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2/6/12
Team || Hybrid This week, the team continued to prepare for the construction of the chassis. A part drawing was printed for each individual component of the chassis side assemblies, and these parts will be cut and sized before welding begins. All team members now know the details of the electrical components, and are able to use them. All additional parts were ordered, and are now available for assembly. A coupler was designed to attach the freewheel clutch to the axle, and this part will be machined by the team, with assistance from Charles and Ash. Over the next few days, the team will begin the physical construction of the chassis sides, and work on the engine throttle assembly.
JimmE-V As the JimmE-V team continues moving forward, the JimmE-V is looking more like a vehicle once again. After a successful salvage yard trip, and cleaning up the salvaged bolts and body clips, Patrick worked with Josh and Ryan Bittel to reinstall the fenders and wheel wells onto the JimmE-V. Patrick and Tim are still trying to locate a usable accelerator pedal. The motor controller technology is fairly new and there is a lack of pedals out available for a CAN controller. However, once the controller is set up, a potentiometer can be used to determine motor drive rotation directions. With the front fenders assembled, Patrick will be taking final measurements for obtaining the donated 80/20 from Dr. Dougherty. Kim has been finalizing her battery box shelf design. She looks to begin welding, spray painting, and installation next week. Josh continued his work on the sound deadening, but he must wait on elements of some other team members’ work before he continues forward. Josh intends to get back out to the barn on Monday to continue his work. Dustin has been particularly concentrated on developing the Genset trailer. He has been looking into trailer vendors, researching battery chargers, coordinating the delivery of the purchased generator, researching multimeters to measure generator power, and purchasing the trailer and multimeter. In the upcoming weeks, Dustin will assemble the basic generator components, look into an exhaust gas analyzer for generator experiments, locate a scale to weigh the fuel tank for generator tests, coordinate the trailer delivery, develop the experimental procedure for the generator, determine the cables for the generator to charge the battery pack, look into modifying the trailer, and attempt locating a powder coat sponsor the trailer. Dustin has also continued further development of the interior divider panel template, which will continue to be refined. Kyle has been working on his section of the report, and helping assemble the components under the hood. Next week, he will machine the steel plate for mounting the A/C and power steering pump. He is also meeting with the KU writing center. Ryan Bittel ordered the butanol, which has now arrived. He has also assisted in assembling the front panels and rear bumper of the JimmE-V. Next week, he will take the butanol out to the barn, help prepare the generator, and develop a test procedure for the butanol/gasoline blend ratio. Tim has been working on the electrical schematic and helped deliver the generator to the barn. Next week, he wants to help with completing the battery box or mounting components. The electrical schematic will also be further along, if not finished. Matt has been working on the JimmE-V dash with disassembling the old wiring harness, and has been trying to locate a wiring kit. Painless Auto has proved to be more painful than expected. He ordered the microprocessor for the 12-volt system as well. Next week, he is going to discuss wiring options with Austin Hausmann, make a decision, and place an order. He also wants to clean the Jimmy dash and disassemble the steering column. Chad ordered a brake light switch and brake lines. He is locating and ordering a flaring tool and any other necessary tools to create the rigid tube sections of the brake lines. Ryan O’Malley finished drilling the holes for the locking bars of the battery boxes and began a research slide. Next week, he is going to square off the locking bar holes. Ryan O’Malley also wants to finish his research slides and work on contacting sponsors. These significant progressions of the JimmE-V will continue as the team further develops and assembles its components.
CAES Turbine Team We are still in the midst of receiving our inventory of various parts needed for the construction of the Compressed Air Energy Storage system and the Shrouded Wind Turbine. By the end of this week we should have all of the necessary pieces to begin assembling. Details of the construction methods are being addressed such as what basic tools will be needed and a time line put in place to insure that we have ample time to conduct the many tests to come after the prototypes are up and running. For now things are pretty calm but they are going to ramp up very soon. The idea circulating is to build the prototypes and have them working in approximately four weeks, hopefully yielding some very interesting updates in the near future. EcoFreakos The past week spelled great team achievement for Team EcoFreakos. The team gathered last weekend to disassemble the standing golf carts, previously donated to us. The carts were torched, wrenched, and pounded into a recyclable portion. The non-recyclable parts were trashed, while the aluminum frames were recycled. Also, a majority of the team has dedicated time to create simple CAD models of certain components to assure spatial constraints (i.e. steering and braking systems, motor/controller/batteries, drivetrain components – as received). Specifically, Jon Collins has created a simple model of our brake system, Steven Callen has been busy with CAD models of the seat, seat suspension system, and the new engine, and William and I have been trying to run a simulation on the chassis CAD to confirm spatial constraints and stress capacity. This has proved difficult because of our lack of experience with simulation software. In addition, William Marshall and Kyle Volle have confirmed the working order of the motor, controller, and battery system. As I previously mentioned, components are coming in daily. We have confirmed the specs of these components and assembled them for a better idea of how implementation will be take place. In example, Steven Callen and Jon Collins assembled the steering and braking system, while I (Shane Gooden) assembled the received components of the drivetrain (engine, centrifugal clutch, chain, sprocket, etc.). Finally, the team has focused a reasonable amount of time to revising the EcoHawk’s deliverables (proposal and presentation).
Greenhouse Team The prototype collector reached a temperature of 160F, with the solution attaining approximately 108F. With the increased pipe length of the full-size collector, the liquid will spend more time exposed to heat and should thus attain a higher temperature. With a pump and tank in the works, we are in the process of purchasing all of the materials for the 4’x8’ collector. The placement of the storage tank has been reconsidered due to electrical availability and reduced tank size. It will now be positioned on the north side of the greenhouses, next to the head house door. This will provide a more direct route to the collector while significantly reducing pipe length, which will hopefully help to minimize heat loss.
HVAC and Heart Attacks We have spent the week figuring out all the supplies we still need. With help from the machine shop, we figured out a final design for our parabolic trough. We are making it out of aluminum and will be about 130 lbs, light enough to place on the roof. The parabola will be made out of an aluminum sheet and bent by P1 Group. The plan of using mirrored acrylic as the reflective surface is being scraped due to weathering concerns (might as well use Mylar). We will see how reflective the aluminum is by itself. The frame will consist of aluminum ribs/endplates and square aluminum tubing will be used as struts. The aluminum tubing will also be used to get the ~40 degree tilt needed. The parts will be bracketed together and to the roof. The aluminum has been purchased and has arrived from Wichita. We are in contact with several companies about a storage tank. From our calculations, we are looking at an 80 – 100 gallon one that can handle higher temperatures. We are working with Grundfos on getting a pump. The piping will likely be copper, as it can handle the higher temperatures. We purchased supplies for dynamic testing. The solar parabolic trough prototype was modified for dynamic testing. We need to write the test procedure and are looking to test on Wednesday.
1/30/12
JimmE-V The JimmE-V team has continued to work hard and move forward in multiple aspects of the project. Matt has located a wiring schematic for a 1997 Jimmy, and has labeled the dashboard wires with a newly purchased label maker. He also spent some time talking to electrical engineers (EEs) about his design for the 12-volt system. The EEs agreed that his work is going in the right direction. Matt is also looking into the Painless wiring product that Dr. Depcik has referred him to. Next week, Matt intends to order the necessary wiring and the Arduino processor, remove old wiring from the dashboard, and prepare the dashboard for installation of the new wiring harness. Kyle helped with disassembling the 80/20 rig in the shop and has been working on locating sponsors. Next week, he will figure out how to machine the steel base plate for the power steering, AC compressor, and controller. He also wants to continue contacting sponsors for the vinyl wrap, and work on revising his sections of the report. Dustin has paid for and ordered the generator for the Genset trailer. He began work on the cardboard template for the interior divider panel, and has been looking into Genset trailer suppliers for sponsors. He is continuing research for the Genset trailer battery charger, fuel cells, and other accessories. A general layout for the Genset plans will be completed soon. He will be talking to trailer suppliers about the trailer design, purchase/allocate funds for remaining components, and work with Ryan Bittel on obtaining a butanol supplier. Tim read through the entire motor controller manual and helped Matt with labeling the dashboard wires. He has also been helping Patrick search for a compatible accelerator pedal for the motor controller. Next week, all labeling is hoped to be finished, along with the wiring diagram. Chad spent the week researching into brake lines, and then visited the barn to determine what brake components we had and what we need. Kim measured the JimmE-V interior and is finalizing her CAD design for the battery box shelf. All her materials have arrived and she intends to begin welding in the coming week. Josh sprayed more sound deadening material on the JimmE-V. Soon, he will begin applying the vinyl matting to the JimmE-V. Ryan Bittel has been helping Josh with the sound deadening application and locating butanol suppliers. Next week he hopes to order butanol, select the Genset charger with Dustin, and look for sponsors. Ryan O’Malley has finished cutting the PVC for the battery boxes and has already contacted two sponsors. Next week, he will drill the holes for the locking bars and begin his research slides. Patrick was able to get Dr. Dougherty’s 80/20 assembly disassembled with the help of Matt, Kyle, Tim, Chad, Dustin, Ryan Bittel, Josh, and Ryan O’Malley. Without the help of the team working together, it would not have been completed as quickly and easily as it was. Patrick has also been working on the hood and fender area on the JimmE-V to get it assembled and finalize 80/20 sub-frame assembly clearances. Many bolts are still needed to complete the fender assembly. Patrick is planning to visit a salvage yard to find parts. These parts will be cleaned, sandblasted, and then painted to prolong life. Patrick has also been working on locating a pedal, but it is proving to be more difficult than expected as the technology required may not be available yet. The 5Kohm potentiometer from the Beetle can be used to test the motor controller in the meantime, but this will not be a final solution. More research is needed to ensure that the correct pedal is purchased. In the coming weeks, Patrick intends to determine the necessary amount of 80/20 to begin assembling and mounting the sub-frame.
