73.227 72 1.7
4.3 30 5.5370 11.074 61.316 60 2.2
TestingExperimental DesignExperimental Design
– Accurate high speed video Accurate high speed video analysis analysis
– Precision scalePrecision scale– A high intensity light for A high intensity light for
maximum resolutionmaximum resolution– EquipmentEquipment
• Camera: Photron Ultima APX Camera: Photron Ultima APX digital videodigital video
• Lens: Nikon AF Micro Lens: Nikon AF Micro NIKKOR 105mm 1:2.8 D with NIKKOR 105mm 1:2.8 D with optional 2x magnification.optional 2x magnification.
• Light: 600 watt halogen Light: 600 watt halogen continuous sourcecontinuous source
• Fan: High CCM 24 voltFan: High CCM 24 volt• Scale: Stainless, Scale: Stainless, ++ .01 mm .01 mm• Camera mount: standard x-y Camera mount: standard x-y
mountmount• Base: optics tableBase: optics table
Experimental Design for HS Camera Analysis of a Micro Nucleating Bubble Engine
Placement of Scale should Correspond to the CL of engine piston.
High Capacity Fan
Scale
X-Y axis
HS camera
Base
BubbleEngine
WhiteBackgroud
High OutputLight Source
Preliminary Test Conclusions
Problems encountered during preliminary testing Problems encountered during preliminary testing – More power is neededMore power is needed
– Higher resistance heaterHigher resistance heater
– Ability to solder small scale – Micro-e departmentAbility to solder small scale – Micro-e department
– Solder to withstand high temperaturesSolder to withstand high temperatures
– A more stable platformA more stable platform
– Formal setupFormal setup
– These details will be worked out in Senior Design II by the senior These details will be worked out in Senior Design II by the senior design teamdesign team
Senior Design II PlanTasks Week 11 Week 12 Week 13 Week 14 Week 15 Week 16 Week 17 Week 18 Week 19 Week 20
ResearchResearch MEMS DevicesResearch bubble bynamicsResearch patents
PlanningDelegate tasksDetermine sponsor meeting timesDetermine mentor meeting timesDetermine team meeting timesCreate work breakdown structureReview and revamp WBSCreate Gantt chartReviw and revamp Gantt ChartMission statementTechnical requirementsRisk AssessmentConcept developmentFeasibility assessment
DesignElectrical engineeringSystems engineeringFluids engineeringThermodynamic engineeringMechanical engineeringDrafting
Production & AssemblyManufacturing engineeringAssemble system
TestingDetermine what data should be recordedDetermine how to test systemCreate experimental setupRun test setupRecord dataAnalize dateGenerate data charts, tables, etc.
ReportsPeer reviewPDRCDR
Demonstrations
• Enlarged mock-upEnlarged mock-up
• MATLAB SimulationsMATLAB Simulations– Bubble growthBubble growth– Piston movementPiston movement