Cornell University Autonomous Underwater Vehicle Team Spring Frame

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1 Cornell University Autonomous Underwater Vehicle Team Spring 2014 Frame Technical Report Kent Esslinger (kde26) May 21, 2014

2 Contents 1 Abstract 2 2 Design Requirements 2 3 Previous Designs Drekar Killick Ragnarok High Level Description Mounting Capabilities Handles and Crane Mounts Thrusters Main Hull Battery Pods Doppler Velocity Log Killswitch Air Tanks Structural Analysis Current Status 16 6 Future Improvements 17 1 Spring 2014

3 1 Abstract The purpose of the frame is to provide a mechanically sound structure for mounting all vehicle components as well as having strategic locations for thrusters, cameras, the DVL and other crucial components and sensors. Gemini s frame is smaller and lighter than past years, providing better control of the vehicle. The components on Gemini are tightly and strategically placed to optimize the vehicle s profile in the water as well as accessibility of components. The frame is comprised of very few pieces, is manufactured using CNC technology, and has an efficient T beam cross section. 2 Design Requirements Constraints: Provide mounting for all components of the vehicle Fit through the width of a doorway, roughly 24 inches Achieve slgithly positive buoyancy Provide clear view cones for cameras and DVL beams Configured to mount thrusters for surge, strafe, and vertical capabilities Objectives: Minimize weight Minimize drag profile Minimize blocking of thrust cones Maximize ease of carrying vehicle and mouting with crane Maximize sheltering of sensitive components such as DVL and camera lenses Minimize distance from DVL to center of buoyancy Maximize ease of wire routing 2 Spring 2014

4 3 Previous Designs 3.1 Drekar Figure 1: Drekar s frame Drekar s frame was designed to be very sturdy while providing regularly spaced holes for mounting. This was important as many aspects of the overall design changed drastically throughout the design process, making adaptability a necessity and making it difficult to determine beforehand which sections of the frame could be made lighter. The frame design also aimed to be smaller and lighter than Tachyon s bulky frame. To accomplish this, the frame was made in a boat shape to be compact, and was composed of square tube members with joints that were inserted into the tubes and secured with screws. Many of the components were mounted to the frame by screwing onto metal mounting pieces which were screwed onto the frame. The biggest consideration that year was that the team was considering purchasing a new DVL, but due to a lack of budget, the idea was scrapped and the frame design had to be adjusted to accommodate the old DVL. Other important developments were the beginning of attempts to implement stereo vision and the possibility of using additional Video Ray thrusters for strafing, neither of which was successful in the spring. These were some factors that limited how compact the frame could be. Originally 3 Spring 2014

5 there was a plan to design a shroud to improve the hydrodynamic properties of the vehicle, but this was never accomplished. The Drekar frame was indeed very sturdy, perhaps too much so the point where some structural integrity could easily be sacrificed in order to reduce weight so that less foam was required to make the vehicle neutrally buoyant. The frame itself weighed pounds. The tube and joint design was time consuming to machine, as many pieces needed to be machined and many of the joints included round or angled features and many of the components had their separately machined mounting pieces. Tolerance was also an issue because of the large number of close-fitting joint connections which required precise machining. Figure 2: Killick s frame 3.2 Killick Killick s frame diverged significantly from the previous designs in that the frame pieces were largely CNCed, and there were only five separate pieces in the frame. The design aimed to greatly decrease the weight of the frame, highlighting the idea that during mission runs, when the vehicle s performance actually earns the team points, the frame does not need to bear much weight. Since the components of the vehicle were largely decided in the beginning of the year, the frame was highly optimized to reduce weight and mounting for each component was designed early in the fall. Also, to 4 Spring 2014