Greenhouse Team The flat-plate collector prototype is finished and the prototype system assembled. A bucket test was performed showing a 50% decrease in flow rate due to use of a 55% glycerin solution instead of pure water. This should be helpful in determining appropriate expectations of the pump for the full-scale system. A preliminary 8hr test of the system has been performed during which temperature data was logged. It would seem that both lack of insulation on the pipes and an apparently oversized storage unit are inhibiting the effectiveness of the system. These issues will be mitigated and another test will be performed.
CAES Turbine Team We are continuing our quest for hardware by filling out the appropriate forms and finalizing ordering details. Work on the exact airfoil shape for the turbine blades is being conducted to improve efficiency and maximize power. The transmission of power from the turbine blades to the generator is also in the works. The overall dimensions of the turbine are being increased slightly to provide additional power output. The current concept being explored for fabrication of the blades is to utilize high density milling foam to build cross sections of the airfoil shapes which will then be wrapped in thin mill plastic. A ½ inch wooden dowel is going to run from the hub through the blades to a 27 inch bicycle wheel. This approach should yield a very stiff blade structure and will also allow the angle of attack for the blades to be adjustable.
Team || Hybrid As of this week, construction of the hybrid vehicle is underway. The steel stock was purchased and picked up, and is currently being stored in B171. The drive train components for the engine portion of the vehicle were ordered, and should be arriving this week. The electrical components required some re-wiring, but were eventually assembled and tested, and now work just as expected. Over the next few days, we will order the remaining components of the vehicle (axle, seat, bearings), and continue to test the parts that we already have. Also, the batteries will be assembled into a more permanent pack as soon as one last connector arrives in the mail. The team plans to use this week to practice welding a bit more before starting construction of the chassis, which should begin by early next week.
HVAC and Heart Attacks It was determined that the middle parabolic shape performed better than the shallow one. We then altered the solar parabolic trough to compare the middle and deep parabolic shapes and performed three rounds of testing. After analyzing the data, it was found that the deep parabolic shape performed best. The max temperature was 204 °F. The thermodynamic model is currently being worked to aid us in sizing our system. We have found that to keep the barn at a steady state temperature of 65 °F, about 5000 W needs to be supplied. We are working on calculating how much heat one pass through the trough will provide; it looks to be around 500 W. This shows the importance of the storage tank and making multiple passes. The barn is not used all day, everyday, so energy can be stored in the tank for a few days before being used for an afternoon when students are working in there. According to studies by Stanford and Carnegie Mellon, the flow rate of working fluid through a solar parabolic collector does not matter. We did find a rule of thumb though of .04 gal/min per foot of collector. The greenhouse team is using high temperature PVC for the piping which has a maximum operating temperature of 200 °F. As our collector has gone above 200 °F, we cannot use this material for piping. We will likely use copper pipe. We are purchasing materials for dynamic testing and looking to reset the trough for that and begin next week. We are also looking heavily at storage tanks, piping, pumps, dissipaters so that we can get these ordered soon. For our final trough design, we are looking for companies who can help bend sheet metal in a parabolic shape and then how to apply the mirrored acrylic. We are having trouble figuring out how to frame the final trough and attach it to the roof, while remaining lightweight. We expect the wind to exert large forces on it, so this needs to be sturdy.
Field Station Team As we waited for our solar cells and other equipment to arrive, we spent the week working on more administrative aspects of the project. We measured the Berm building for the roof dimensions which will give us a more accurate representation of the usable area for solar cells on the top of the building. We also measured the exterior dimensions to help with the modeling of the building as a whole. The application for interconnection with the electric company has been started and we have also been working on upgrading the rotating prototype to a larger scale. Next week we will concentrate on finishing the application to the electric company and working on the thermodynamic model of the Berm building.
EcoFreakos As the purchasing deadline nears, the team has been devoting much time into finalizing the design stage of components and placing orders for components. Steven Callen designed a seat suspension system and we are awaiting the material. Before the chassis material was ordered, it was necessary to finish the CAD model for a complete bill-of-material and cut list. William Marshall and I (Shane Gooden) were able to fight around the compatibility issues and model the chassis. The main components were also modeled and placed in the assembly. These components include the golf cart motor, the Optima Batteries, and the new engine. From there, the material was ordered and will be picked up very soon. Alongside this, we created a cardboard layout of the components. From this, we confirmed our spatial constraints and dimensions. In addition, I was able to find the perfect engine for our project. The engine meets the power requirements. However, this find negates all the work we have done on and around the previous engine. So I have effectively added a significant amount of work, but did so in hopes of creating a better end-product. The order was placed for this engine and will be in shortly. The drivetrain components, seat and suspension, Optima batteries, pedals, and motor controller have also been ordered. In addition to placing orders, we have also found some time to progress on EcoHawks deliverables; mainly correcting the mid-term proposals and disposing the donated golf carts. Other than that, time was invested in sourcing components.
1/23/12
Field Station Team Last week involved the major breakthrough of purchasing solar panels and an inverter for our system. We chose to order four solar cells for the preliminary build. In the future we have the potential to expand the system to include 50 or more solar cells on the roof of the Berm building. The inverter we ordered was intentionally oversized to accommodate the projected expansion of the system in terms of the total output of power. Next week we are taking a more detailed approach to measuring the Berm building which will help create a more accurate view of the various models of the building that we have created. We will also be starting the arduous process of filing an application for a renewable-energy system to the electric company, keeping us on schedule to finish our project by the end of the semester. The heavier concentration of administrative work in the next couple of weeks is intentional as we wait for the solar panels and inverter to arrive for installation.
CAES Turbine Team Kicking this semester off, we are ordering the parts specified in our proposal for the compressed air energy storage system and the shrouded wind turbine. This last week concluded with ninety percent of the parts being listed on purchase orders which are now waiting to be signed off on. With the parts on hand within the next couple of weeks we will begin construction of the two prototypes. A few last minute modifications to the shrouded wind turbine are in the works which should be concluded in the next two days. These slight changes in the design are centered round the mechanism connecting the turbine blades to the generator.
Greenhouse Team The flat plate solar collector prototype is complete, as is the collector stand. The required flow rate we have determined is less than a gallon per minute, which is much lower than expected. On the one hand, this has made it possible to purchase a reasonable-priced low gpm pump for prototype testing. It does mean, however, that the pump we were planning to use for the full-scale model is too powerful for our system. We are in the process of seeing what we can do to secure a new pump. Prototype testing is set to begin this week.
Team || Hybrid The first update of this semester shows Team || Hybrid ready to begin construction of the designed vehicle. A majority of the vehicle components have been obtained or ordered, and the rest will be ordered by Wednesday, January 25. Testing on each of the individual subsystems will commence as soon as the required components are available. The construction of the vehicle chassis is currently the main goal. Steel tubing will be ordered this week, while the team practices and improves their welding abilities. Construction of the relatively simple chassis will begin with the matching sides, and will be thoroughly documented to supply additional information for all future reports and presentations. A tentative semester schedule places chassis completion the week before spring break, so this week can be used if the team is falling behind. Several people with fabrication experience have been contacted, requesting possible assistance, if required. As the team members no longer have similar schedules, weekly meeting times were scheduled. Each Wednesday we will meet for an hour or so to update team members on various issues, and each Sunday the team will have mandatory work hours. In this manner, the team hopes to schedule enough work hours ahead of time to prevent panic as the semester continues. As with last semester, the team will also have bi-weekly meetings with Dr. D to update him, and ask or answer any pertinent questions.
