Corporation 4 NASA Project Manager Phillip Young Presenting John-David Jenkins and Jack Becker

Transcription

1 Corporation 4 NASA Project Manager Phillip Young Presenting John-David Jenkins and Jack Becker

2 Outline Electrical Engineer Progress Report EE Interface Diagram Project Management Systems Engineering (SE) Mission Objectives SE Concept of Operation SE Architecture and Design Overall Dimensions Frame Subsystem Linkage Subsystem Bucket Subsystem Bearing Selection Bolt Selection Wheel Geometry Gator Interface SE Verification and Validation

3 EE Progress Report Progress has gone as planned and on schedule (We have a working demo) All components are mounted Xbox 360 controller Joystick controls actuator A Button turns motor ON/OFF Power system was overheating Add heat sink to voltage regulators Add a cooling fan

4 EE Interface Diagram

5 Project Management Presentation Goals 1. To present a detailed design of hardware (i.e. drawings and specifications to fabricate) 2. Establish the basis for proceeding with manufacture - Show that the correct design option has been selected - Dimension all parts and prepare for manufacture - Prepare Manufacture and Assembly plan -Verification methods have been established

6 Project Management (cont) Program Manager (Dr. Beale) Systems Engineer (John Andress) Project Manager (Phillip Young) Frame Subsystem (Lead Alan Gaskins) Bucket Subsystem (Lead JD Jenkins) Linkages Subsystem (Lead Bryant Hains) Subsystem Member (Jack Becker) Subsystem Member (Joe Bryant) Force Analyst (Luke Weniger) Management Structure

7 Project Management (cont) Milestones

8 Duration (Days) % Complete Working Days Days Complete Days Remaining 8 / 18 / 08 8 / 25 / 08 9 / 1 / 08 9 / 8 / 08 9 / 15 / 08 9 / 22 / 08 9 / 29 / / 6 / / 13 / / 20 / / 27 / / 3 / / 10 / / 17 / / 24 / / 1 / / 8 / / 15 / / 22 / / 29 / 08 Project Management (cont) NASA Lunar Harvester Corporation 4 Project Lead: Phillip Young Today's Date: 12/5/2008 Gantt Task Chart [42] Start Date: 8/18/2008 (Mon) 0 WBS Tasks Task Lead Start End 1 Frame Subsystem Alan 10/02/08 12/15/ % Frame 10/02/08 10/21/ % Wheel Structure 10/15/08 10/21/ % Subsystem Interface 10/20/08 11/08/ % Gator Interface 11/09/08 11/28/ % Bucket Subsystem John-David 10/02/08 12/15/ % Bucket 10/02/08 10/18/ % Blade 10/02/08 10/18/ % Front Door 10/02/08 11/09/ % Subsystem Interface 10/02/08 10/29/ % Linkage Subsystem Bryant 10/02/08 12/15/ % Mechanical Links 10/02/08 10/18/ % Actuator 10/02/08 10/18/ % Joints 10/02/08 11/07/ % Subsystem Interface 10/02/08 10/30/ %

9 SE Mission Objectives Mission Statement Create a tele-operated lunar harvester prototype targeting less than 150 W power usage and weighing less than 100 kg for studies on the earth fulfilling environmental requirements of the moon. Mission Level Requirements Shall be designed to conduct studies on earth but be able to operate in a Lunar environment Shall interface with Gator utility vehicle Shall be designed to integrate Electrical Engineering subsystems into the mechanical design Shall collect and hold at least 50 kg soil per hour

10 SE List Concept of Operations i) Lunar Prototype to harvest position, scrape soil from behind Gator in lane-like fashion until bucket reaches capacity ii) Lunar Prototype to transport position, Gator returns to collection point with Lunar Prototype pulled behind, only surface contact is Lunar Prototype wheels iii) Gator drives up and over soil ramp to position Lunar Prototype over hopper opening iv) Lunar Prototype to dump position, empty bucket contents into hopper v) Lunar Prototype to transport position, Gator returns to harvest area vi) Lunar Prototype to harvest position, begin scrape process

11 SE Graphical Concept of Operations Harvesting Position Dumping Position Transporting Position

12 SE Mechanical Architecture and Design Lunar Harvester Prototype Bucket Frame Linkages Blade Wheel Structure Bucket/Linkages/ Frame Interfaces Gator Interface Linear Actuator Pivot Bar Transfer Bar Rotational Bar Container Tire Sealed Bearings Hitch Interface Bracket Sealed Bearings Sealed Bearings Sealed Bearings Welded Bucket Wheel Bracket Socket Cap Screw Frame Mount Slider Base Socket Cap Screw Socket Cap Screw Socket Cap Screw Sealed Bearings Wheel Axle Washers and Spacers Frame Bracket Slider Linkage Actuator Connection Rod Socket Cap Screw

13 Overall Dimensions Total Prototype Dimensions Weight: lbs (55.23 kg) Length:72 inches Width:28.5 inches

14 Frame Subsystem Switch was made from standard square metal tubing to 80/20 Square Tubing for ease of manufacture and assembly Standard brackets for frame are provided by 80/20 Non-standard brackets and tabs will be manufactured in house Requirements: Shall interface with a Gator utility vehicle Shall maintain horizontal orientation of harvester frame for optimal harvesting and dumping positions Shall maintain or enhance structural rigidity/strength of frame subsystem Shall accommodate yaw motion required for trailing Gator Frame Isometric View