6 reduce the complexity and weight of mounting each component, almost all of the mounting holes were positioned on the five pieces of the frame itself. Each of these five at pieces had T beam cross-sections, a design that was largely mimicked in the frame design for Ragnarok. The frame on Killick performed quite well, with both the design and manufacturing being completed in the fall. The frame weighed only 2.42 pounds total and was significantly narrower than the Drekar frame. Assembly of the frame was also extremely foolproof and quick, since there were not many pieces that needed to come together and the screw holes for assembling the frame were easily accessible. Due to the reliance on CNC machining, the frame only took about 15 man hours to machine and the freedom of geometry meant that the frame was made to be aesthetically pleasing as well. Because of the rapid time frame of the design and manufacturing of the frame, as well as the scarcity of auxiliary mounting holes, it was not very adaptable to changes in the vehicle design. For example, holes for the killswitch were not drilled because the killswitch was designed after the right frame pieces was machined, and many of the thruster mounts were not used because Seabotix thrusters had to be used instead of strafing Video- Ray thrusters. Another result of this was that there were only two vertical Seabotix thrusters instead of the planned four, so the remaining two were not placed symmetrically. Another issue was that the frame bent relatively easily in certain places including the strafing thruster mounts and the area near the upper hull mount when the hull was removed and the rack was cantilevered on the upper hull mount. While this did not challenge the frame s structural integrity, it placed unnecessary stressed on the frame. Lastly, the position of the thrusters affected the ability to control the vehicle s movement. Wires blocked the flow of water behind the front vertical thruster and the strafe thrusters were placed below the vehicle s center of drag, with introduced unwanted pitches or rolls. 5 Spring 2014

7 Figure 3: Ragnarok s frame 3.3 Ragnarok Ragnarok s frame was very similar to Killick s in most regards. It was however to be slightly stronger than Killick s so that it would deflect less under loads. The style of holding battery pods also changed with Ragnarok. Instead of mounting by sliding them in perpendicular to the side frame pieces like Killick, Ragnarok had brackets on the side that held the batteries parallel to the side pieces. This made it easy to access the batteries but was less efficient concerning compactness. Ragnarok was also designed to be backwards compatible with the DVL Workhorse while actually planning to use the DVL Explorer. Because of the size and mounting configurations of these options, there was a lot of wasted space underneath Ragnarok, which left room for improvement. Ragnarok s frame also incorporated space for shrouds for the strafing thrusters. This was valuable for keeping wires from blocking the thrust cone to improve effectiveness of these thrusters. Ragnarok s frame was designed to have four vertical thrusters, two strafing, and two surge, similar to Killick s. The overall profile of Ragnarok s frame was slightly larger in size compared to Killick s, mainly because of the backwards compatibility for the DVL Workhorse, while having to design for the rather large electronics en- 6 Spring 2014

8 closure for the DVL Explorer. The hull for Ragnarok also mounted to the frame similar to Killick s via the connector endcap on the top frame piece. 4 High Level Description 4.1 Mounting Capabilities Figure 4: A top view of Gemini s frame Handles and Crane Mounts The frame has four handles: two fore and two aft. Handles are designed for easy grip and carrying of the vehicle for 2-4 people. Because of the compactness of the vehicle, the handles are fairly close to thrusters and the hull, however they were spaced as best possible given the room available. The crane mounts are located on the top piece directly near mounting points for the top piece to the side pieces to help distribute the load. There are four crane mounts in order to allow for rope to go between the two on each side. This rope will then extend high enough to be over the hull where it can be connected with a bar and hook to connect to the frame Thrusters The top piece has wings for the surge thrusters to mount to, giving maximum distance from the side of the vehicle. The side pieces and fore and aft pieces have mounting holes for the 4 vertical and 2 strafing thrusters. The 4 vertical thrusters mounted on each corner of the vehicle give the vehicle 7 Spring 2014

9 pitch control and better roll control than past years. Because the strafing thrusters are mounted on the far fore and aft parts of the vehicle there should not be any interference with wire routing through their thrust cones Main Hull The main hull for Gemini is composed of two hulls and a midcap. In order to mount to the cylindrical midcap, brackets were needed to interface between the frame and midcap. One key improvement on Gemini is the hold down blocks for the these hulls are built directly into the fore and aft frame pieces, further simplifying the vehicle design, assembly, and manufacturing. Figure 5: The main hull and frame isolated Battery Pods Gemini holds two battery pods for powering the vehicle. The batteries for Gemini are new and slightly larger than previous years due to more capacity. The frame s width was specifically designed to exactly fit the width of the new batteries. The battery pods are inserted through the port side of the frame and slide along Delrin rails into place. There is a thumb screw on the frame that then gets rotated to keep the battery pods constrained longitudinally. This will make it very easy to switch batteries as there will be no eclips (like in years past) to remove and clip on each time. The batteries being mounted in the front of the vehicle also helps balance out the vehicle seeing that the main hull is very rear weighted. 8 Spring 2014