JimmE-V After a well earned break, the JimmE-V team is off and running. The team has already had its first meeting, deciding on meeting times, workday times, and resolving other concerns such as recognizing major items to be purchased. The current priority is to order all remaining large-expense (above $40) items before the February 3rd deadline. Patrick has been working on obtaining the necessary 80/20 material by disassembling the unused set up in the machine shop. After speaking with Ash in the shop, it was determined that he and Charles may have to disassemble much of the piping that the 80/20 structure is supporting. The 80/20 structure may be disassembled by as soon as the end of next week. Once all the material has been gathered, more detailed measurements will be taken. This will permit the cutting and assembling of the sub-frame for under the hood of the JimmE-V. Patrick has also been in contact with a control system company in regards to locating a CAN-compatible accelerator pedal. Dustin has received notice of the UGRA funding for the Genset Trailer Generator, and intends to purchase it once the funds are accessible. Dustin is also working with Ryan Bittel on locating an independent charging system for the Genset Trailer, along with a trailer through sponsors. Some of the miscellaneous Genset items Dustin is looking into are wiring and a fuel cell. Furthermore, Dustin is also working on the JimmE-V interior divider template. At the barn, Josh finished spraying the underside of the JimmE-V with sound-deadening coating, using the leftover material from last semester. Work will begin on applying the vinyl sound-deadening mats to the firewall and interior of the JimmE-V. Ryan Bittel helped Josh spray the under-body. While he was out there, he reassembled a seat after deciding to focus on finding seat covers at this time. He also found a potential lead for butanol fuel. It is not certain to follow through, but it is worth contacting as a potential sponsor. Ryan O’Malley has been preparing to build the full-size battery boxes, having started toward the end of break. The majority of the PVC material for them has been cut. All that remains is to cut the remaining PVC and glue the boxes together. Matt Martin obtained the 12 VDC battery from Austin, took it to Kurata, and began a detailed electric schematic of the 12 VDC system. Next week, he plans to order the respective microprocessor and relay. Matt will also finalize the electric schematic. Kyle Flynn and Kim Self are looking into a vinyl body wrap for the JimmE-V, speaking with sponsors located by Dustin. Kyle is also looking into the possibility of LED taillights to accompany the new headlights that are at the barn. Kim ordered/received donations of her materials for the battery box shelf. Her materials should arrive next week so she can begin fabrication. Tim has been working on identifying the wiring needs and looking into the actual process of connecting the motor controller. He has also been working with Matt on the electrical diagram by making a list of all the electrical components. It may be completed by next week. Chad had a productive break, deciding on an ABS system for the JimmE-V and ordering many of the necessary parts. He also began constructing CAD models of the control module and researching into brake lines. Next week, he is hoping to finish his CAD models, determine and order brake lines, and begin mounting wheel speed sensors on the JimmE-V with aid of the machine shop for fabrication. Teammates are also beginning work on research slides, editing content for the team report, and locating at least five more sponsors.
HVAC and Heart Attacks Over the break, we have begun testing. The LabView program used to log temperatures during testing was completed. The solar parabolic trough was then set-up at the barn and after significant troubleshooting testing began (the main problem was that one of the brand new cables was bad). Three rounds of static testing have now been completed (with a fourth underway) comparing the shallow and medium parabolic curves. Data is being filtered and graphed to be analyzed. The pyranometer is not working properly and we are troubleshooting it. While it is not essential to static testing, it is essential to dynamic testing. After one more good day of testing (hopefully the one underway), we will alter the ribs in order to compare the better performing parabolic curve to the deepest parabolic curve. Components for the dynamic testing, which will follow this, are being gathered. The scope of the project has been altered to call for placing a lightweight solar parabolic trough on the barn and connecting it to a storage tank. A secondary loop from the storage tank to the radiators in the barn will be added as time permits. Either way, the thermodynamic model will be finished in order to estimate the heating the radiators will supply. We have decided that the loop between the trough and the storage tank will use a 50-50 glycerin water mix. Components for the rest of the system are being investigated as well so they can be purchased soon.
EcoFreakos After what is supposed to be a relaxing winter break, the semester is back in full swing. Over the break, Steven Callen was able to order the seat and mounting hardware. The seat and the associated hardware have been received and measured in hopes of mocking up a simple CAD model to suit spatial constraints. In addition, Kyle Volle sourced and ordered the throttle pedals and a manufacturer’s replacement motor controller. He is also continuing to work with the EECS students with their creation of a specified motor controller. We are awaiting shipping of these items for simple CAD models and any installation preparation. The brake system was also order by Jon Collins. Also, William Marshall, Kyle Volle, and I (Shane Gooden) have all contributed to the chassis CAD model. In addition to this, William has created simplified CAD models of the motor, the batteries, and the engine. Finally, all team members have worked on their sections of the Final Proposal and plan on taking them to the writing center for editing and a grade.
12/5/11
JimmE-V As the semester begin winds down, the JimmE-V team is hard at work to meet final deadlines. The team recently completed the research book for submittal it to Dr. Depcik. Team members are contacting sponsors for the end of the semester. This coming week will be spent preparing for the presentation on December 8th at 5:30pm, along with updating and making final revisions to the proposal due December 12th. KU EcoHawks are having a sponsor event Monday, December 5th, all day at the Chili’s at 23rd street and Iowa St. 10% of the money spent on each Chili’s bill will be donated to the EcoHawks when the sponsorship is mentioned. Along with completing deliverables for the upcoming deadlines, the team has found time to make further progress on the JimmE-V. The battery box prototype has been constructed, and materials are going to be ordered soon for the full scale battery boxes. Dustin will know the results from his Undergraduate Research Award application this coming week. If it is approved, the team will receive funding for the Genset generator trailer and biobutanol research. Josh did an excellent job leading the team in preparing and spraying the JimmE-V for the sound deadening spray. The next step is to install the sound deadening mats. Dustin has sponsors interested in providing a discount on a trailer or assistance in manufacturing a custom trailer. He also has a sponsor coming out to look at and remove the large dent in the JimmE-V. Patrick discussed the 80/20 design for the sub-frame under the hood with Dr. Dougherty. After proposing the idea of using scrap 80/20 that Dr. Dougherty has in the machine shop, Dr. Dougherty agreed to donate the needed materials, under the condition that the team completely disassembles the 80/20 rig to help Charles get it out of the way in the shop. Work will begin on disassembling the rig over winter break. During this break, some students will remain in Lawrence, who can continue making progress on the JimmE-V. Thank you to the 2011-2012 JimmE-V team for all your hard work this semester.
Field Station Team The past couple of weeks have been very busy as we try and put ourselves in a position to be able to come back from Winter Break ready to start buying the necessary materials (solar cells, inverters, grid-tie equipment) needed to construct the solar array. We have identified several grants that we can apply to for funding so that we are able to purchase our materials. One of the rotating solar prototypes has been built and two others are in the process of being built which will enable us to test the rotating solar cells and the stationary solar cells on the same day to test the efficiency of each prototype. We are also very close to finished with the thermodynamic model of the Berm building – a few surface area calculations need to be made and we will be ready to calibrate the model and expand upon it for future use. Each team member concentrated on five additional slides to add to our Research Book, covering various researched material from heat transfer equations to prototyping options. Next week we will conduct our presentation over the material we have learned this semester and also write our proposal over the more technical aspects of our project.
We have received the weather station and solar data logger (SDL). The weather station has been assembled and the SDL has been calibrated and a stand constructed. Both are ready to be installed this week. Facilities has been contacted concerning access to the head house and we are waiting on a response. The prototype design has been finalized and materials selected and sourced. Efforts are currently focused the semester presentation and funds proposal.