15 Linkage Subsystem Derived Requirements Shall be able to move bucket into the three desired mechanical positions Shall be powered by motorized actuator Shall provide mechanical advantage in operating bucket Shall constrain bucket movement to safe bounds Shall allow variable digging depth that includes the range of 1-5cm

16 Linkage Subsystem (cont) Provides variable 1-5 cm cutting depth At 1.25 Digging Depth (In inches)

17 Linkage Subsystem (cont) Dumping Position 70 angle achieved to ensure dirt removal Bumper stop could be implemented to restrain linkages from obtaining toggle position

18 Linkage Subsystem (cont) Linkage Interface Rod Linkage Interface Rod allows 1 linear actuator to use both sets of mechanical linkages ½ Diameter Alloy Steel

19 Link Subsystem Cont. General Description Tolomatic mxe32s Linear Slide High degree of customizability Critical Review Update Single Actuator with Linkage Interface Rod Brackets integrated with actuator Can handle extremely large vertical forces Maximum Forces the MXE-S can handle

20 Shock Load Information Worst case scenario shock load for FEA was 500 lb Calculated using impulse For Normal Traveling Velocity: If traveling just above the required velocity of 2.2 cm/min (3.67x10-4 m/s) and a maximum mass of 150kg stopping nearly instantaneously (.001s), the impulse average force is calculated to be 12.36lb-force. If this force were translated through the linkage system, the actuator would experience a force of about 26lbs acting vertically and about 8lbs acting along the axial direction.

21 Force Transfer Bar Force Load Case

22 Force Transfer Bar FEA (stress)

23 Pivot Bar Load Case

24 Pivot Bar FEA (stress)

25 Rotational Bar Load Case

26 Rotational Bar FEA (stress)

27 Linkage Interface Bar M max I r y.5in max 12in 250lbs 4 / 4 / 64 My/ I 96000/ 3000lb in lbs / in 2 F=250 lbs F=250 lbs F=250 lbs F=250 lbs

28 Bucket Load Case

29 Bucket FEA (Stress)

30 Blade Load Case 100 lbs distributed across the front of the blade

31 Blade FEA (stress)

32 Bearings Manufacturer: Daemar Bearings Inc Dry slide self-lubricating bearing with PTFE coating

33 Bearings (cont) Bearing Specs (in) Max. Load (N/mm^2) (psi) Outer dia Static Load Inner dia Very Slow Speed Width 0.75 Rotating/Oscillating Radial Load (lbs. to psi) Shaft Diameter (in) Width (in) Load on Bearing (lbs) P (psi)

34 Bolts Bucket and Linkage Bolt 5/16-18 socket cap screw 1-1/4 long Linear Actuator Interfacing Bolt ¼ 20 socket cap screw

35 Wheel Geometry Tires have built in bearing Axle is stationary Wheel Diameter 13.5 Aluminum Bracket Tire Type Pneumatic Rim Size (in.) 6 Tire Size 13.5 x 400 x 6 Diameter (in.) 3/4 Bearings Included Yes Hub Width (in.) 6 Load Capacity (lbs.) 300 Rim Included Yes Tubeless Tire Yes Tread Type Ribbed Shipping Weight (lbs) 7

36 Gator Interface Hitch will be purchased off the shelf Brackets will be manufactured in house using.25 inch thick aluminum plate Will be replaced by interfacing plate on final lunar design