10 Figure 6: Battery Pod Retainment Doppler Velocity Log The Doppler Velocity Log (DVL) used on Gemini is the Teledyne Explorer DVL. For this first time this year it is mounted directly to the main hull pressure vessel, which is then mounted at the very center of the vehicle. The emitting cones of the DVL transducers were carefully oriented so that there is no interference with other components. The side frame pieces were designed specifically to allow the emitting cones of the DVL to have free space to pass through. Figure 7: A bottom view of Gemini shows the DVL Explorer location at the center of the vehicle. 9 Spring 2014

11 4.1.6 Killswitch In addition to the frame, I took on a second project this year: the killswitch. The killswitch is made to mimic that of the killswitch designed (although never actually implemented) for Drekar. It is a competition requirement that in order for the vehicle to move at all, a killswitch must be activated in the vehicle enable position. In case of emergency the handle can be pulled to kill the vehicle. The red push button on top functions as the mission start button, sending the vehicle into autonomous mission mode. The killswitch is located conveniently in the aft port portion of the vehicle. It is easily accessible yet not intrusive to the vehicle profile. Figure 8: Killswitch on Gemini Air Tanks Both the paintball tank and secondary air tank are mounted on the starboard frame piece with plastic tool holders purchased from McMaster. These allow for easy removal and clipping on of the tanks as well as clear wire routing. 10 Spring 2014

12 Figure 9: Airtanks on starboard side of Gemini 11 Spring 2014

13 4.2 Structural Analysis In order to prevent unforeseen failures and weak points as best as possible, ANSYS structural analysis was used to analyze the frame. Worst case scenario loading for the hull, thrusters, enclosures, batteries, etc. were used and tested for a variety of scenarios. Below are the results and some brief descriptions. Figure 10: Stress induced from grabbing the vehicle by only three handles 12 Spring 2014

14 Figure 11: Stress induced when holding the vehicle by the crane mounts After doing the analysis I decided to reinforce points of high stress near the handles and center of the side pieces. I also decided to reinforce areas of the top piece because of the deflection in the wings that the thrusters mount to. While ANSYS cannot be trusted as a predictor for whether or not something will or will not fail, it can point out weak areas in the design, and help compare one situation and/or design to the next. 5 Current Status The entire frame is machined, assembled, and currently in use. The battery pod retainment system has been tested for over one month and is extremely functional and easy to use. The thumb screw retainment is the simplest, quickest retainment design the team has had and should be used again in the future. The built in clearance holes on the fore and aft frame pieces for mounting the two main hulls both aligned very well enabling easy fastening and removal of the main hulls. Overall the frame is posing no issues and functioning as it was intended to. 13 Spring 2014

15 6 Future Improvements Overall this frame has been very successful and Gemini is lightest, smallest profile vehicle the team has produced, however, there are a few things that could be improved in the future. One is that if the DVL could be lowered it would help greatly because the transducer cones spread out very far when the DVL is up high that it wastes space underneath the vehicle. Another area for improvement is possibly thinking of a different way to mount the midcap besides the sturdy, relatively heavy brackets in the current design. Another design option could be creating a frame that encapsulates the main hulls with mounting above and below rather than having everything mounted below the frame, although this idea is partially just aesthetic and personal preference. Another improvement could also be incorporating killswitch mounting directly in the a frame piece rather than designing separate brackets that mount to the frame piece to then mount the killswitch to. One other thing to note is that the small rectangular part of the port frame piece that has 4 number eight clearance holes was added in case of need for the forward manipulator and/or forward camera because that design had not yet been completed when this frame piece needed to be machined. The design later ended up not requiring this so this portion is currently not in use. 14 Spring 2014

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