Team || Hybrid The last few weeks of the semester have mostly been spent finalizing the vehicle design and completing the required work for the ME640 EcoHawks course. As of last Friday, the first semester research books were completed, and the team has been working on our proposal edits, and completing and practicing our presentation. We are still in contact with Briggs and Stratton regarding changing out the engine shaft and Charles regarding the construction of a coupler. Brake force estimates have been completed, and a brake package has been decided upon. Similarly, the batteries and charger are ready to be ordered, and we are simply waiting to see if a bulk order might save on shipping costs. Chassis design has been completed, and stress analysis is being done to see what modifications need to be considered. The rest of this week will be spent on the presentation (Wednesday) and completing our written proposal (due next Monday).
HVAC and Heart Attacks The prototype stands the same as it did the last update. A draft of the static testing procedure has been written up. We have finished working on research book slides which cover a variety of components of our system and a thermodynamic model of the barn. We have begun work on the presentation and will soon begin on the proposal.
EcoFreakos Although a majority of the past week’s efforts have been devoted to the rigorous deliverables of Dr. Depcik, we were able to make some progress on our Parallel Hybrid Go-Kart. Jon was able to formulate a spreadsheet of the braking calculations with assumptions. He was meticulous in this: taking into consideration every level of force/torque/pressure/power calculation and mechanical and hydraulic efficiencies. These, along with a few other parameters, are user-input variables in his program. The distance required to stop is the output as a function of force applied by the driver on the brake pedal. He will confirm that the proposed brake kit will perform up to our requirement (90 feet from 30 mph to 0 mph). After confirmation, the brake kit will be ordered and, eventually, fabricated into our design. The engine parts ordered by William a week ago came in. However, it was realized that the parts were incomplete. He was placed another order with the company, of which, we will hopefully receive within a week. Once this order is received and all components confirmed, the parts will be installed and the engine will be given a final tuning to ensure optimum operating condition. William was also able conduct a rolling resistance on the purchased tires. The result was incorrect in magnitude, but will provide a baseline for future tests. The chassis CAD has been started by William as well. The progress is limited, but a good start has been designed. Kyle determined that the motor controller is unusable. However, he was able to speak with a team of Electrical Engineers to discuss the best possible way to control our motor. In discussing this, Kyle made it clear that some kind of safety precaution was necessary to prevent throttle failure. Kyle has also helped out with the CAD. He created a battery, motor, and gear box CAD models. I (Shane) created a spreadsheet, as requested by Dr. Depcik, detailing the different battery options, their associated weight, and the acceleration (both on a flat surface and up a 5 degree incline) of the cart with the options and weights. This was followed up with a thorough examination of the chassis strength calculations. I confirmed my calculations and can comfortably say the chassis will support the static weight of the cart, components, and driver. I have also spent some time locating and sourcing drivetrain components. These include the centrifugal clutch, chain, and sprocket for the engine drivetrain; the rear axle; and the pulleys, belt, and belt tensioner for the motor drivetrain. Steven is over-seeing all work, serving as the extra eyes catching errors. He has also motivated the team to stay on top of deadlines given by Dr. Depcik. Other than this, the team has been putting in a very large amount of time to meet and exceed the steep requirements set by Dr. Depcik, including the EcoHawks Research Slides, Sponsorship Attempts, Proposals, and the Final Presentation.
CAES Turbine Team As we bring this semester to a close, we are delivering our presentation for our project, and submitting our final proposal in which justification for the project and the scope of work to be performed over the next semester will be discussed. A moderate system has been chosen that will allow for the verification of the overall process of storing energy produced from a shrouded wind turbine in the form of compressed air. The prototypes have been designed from the perspective of keeping the system as simple and robust as possible. We are summing up this semesters work in order to hit the ground running when we return from winter break. We appreciate all of you that have followed our progress over the past four months. Thank You.
11/21/11
JimmE-V The JimmE-V team spent its work day preparing the JimmE-V for the installation of the sound-deadening spray material. The front of the JimmE-V was disassembled, and all the surfaces to be coated were wiped clean with acetone. The team then planned for meeting on two consecutive days the following weekend, intending to finish cleaning the surfaces and spray the first coat of the material, followed by spraying the second coat on the following day (Sunday). It was also decided to hold the weekly team meeting on Sunday evening to comply with the Thanksgiving break. The team has been working on contacting sponsors, updating the research book, and updating the proposal. Preparation for the presentation on December 7th at 5:30 pm will also begin. Ryan O’Malley has been working on the battery box prototype and intends to have it at completion in the coming weeks. Chad has been researching into the vehicle braking system for the JimmE-V. Dustin has been researching alternative materials for the interior divider to justify his decisions, including verifying the application of polycarbonate. Theoretical heat flux rates of various materials and divider thicknesses are being compared in this analysis. Ryan Bittel has been researching options for the occupant seating, including new leather covers for the previous seats. Josh has been leading the team in preparing the JimmE-V for the sound deadening spray. The sound deadening matting arrived this past week and will be installed once the initial spray has fully dried (potentially a few weeks). Matt continues research into the relay for the solar panel charging system. Kim has been researching battery box supports and has ordered the rubber matting for the battery box. Patrick and Tim met with graduate student Austin to finish the CAN work on the electric Beetle, but data logger complications hindered further progress. Once Austin has finished trouble-shooting with the Beetle CAN, the three will finish up the ‘small-scale’ testing.
HVAC and Heart Attacks The ribbing has been cut and installed in the prototype solar parabolic trough. The mesh backing was attached to the ribbing and the Mylar to the mesh. The pipe for the working fluid is secured at the proper focal length. Our prototype is now complete except for the fixing of the end caps and temperature probe, both used for static testing. The static testing procedure is being written up. We are getting into our next set of research book slides, with research being conducted on: reflective materials, working fluids, pumps, piping, radiators, and heat storage. Thanks to Greg Towsley, we have been put in touch with Dave Bartelli, President of Baxter Mechanical Contractors Inc, who can offer advice on radiant heating. We are working on improving our thermodynamic model and energy estimates as well. This information, along with the testing results, should allow us to fully design our system. We should be able to begin testing after the Thanksgiving break.
Team || Hybrid The last week seems to have introduced a slight setback to our progress. We are having some serious issues dealing with the tapered shaft on the engine. Briggs and Stratton does not seem to have clutch systems available for this shaft, because this particular engine is not designed specifically for this application. We have contacted Briggs, and hope they may have a simple solution for us, otherwise we are looking at some involved coupler design with the machine shop. On a lighter note, most of the components for the electrical drive train have arrived. This will allow for testing and troubleshooting, as soon as batteries and a charger are acquired. We are still in contact with a potential donor for the batteries, but are prepared to order some if this does not pan out. Having received the steering and wheel components, we can begin assembly and testing with these, and hope to do so soon. A preliminary chassis design should be completed soon. Finally, we have been editing our proposal and completing our research slides, slowly but surely.
This week the Greenhouse Team finalized its decision to construct and implement flat plate collectors at the greenhouse. The semester research book and presentation are almost complete, save for transition editing and presentation practice. Prototype design has been agreed upon and material descriptions are being compiled for the final report. Flyers have been printed for the Chili’s EcoHawks fundraising event. 10% of all sales taking place on Monday, Dec. 5 from 11am-10pm at the Chili’s restaurant on 23rd St. in Lawrence will be donated to the EcoHawks. The EcoHawks name must be mentioned for the transaction to qualify. Please take your friends and family, and remember to mention the EcoHawks!!
EcoFreakos This last week was a very productive one in regards to our EcoHawks senior design project. Steven has chosen a few preliminary choices of seats and is awaiting responses for possible discounts/sponsors before making a choice and purchasing. Jon Collins has done work on both the steering calculations (via Ackerman method) and brake force calculations. The brake force calculations will take precedence as we will justify our choice of brakes with these calculations. Shane Gooden has been working on the corrected chassis calculations with steel as the material. William Marshall has been working on designing the chassis in CAD and working alongside Shane to ensure correct, corresponding dimensions are being used. Also, William has ordered the parts for the engine to run well. These parts will be installed after shipment received. Kyle Volle has attempted to test the motor controller, but the wiring diagram found on the internet is illegible. He has found a better copy of the wiring diagram recently, and will be testing it asap. He is also in the midst of creating the Gantt Chart. Finally, the team is still working on correcting mid-term items (research slides and proposal).
Field Station Team We have been focusing on the thermodynamic model of the Berm and figuring out the scope of the model. Several values must be measured, like surface areas of the respective sides of the building, while other values must be assumed by finding an appropriate source for each parameter. Some of the values or constants that we need for the model we do not have so we must calibrate the model in order to find the constants (through a simple system of equations). The idea is to keep the model as simple as possible and expand upon it as needed in the future. We completed a round of stationary prototype data on an overcast day which gave us a realistic approach to the amount of power we might expect from our solar cells on a less than ideal day. We have gathered all of the necessary parts for the rotating solar prototypes, so we will try to complete the prototype build over Thanksgiving break. The team will have a set of research slides compiled by the end of Thanksgiving break as well so that we can spend the following week compiling and tweaking the research slides so that they are ready to pass onto a future set of students.