37 Bill of Materials Item # Part Item Quantity Material Part # Cost Supplier 1 Frame Rail Square Tubing " 2 80/ $10.55 BA 2 Cross Beam Bracket 80/20 2 Hole Bracket 12 80/ $35.40 BA 3 Frame Bracket 80/20 4 Hole Bracket 8 80/ $35.20 BA 4 Straight Tongue Style Coupler 2 " Ball with 2" Channel Coupler $15.90 AAC 5 Gator Interface Beam 2" square tubing (.25" thick), 24" long 1 Al 6063 T52 - $28.00 OM 6 Hitch Ball 2" Regular Duty, Zinc Trailer Hitch Ball 1 Zinc $7.45 TPS Adjustable Quick Release 2" sq. Hitch Ball Hitch Mount 7 Mount 1 Black Powder Coated Al $69.95 TPS 8 Extruded Aluminum Rectangle 1.5" x 3" x.25" 1 Al 6061 T6 - $7.00 OM 9 Linear Slider Actuator MXE32S BN08 SK17 LMI Actuator $1, TI 10 Carrier Bracket 3 X 3 X 12 inch Aluminum Square 1 Al 6061 SQ33 $81.00 MD 11 Actuator Grounding Bracket Included with Actuator $0.00 TI Wheelbarrow Assembly, 3/4in. Bore 13.5 Wheel 12 x 400 x $49.88 NTE 13 Wheel Structure Bracket 1/4" thick sheet aluminum 12" x 12" 2 Al Alloy K13 $23.46 MCC 14 Wheel axle 3/4" diameter steel rod 6' in length /4142 Alloy Steel 8935K39 $29.97 MCC 15 Bucket Sides 24" x 24" x 1/2" Square Sheet Steel 1388K181 $ MCC 16 Bucket Rear Plate " - " - - MCC 17 Bucket Bottom Plate " - " - - MCC 18 Blade 5/8" x 3.5" x 24" 1 ASTM A K38 $70.70 MCC Rectangular Bar 1/2" Thick, 4" Width, 3' 8 1/4" Pivot Bar 19 Length /4142 Alloy Steel 6554K323 $ MCC /4" Force Transfer Bar " " - - MCC /4" Rotational Bar " " - - MCC 22 Rotational Bar Bracket " " - - MCC 1L40 Alloy Steel Rod 1/2" Diameter, 3' Linkage Interfacing Rod 23 Length 1 41L40 Alloy Steel 6776T132 $18.21 MD 24 Frame/Bucket/Linkage Nut 5/16" 18 nut (100 per box) 1 Steel 90499A030 $3.78 MCC 25 Actuator Nut 1/4"-20 (25 per box) 2 Steel 90630A110 $ 9.78 MCC Zinc & Yellow Stl SAE HI-Strength Flat Washer All Purpose Washer 5/16" Screw Sz, 11/32" ID, 11/16" OD,.055"- 2 Zinc 98023A030 $8.40 MCC " Thk (50 per box)

38 Bill of Materials (cont.) 27 Actuator Bolts 1/4"x1"-20(100 per box) 1 Steel 91251A542 $ MCC 28 Frame/Bucket/Linkages Bolts 5/16"id 1 1/4" socket cap screw 1 Steel MCC 29 Bearing 5/16" i.d. Self Lubricating Bushing 30 Steel/Bronze/Teflon 05TH06 $67.50 ABI 30 Bucket/Linkage Ream Solid-Carbide Fractional Chucking Reamer 3/8" Dia (.3750"), 3-1/2" L O'all,.3745" Shank Dia 2 HS Steel 3026A MCC Jobbers Twist Drill Bit Black-Oxide, 3/8" Size, Bucket/Linkage Drill Bit 31 5" L Overall, 3-5/8" L Flute 8 HS Steel 2931A MCC Solid-Carbide 2 in 1 Countersink Trade Size 2, Bucket/Linkage Center Bit 5/64" Drill Size, 3/16" Body Diameter 32 1 HS Steel 2925A MCC Bright Finish High-Speed Stl Spiral Point Tap Bucket/Linkage Bottom Tap 33 1/4"-20, H3 Pitch Diameter, 2 Flute 1 HS Steel 2523A411 $5.05 MCC 34 Layout Fluid Blue 16 oz. Layout Fluid A17 $7.61 MCC 35 NA Cold Saw Blade (180) A61 $92.97 MCC 36 NA Vert. Band Saw Blade A316 $43.26 MCC 37 NA Horz. Band Saw Blade A979 $55.05 MCC 38 End Mill 5/8" 2-Flute 4 HS Steel 2782A77 $ MCC 39 End Mill 1/2" 4-Flute 1 HS Steel 8912A45 $26.12 MCC 40 MCC - Mc Master Carr BA - Bertelkamp Automation AAC - Automotive Accessories Connection OM - OnlineMetals.com TI - Tolomatic, Inc. TPS - Trailor Parts Superstore NTE - Northern Tool + Equipment MD - MetalsDepot.com ABI-Alabama Bearing Inc. Total $2,840.82

39 Manufacturing Plan Linkages will be purchased as close to final design as possible Linkage machining will be carried out using mills Brackets will be made out of sheet metal Bracket machining will also be carried out using mills All machining will take place in the Design and Manufacturing Lab All parts will be measured to insure correct tolerances before being approved Bucket will be manufactured out of sheet metal and welded

40 Assembly Plan Frame will be assembled using pre-existing bolt pattern and brackets purchased from 80/20 All brackets and attachment points will be connected to the frame Linkage sub-assembly will be attached to their respective mounting points Bucket will be attached to rotational and pivot bars Actuator will be mounted to frame Actuator and force transfer bar will be connected Tire axle will be attached to frame Tire will be attached to tire brackets Trailer hitch will be attached

41 SE Verification and Validation Phase C Verification: Determine forces acting on individual links. Verify linkage/frame construction by performing FEA using ALGOR. Total picture verification Plan for Phase D Verification: Assemble linkages separately to test effectiveness. Assemble total system for manual proof of concept testing. This could consist of manual movement of bucket positions, manual pushing of bucket through pseudo-regolith. Conduct proof of concept testing at USDA facility using all components and interfacing to the Gator vehicle

42 Summary Electrical Engineer Progress Report EE Interface Diagram Project Management Systems Engineering (SE) Mission Objectives SE Concept of Operation SE Architecture and Design Overall Dimensions Frame Subsystem Linkage Subsystem Bucket Subsystem Bearing Selection Bolt Selection Wheel Geometry Gator Interface SE Verification and Validation

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