CAES Turbine Team We are putting together a presentation for our project which requires us to go back and analyze each of our findings and justify the decisions made over the past couple of months. In doing this it is fun to see how the project has evolved. In the beginning the hope of constructing a prototype for supplementing power requirements for a small home or office was proposed. It was quickly decided that this was an overly ambitious goal due primarily to the fact that the tank needed for such an endeavor was enormous in cost and in size. It was then found that the use of hydraulics combined with pneumatics would permit a feasible system with a less sizeable tank but the cost associated with the technology needed to implement this approach was also quite expensive. Therefore a more moderate system was chosen that would allow for the verification of the overall process of storing energy produced from a shrouded wind turbine in the form of compressed air. At this point we have settled on a shrouded wind turbine with an input rotor diameter of around 18 inches which is quite small when compared with that of the original proposed size of 6 feet. The compressed air portion of the system will utilize high pressure but with a tank size of 80 to 120 cubic feet instead of tens of thousands required for a small business or home. The air compressors will operate at less than 1 cubic foot per minute, much smaller than a typical shop compressor that operates at several if not more cubic feet per minute. The air motor chosen will have an output in the neighborhood of 4-500 watts vs. the 3-5 horse power air motors that were initially studied. Instead of replacing batteries with our CAES system which was one of the primary goals, we are incorporating two battery packs throughout our prototype. These modifications to the prototypes have been deemed necessary from the perspective of keeping the system as simple and robust as possible, allowing for testing of theoretical models and confirming that certain assumptions made are true.
11/14/11
JimmE-V Work is continually moving forward for the JimmE-V Team. The graded mid-term proposal was returned for updating, and the team understands its direction from this point onward to the end on the semester. Kim Self set up a Dropbox file for the team. This allows for easy sharing and updating of files from home computers or other online locations. All team members should be focusing on contacting the remaining sponsors, researching various topics, and correcting and adding material to the research book and proposal. Patrick and Tim have been developing a CAN data base for the Beetle. The data base will allow Austin, a current graduate student, to collect various data on the Beetle for modeling the vehicle. Work on the CAN data base for the Beetle should conclude this weekend. Once completed, initial testing to determine whether the data is being logged correctly may begin. Kyle has been reviewing A/C system research from last year to determine what all needs to be installed under the hood. Doing this will allow the team to better plan where all the electronic components will be installed under the hood. Ryan O’Malley has been working on the battery box prototype. He gave Ash, a M.E. machine shop technician, the PVC and the necessary plans for what needs to be cut to build the box. Assembly will begin after these pieces are cut and received. Matt is continuing researching on the solar panel relay for the 12 volt system. Josh received the materials for the initial sound deadening layer in the JimmE-V. The materials were moved out to the barn Friday. The team will need to spend two days preparing the JimmE-V for being sprayed. Areas upon which the spray will be applied need to be thoroughly cleaned with solvents, and tape masking will be done such that windows and other parts do not get coated. The second day will be for spraying the insulating material. Dustin has been working on interior restoration, expecting to finish soon in preparation for sound deadening material. The interior divider polycarbonate material was received, and Dustin will begin basic theoretical heat transfer calculations to see how this material’s thermal resistance compares against alternate options. Chad has been continuing to gather information about the brake system on the JimmE-V. Speed sensors need to be located and ordered, as well as a ‘brake controller’, as it is not known if the ECU will perform this function well in our new vehicle setup. Kim is modeling concepts for the battery box shelf for the back seat of the JimmE-V. Materials are being researched and ordered soon to begin initial testing on them. She will be talking with Charles in the M.E. machine shop about her design. Ryan Bittel is working on contacting a sponsor or source of biobutanol for the Genset generator.
HVAC and Heart Attacks The team decided to draw the parabola equations on a computer and send them to a plotter to make full size templates for the ribbing for our prototype. MatLab and PowerPoint were used to carry this out. We utilized the ECS to plot the parabolas. The shapes were then cut out to be used as templates. The 2’ x 2’ plywood pieces for the ribbing were cut down to the exact size of the trough. The templates were used to paint the parabolas onto the plywood ribbing pieces. The ribs will be cut out in the next couple of days. The copper pipe that the working fluid will flow through was painted black in order to increase its absorptivity. The team discussed areas that need further research and we will begin making research slides on them. More thermodynamic calculations will be done providing additional baseline data. The school of engineering held a high school design competition this week. During the competition we talked to the high school students in order to elucidate what EcoHawks does and to increase their interest in engineering, KU, and the EcoHawks program. Also for EcoHawks as a whole, proposals for ME Department and FAC funding were submitted. The ME Department will fund the amount requested from them and a successful presentation was given to the FAC committee. Our team will finally complete the prototype this next week.
Team || Hybrid The past week was spent dealing with the portions of the design that have already been decided. Multiple orders were placed with vendors, and very soon we should have the electric motor, controller, key switch, sprockets, a clutch, the wheels, and a steering kit for our vehicle. On top of this, we researched the engine we received from Briggs and Stratton and determined the power capacity, fuel/oil requirements, and the maximum engine speed. After discussing drivetrain possibilities with Michael Mangus and Charles Gable, we have decided to look more into centrifugal and electric clutches before finalizing our design. The next few weeks will revolve around decisions for the drivetrain, the chassis, the potential suspension system, and the battery pack, as well as updating our proposal and research slides.
Field Station Team The Field Station Team has worked on the thermodynamic model of the Berm in the past week. Each team member was assigned to research and design a specific portion of the model, so the following week will be spent on compiling the individual contributions of the team into what hopefully becomes a working relationship between the amount of energy the model specifies that the Berm needs and the amount of energy the Berm actually uses for each month of the year. This relationship will allow us to scale the amount of output needed from the solar cells accordingly. After finding the dimensions of the roof of the Berm last week, we were able to determine the maximum number of “normal” sized solar cells we can place on the roof at around 9 solar cells. This number could vary depending on the type of solar cell we decide to order and, of course, the size of solar cell chosen. We also ordered stepper motors and stepper controllers so we can start building the rotating prototypes as soon as the parts are delivered sometime in the coming week. We will also take another round of stationary solar cell data this week. We have a functioning multimeter which will allow for both voltage and current measurements, giving us an estimate of the amount of power the solar cells output depending on the time of day. The data gathered will allow us to scale the amount of power we can generate to any size of solar cells we decide to order in the future.
EcoFreakos After another week of work, the team has made more progress towards a finalized, working parallel hybrid go-kart. Steven picked up the donated batteries and ordered a suitable charger. This will lead to Kyle being able to test the motor controller. He plans to test the motor controller this evening and we will have results soon. Will ordered the steering kit and wheels. Will and Shane also got the donated engine running. William will soon order the parts to get the engine running better. Jon found a suitable hydraulic disc brake system and is awaiting approval to purchase it. Also, Jon is well on his way of calculating the braking force required by the braking system. This will further confirm the proposed braking system. Shane has figured out that the wrong material for the chassis was initially chosen. This will require much more work and re-calculations of the chassis design, to this point. In addition, the team is correcting the mid-term proposal and first set of research slides in order to make devising the finalized documents much easier. And finally, Kyle is formulating a Gantt chart to ensure the project continues to stay on track, time-wise and task-wise.
CAES Turbine Team We are determining the cross sectional areas of the shrouded wind turbine based off of the continuity equations along with analyzing what geometries have been used in previous designs. The increase of velocity across the turbine blades can be achieved through the use of a diffuser and a nozzle. A large extent of the existing designs attempt to use a nozzle before the turbine blades followed by a diffuser. This means that the area around the turbine blades should be less than the entrance or exit area so a gradual decrease followed by a gradual increase in the diameter of the shroud will be best. With regard to the diffuser portion the increase in area should continue until there is boundary separation at the interior of the shroud’s surface. In order to maximize the exit area by stalling this boundary layer separation, the use of internal baffles that slightly redirect the flow in the shroud can be used. This internal network of baffles is something that can be easily tested and deployed with our current design. Our test rig will be constructed to allow the testing of the turbine with or without the shroud in place. This will facilitate assessing performance improvements while the project progresses.
The team was finally able to place the Lexan boxes for the thermal mass test. The box containing the glycerin water mix had the same temperature curve as the control box, but the high and low temperature spikes were less severe than those of the control box. The box containing water showed the same trend as that of the box containing the glycerin mix except the water served to level out the temperature fluctuation even more. These results are consistent with our expectations and indicate that implementing thermal mass into our design should in fact aid in normalizing the extremes of the temperature fluctuations within the greenhouse thereby making it easier, relatively, to heat. Work on the final proposal continues as we narrow our options for collector materials, and communicate with Grundfos regarding the donation of a pump for our system.
11/7/11
HVAC and Heart Attacks We met with Dr. Depcik and discussed testing and parabolic shape needed for our prototype. We are looking to publish our project as a conference paper, especially the parabolic shape testing results. Our research shows that there is nothing immediately out there on the parabolic shape and publishing our results will help fill this gap. Grundfos has offered our team pumps and put us in contact with a doctoral team at Purdue working on a similar project. The temperature datalogging method we chose is almost ready to use. We decided on three parabolic shapes to test: one shallow, one deep, and one in the middle. We expect the deepest one to perform best, but the middle one to do almost as well. More plywood and u-bolts have been purchased in order to make the ribbing and finish our prototype. We hope to finish the prototype early next week.
JimmE-V This week, considerable time was spent on book-keeping and planning for the JimmE-V team. During the Tuesday meeting, “soft” deadlines were established for the research book, sponsors, and the final proposal – all which are prior to the actual due dates. The work day on Sunday was photographed by David McKinney of KU Relations. The photographs may be featured in University of Kansas publications for prospective students, particularly future engineers. Interior restoration of the Jimmy is continuing this week. Materials were purchased to help seal small holes to prevent moisture and noise from entering the vehicle. Dustin put much work and effort into the Undergraduate Research Award (UGRA) proposal for the Genset generator and biobutanol fuel this week. Polymer components have arrived for testing of the interior divider concept and assembling the battery box prototype. Ryan O’Malley has developed plans for cutting the pieces used for constructing the battery box prototype. Kim received rubber samples for the purpose of battery box vibration dampening. CAN experimentation is intended to begin on the Beetle this week. With all of the Jimmy’s body bolts installed, the team will begin more focus of their efforts on parts and equipment underneath the hood. The front panels need to be fully assembled, and cardboard modeling will be utilized to determine component locations. Matt rated the 12 VDC DC-DC converter at 53 A of current, determining that 16-gauge power transmission wires are the maximum gauge needed, with smaller diameters still possible upon further calculation. Matt is also working on the voltage relay for the solar panel. What all is required for the relay still is to be determined, along with locating a suitable supplier for the relay. Chad is working on the placement of the brake and accelerator pedals for the driver.
Greenhouse Team This week, the team paid a visit to the greenhouse to measure the head house and pick up some of the scrap Lexan stored there for use in constructing boxes for thermal mass testing. It turns out that the head house is much larger than anticipated, measuring approximately 38m2. The team will build one solar collector but will now be able to recommend that several additional collectors be build in the future to maximize the solar collection potential. The Lexan boxes are built and the temperature data loggers are programmed and ready. The boxes and liquid have been scaled to mimic the amount of solar thermal mass that could theoretically be incorporated into the space under the plant tables in the greenhouse. The Lexan box test will be performed this week.
Team || Hybrid For now, the research for our design has slowed slightly, and the team is focused on the portions of the project that have already been decided. The IC engine arrived last week, and a coupler must be implemented to adjust for the tapered shaft on the engine. Decisions have been finalized regarding the motor/controller system, and the order for these parts should be put through early this week. Both hybrid teams met with the EECS students last Friday, and will be working with them in the future to implement an alternative controller design. Also, the order for the steering package will be submitted this week, as both teams are ordering from the same vendor. Chassis, suspension and braking system research will continue as the design must revolve around the decisions that have already been made. As these parts and pieces of the design begin to come in, testing and troubleshooting the components will be our primary concern.
Field Station Team The past week we have worked on developing heat transfer equations for the thermodynamic model of the Berm. The goal for the coming week is to split up the responsibilities for the model amongst group members so that we can build the model faster and have the ability to tweak and perfect the model down the road. The following week will also be spent on furthering our understanding of the components needed for the solar tracking prototypes by researching different servo motors and photoresistors to find the best fit for the prototypes. Another round of testing of the stationary prototypes also needs to be completed in the near future to demonstrate the effectiveness of our selected “ideal” angle for the prototypes.
EcoFreakos The team’s efforts towards our project have been limited during the past two weeks. Jon and Steven did some editing to their research slides. William and I confirmed the center of gravity calculations. Therefore, we can move forward by calculating the minimum spindle size in order to support our weight. We also took some time to attempt to get our donated engine running. It was determined that the engine would need some cleaning and a few parts after finding out that the engine was capable of operation. Kyle, Will, and I extracted the motor controller from the donated golf carts and Kyle is planning on testing the motor controller some day. In addition, Kyle partially confirmed the power calculations that I devised and is in the process of correcting his calculations. Finally, Jon researched some brake options only to determine that an option that Dr. Depcik suggested only fits an axle size of 1.25 inches in diameter.
CAES Turbine Team In order to achieve the goals of this project which are to build and test prototypes of the CAES system and the shrouded wind turbine, a host of testing equipment must be sourced. The main sensors needed for the testing will be analog pressure gauges and thermocouples. Flow rates must be ascertained at certain points also. The current idea is to use data acquisition equipment for the thermocouples paired with LabView and analog pressure gauges that will be monitored via a camera. This will help avoid the costs associated with electronic pressure gauges and will still allow us to sync all of the data with respect to time. Work on the thermodynamic model is still underway, with a variety of approaches being taken to date. The current model is getting very close to allowing reasonable predictions to be made about performance of the individual components and the system as a whole. A mock up of the basic shrouded wind turbine design is going to begin soon which will allow us to see possible flaws in our design, making for a swifter build when it comes time to construct the real prototype.
10/31/11
Team || Hybrid The last week was largely spent completing our proposal and estimated budget. The process over the last few weeks of organizing all of our separate research and design decisions has really helped the team get an idea of where the design is headed, and what needs to be done next. In the next few weeks, our team will begin the process of ordering the vehicle parts we are sure about, while continuing our research and design process for the other subsystems. As of 10/29, the Briggs and Stratton engine was shipped, and should be arriving soon. It has come to our attention that this donated engine has a tapered shaft, so some additional research and design will have to be done to incorporate a coupler into our drive train design. Most of the components for the electrical portion of the drive train have been selected, and will be ordered soon. As soon as we have all of these components, we will be able to begin testing both portions of our vehicle power systems.
Greenhouse Team This week the team focused on finalizing the mid-term proposal. The process of writing the proposal allowed each team member to reassess his/her research progress and use it to draw concrete conclusions. It became apparent that the size of the head house is a very significant limiting factor. According to heat transfer calculations for the proposed system, 8m2 of trough space will only allow for the collection of enough energy to heat the greenhouse for 27% of the night. That is assuming that heating is only required during the night. Those calculations also assume 100% collector efficiency, and commercial open trough collectors only have an efficiency of approx. 40%. However, covered trough collectors have a much higher efficiency, around 80%-90% so including this technology in the collector design may prove to be highly beneficial.
JimmE-V The JimmE-V team spent a majority of this week focused on the midterm proposal for this project. Dustin represented the JimmE-V Team for the EcoHawks at the ME Advisory Board presentation Friday, October 28. Major progress continues to be made on the JimmE-V. The final body bolt was installed, uniting the vehicle body with the restored chassis. The team has begun interior restoration, including the removal of rust to prepare the body for sound-deadening material installation. Cardboard models of both DC-DC converters were constructed, allowing their placements to be determined without the risk of damaging equipment. Dustin practicing MIG welding in preparation of body patching and mounting supports. He also purchased safety supplies for the barn. Kim has brainstormed methods of mounting the battery boxes, including vibration dampening. Chad compiled a list of missing parts needed for the back bumper. This week, Patrick intends to contact Susan of LMC Truck about potential sponsorships or donations and place an order as needed. On Sunday, October 30, the team has a photo opportunity at the barn to be done by David McKinney of KU Relations. The team will continue with interior restoration, along with beginning experimenting with the control area network (CAN) on the Beetle. The DC-DC converter arrived this week for the 12 volt system, and further research will done on the relay for the solar charger. Ryan Bittel is determining whether new seats should be purchased, or if the old seats should be reupholstered. The UGRA proposal will be developed by Dustin this week with Ryan Bittel’s assistance, with the intent to receive funding for Genset generator testing with biobutanol fuel. Chad will begin taking inventory on all of the brake components to determine what needs to be installed, as well as setting up a friction test. Ryan O’Malley intends to begin fabricating the battery box prototype to verify his design for the main battery packs.
Field Station Team The Field Station Team was able to find a decent day to take data on the stationary prototypes and successfully took the voltage across both the monocrystalline and the polycrystalline solar cells. Unfortunately, due to some technical difficulties, we were unable to procure the data for the current across the solar cells and were therefore unable to calculate the amount of power generated from the solar cells (Power = Current * Voltage). We will look at taking another shot at testing the solar cells in the coming weeks so that we can get a ballpark estimate as to the amount of power output we can receive from the “big” solar cells once we install them on the roof of the Berm. Outside of the prototype testing, we spent the majority of the week writing and rewriting our Midterm Proposal that included everything we have learned in the past couple months as well as our future plans for the project. Next week we will start to build the thermodynamic model of the Berm building which will undoubtedly be a slow and arduous process but we expect to make some early strides and perfect our work as we move forward.
HVAC and Heart Attacks Our midterm proposal is now complete. We have spent gobs and gobs of time on writing and editing the proposal. We wrote up individual sections and wrote the team sections in groups. Every part was edited several times and all the parts were formed into a coherent document. We met with SPX Cooling and had a very interesting tour of their R&D facility. Grundfos has expressed interest in a possible sponsorship. We are going to finalize the parabola shape and finish our prototype. The datalogging equipment is almost set up and ready.
CAES Turbine Team We have finished our midterm proposal for this project and it has allowed us to refocus on key aspects that are most important. The design has been continually streamlined in order to insure that the production of prototypes is an obtainable goal. This current proposal ties together the decisions that have been made along the way and gives specific information on what pieces of hardware will be used to construct the CAES system. There is still much work to be done on the shrouded wind turbine concerning hardware but that is where the team will now focus for the next couple of weeks. The latest decision regarding the geometry of the shroud is to use a simple truncated cone shape for the initial tests and expand from there. This will allow us to take test data and serve as a base for testing further refinements regarding differing shapes and sizes of shrouds.
EcoFreakos The progress on the project was limited this past week due to the immense amount of time required to complete the EcoHawks midterm proposal. Of that progress, decisions are being justified and we are preparing to make final decisions for purchasing. Jon Collins has researched options for steering and brakes and decided on a mechanical disc brake on the rear axle. He will research purchasing options and present them to the team, and then to Dr. Depcik. Jon is collaborating with William Marshall to ensure the steering kit can be integrated with the selected wheels, which Will is researching. In addition, Will decided on a spring suspension versus a leaf suspension. Also, Will was able to get a 10 to 12 HP engine from his Uncle. However, the engine needs minor work: the brushes need to be sanded and the carburetor needs to be cleaned. We will accept this engine and begin the necessary work as soon as possible. Kyle Volle has access the motor controllers off of the 2 donated golf carts. He has discovered that the older golf cart utilizes an open-loop controller (with a potentiometer and voltage divider circuit), while the newer golf cart utilizes a feedback controller (more like an actual motor controller, like a controller one would buy, not build). He is conducting further research to determine pros and cons of simpler, open-loop controller. Also we will be working side-by-side with an EECS group. They will be constructing a motor controller for our (one for either Team || Hybrid or Eco-Freakos) design. However, it is necessary to note that we will be devising our own controller. In other words, their controller will be implemented next year. With Steven Callen’s full battery donation, Shane Gooden has researched battery chargers and will present the options to team and Dr. Depcik as soon as possible. As these decisions get made, we will be coordinating with all other EcoHawks teams to, with regards to purchasing, as to minimize shipping costs. Specifically, we will be corresponding with Team || Hybrid for a comprehensive order from www.gokartgalaxy.com.
10/24/11
Greenhouse Team This week was spent primarily on completing, compiling and editing research book slides so that the team that takes this project over next year will be able to benefit from our efforts. We have begun writing our midterm proposal and are in the process of ordering temperature data loggers, glycerin and a weather station for our thermal mass Lexan box tests and eventual solar trough testing.
JimmE-V This week, the JimmE-V team made significant progress in research developments. Last Sunday, the team managed to stretch the JimmE-V body enough to properly install the remaining rear bolt. We still need to install the body bolt by the wheel well. Dustin gained Bayer MaterialScience as a sponsor and requested two large samples of Makrolon GP polycarbonate of 4’ x 8’ size panels, 1/4” and 3/8” thicknesses. They can be tested for both an interior divider panel, and battery box lids. Dustin is also preparing the generator proposal for the Undergraduate Research Award. The team continues creating cardboard models of the components too heavy or fragile to handle frequently. We are also trying to remove as much interior rust as possible before sound deadening material is purchased and installed. Tim and Patrick will be working with Austin on developing CAN databases for the Beetle. This is for gaining hands on experience with CAN to further their knowledge on the subject. Friday, the midterm research book was completed and turned in. Some of the research topics covered included: CAN networking, biobutanol fuel, thermoplastics for the interior divider panel, PVC for the battery box, regenerative braking systems, DC-DC converters, and relay and wire gage information. Ryan O’Malley designed the 4 x 13 battery box and is planning to begin construction on the prototype soon. Kim Self is testing her PVC sample to determine if it will hold the batteries with its strength. After further research and testing, we will place an order for the necessary materials for the full size battery box. Ryan Bittel ordered the trailer hitch for the Genset trailer. When the hitch arrived Friday, Ryan B. picked it up and delivered it to our barn. Meanwhile, Josh and Patrick took the cell boards, onboard battery charger, and the DC-DC converters to Kaurata building on Friday as well, to be used for cardboard models. After Ryan delivered the hitch, Patrick and Josh were able to install the hitch on the JimmE-V. This coming week, the team will be focusing heavily on the mid-term proposal that is due Friday. The team also has a meeting Tuesday, and a bi-weekly meeting Wednesday with Dr. Depcik. On Friday, October 28, Dustin is representing the team in a presentation to the ME Advisory Board.
HVAC and Heart Attacks We completed our research slides and have coherently combined them into a midterm research book. This will be placed on our team wiki, and hopefully also in a more accessible place, so that other teams can use the information contained within. We have still not found a source regarding what parabolic shape should be used, but we have found several sources and equations on how to determine the focal length. We have decided to determine our parabolic shape by choosing a convenient focal length and maximizing the area (limited by the frame size). This will allow us to finally finish our prototype and get started on testing. Joe has been working with Professor Yang on getting the temperature data logging set up for testing. We are working on our midterm proposal and have divvied up the sections among the team members. These sections will be completed by Tuesday night and we will then combine and finish the midterm proposal.
Team || Hybrid Much of the last week was spent completing our research book, but design decisions were made, as well. As of last week, our donation request for the Briggs and Stratton Engine was submitted, and since this engine will not have an electric start system, the implementation of one is an important issue. Luckily, B&S sells a conversion kit, so this should not be a problem, but we will need to determine what additional parts are needed. The donated electric motor is not operational, so the decision was made to purchase a 48V, 1000W motor for this portion of the vehicle power. This will require 4 12V batteries rather than 3, so the decision must be made whether to cut down on the storage capacity of the batteries to save some money. Also, a 48V charger must be acquired for the battery pack. Lastly, a preliminary parts list and BOM was generated, and the decision was made to use a rear suspension system for this year's design, to simplify this portion of the project. The next week will center around completing our project proposal, and should see the team begin the process of ordering the parts that have already been decided upon.
CAES Turbine Team We are establishing the preliminary design constraints regarding the shrouded wind turbine. For structural rigidity and ease of construction regarding the prototype, bicycle wheels will be incorporated in several key components. The first is the diffuser which will utilize a 28 inch bicycle wheel as a frame for the diffuser blades. A 26 inch wheel will be used for the turbine blades and another 28 inch wheel will be placed after the turbine blades to insure a stable housing for the turbine blades to rotate within. The generator housing will be formed into a nose cone in order to streamline the air flowing past it. The material used for the blades and shroud are still being addressed. We are focusing on materials that will allow easy assembly while providing the structural stability that is crucial for any type of device such as this. The use of additional shrouds are also on the table with the focus on how to create a strong vortex suction flow behind the turbine blades in order to increase air velocity through the shroud and ultimately increase the power output.
EcoFreakos The past weeks efforts were dominated by the research slides. As far as work on our project, we have kept plowing forth. Kyle Volle tested the motors and found that one of them works and the other does not. Our plan is to have the working motor cleaned and use it in our parallel hybrid mid-scale. As for the non-working motor, we have offered it to the II Hybrid Team, suggesting a rebuild. Kyle Volle has also done some research on electric motor controllers in preparation for testing the controllers from the donated golf carts. We intend on using the controllers from the golf carts if they are in working condition. In addition, Jon, Kyle, and I discovered the engine found by Kyle Volle (11 hp, electric start) is actually a vertical shaft. This is extremely unfortunate, as integrating a horizontal shaft is ideal and much simpler. So more work is necessary here. As for wheels, William Marshall has devised an alternative rolling resistance test and plans to make a wheel purchase for additional test sample next week. Jon Collins has inquired about a steering kit found on-line and awaiting answers before a decision is made. Steven Callen has created a skeleton budget spreadsheet for future use. And finally, all team members are continuing the search for in-kind sponsors.
Field Station Team We concentrated on compiling our research for the first half of the semester into a Research Book for future students which took a fair amount of time to organize and complete. We also talked about creating a thermodynamic model of the Berm building in order to better understand the effect that the demand of power might have in the future with respect to the number of students conducting research in the Berm building. The model would then reflect a reasonable amount of energy output we should expect to need from the solar array we wish to construct. The coming weeks we will concentrate on improving our prototypes and finding ways to accurately construct each component of the model so that it represents the real-world physics of the Berm building.
10/17/11
EcoFreakos The last 2 weeks progression consisted of attempts to complete analysis in order to begin making decision, most of which is research and testing. After Will and Kyle got the golf carts to Kurata we dissembled them. From this it was determined that the condition of the chassis was not up-to-par. So, we decided it would be best to design and fabricate a chassis of our own so we can dimension the chassis and place components according to even weight distribution. A good majority of this work will be completed in the next week or two by Will and myself. Also, it was determined that all only one golf cart tire was in good enough condition to test. This tire, a spare car tire, and a purchased motorcycle/moped tire will be use to test and compare tires for a decision in the near future. Will will be purchasing the tire(s) and conducting the rolling resistance tests. Jon has continued research on brakes and steering and options available. Kyle has created a couple key plots from our power calculations so we can get ball-park figures before we purchase options and assess them with tests. Steven created a skeleton preliminary budget for future use. Each member got their 10 sponsors updated on the team sponsor spreadsheet. And finally, both teams finished the designs of the electric hill climb vehicle for the Expo event.
Greenhouse Team This week, several concrete decisions were made based on our research. The collector will be a solar trough and it will be located on top of the head house. For now, we anticipate securing it to the head house with weights as it will be some time before our collector design is finalized to the point where we are ready to secure it to the roof structurally. We will use the eastern-most greenhouse (#4) as our test model instead of the western-most (#1), as previously thought. The reason for this decision is two-fold: 1) Greenhouse #4 is located directly in front of the head house, allowing us to run pipe directly across the roof of the greenhouse instead of across a walkway. 2) The pipe route it affords us facilitates placement of the storage container on the exterior of the greenhouse as it allows us ready access to the south side of the greenhouse plaza. This area is much less windy than the west side so it will aid us in our efforts to retain as much heat in the storage container as possible. Heat transfer equations and material selection are coming along and we are ready to begin writing our mid-term proposal.
Field Station Team We have concentrated on getting sponsorship from companies in the last couple of weeks so we have the financial means to continue our project next semester. Over fall break, we were able to build a weatherproof box for the data logger of our pyranometer sensor which allows us to install the sensor at the Field Station once we are done with our prototyping. The historical energy usage data from the Field Station came in the mail, so we have compiled the data into an excel file to find the time of the year that energy is in the most demand. Once we figure out the peak demand time, we can adjust the angle of the prototypes accordingly such that the prototypes can demonstrate the effectiveness of the system on a small-scale before we consider the large-scale application on the roof of the Berm. Next week we intend to start taking data on the stationary prototypes while we begin build the solar tracking prototypes. We will also concentrate on creating the first of our research books, filled with information we have gathered the last few months for future students to use and apply.
Team || Hybrid Quite a bit has happened over the last two weeks. We decided not to risk the complications from using a geared centrifugal clutch drive train, and so are now focused on implementing a dual freewheel clutch system. We are still waiting to find out if we have access to a donated motor, but if not, we have decided on a motor to order, and are ready to do so. This decision will be made by the end of the week. We have a battery pack design finalized, and are simply considering options for charging the pack, or the individual batteries. We assisted the EcoFreakos in disassembling their donated golf carts, and performed some preliminary rolling resistance testing. The decision was made to purchase a Pitman arm steering package, and to use two rear axle mechanical disc brakes for braking. Lastly, through a contact at Briggs and Stratton, we placed a request for a rebuilt horizontal shaft engine donation, which should be available to us later this semester. Upcoming goals involve the completion of our research books, our proposal, the ordering of decided materials, rolling resistance testing, and continued research and design for the vehicle.
CAES Turbine Team We are moving along in pinpointing the power production side of the CAES prototype. It has been determined for reasons of simplicity and budget that we will utilize a 4500 psi air tank, a 300-350 Watt rotary vane air motor, a car alternator and a 12 Volt car battery to prove initial system. The compression side of the CAES is now set to incorporate a first stage compressor yielding a modest 85 psi combined with a second and third stage compressor that will elevate our pressure capability to 4500 psi. This should give us an experimental run time of approximately 5-10 minutes. This will enable us to take the various data needed to verify our system from a thermodynamic standpoint and give us a platform to work off of in order to increase efficiency. The power input side of the CAES system is waiting to be specified until we fully develop the shrouded wind turbine specifications. Once the shrouded wind turbine’s physical characteristics have been determined we will have a better idea of the actual power output capabilities in regard to the local average wind speed.
HVAC and Heart Attacks These past two weeks have been busy for us. We purchased the rest of the supplies for the solar thermal parabolic trough and then built the frame. We are held up right now on what curvature of parabola to use. We have been researching this and have found there to be a strange lack of easily accessible information on the topic. We are slowly coming up with an idea though. Once we have the parabolic shape, we can finish building the solar trough. We have started coming up with static and dynamic testing procedures for the trough. We will start with the simpler static test and use it to gain comparison information on reflectivity, parabolic shape, and working fluid type. We are working on a simple and cost effective solution to our need for temperature data loggers. We are looking to use a thermocouple connected to a DAQ. We have contacted potential sponsors for the project. So far P1 Group and SPX Cooling have agreed to sponsor us. We are very thankful for their support. A couple other potential sponsors look likely. This is a tremendous help to our project. We are currently working on research slides for our research book.
JimmE-V The past two weeks have been very productive for the JimmE-V team. The K-16 exercises have been completed by all teams, and everyone has contacted sponsors and uploaded their corresponding information to the online master sponsor list. Team members have been working on installing the Jimmy body bolts, and there are only two remaining to be installed. The team is also working on cardboard mock-ups of the various components that will be installed. This allows us to experiment with various placement options, without the risk of damaging expensive equipment or injury. Patrick sorted through the shelves of removed Jimmy parts to determine what we have on hand, and think of any potential uses of these parts. A document will be compiled that lists the parts that we still need for the Jimmy body. We are attempting to gain LMC Truck as a sponsor, who could potentially donate or sell parts at discounted rates. Matt is preparing to submit the TRI form to order the DC-DC converter for the 12-volt system. Team members are also working on their research slides for this upcoming Friday. The various research topics include: CANbus networking, Genset trailer (trailer, generator, and fuel), the DC-DC convertor for the smaller 12 volt system, battery box materials and construction, and thermoplastic interior divider. A trailer hitch for towing the Genset trailer has been located and is being purchased for the Jimmy. We are also looking into sound-deadening materials for the firewall and interior to reduce road noise and vibration. Before we can do that, we must locate and remove any rust to help protect and prolong the life of the Jimmy body, and prevent future complications.
10/3/11
JimmE-V This week, the JimmE-V team focused on completing the K-16 project. The homemade solar cells were successfully built and tested, and the battery powered hill climb cars are all assembled. One group is still working on testing and fine tuning their car. Pertaining to the JimmE-V, a small scale battery box will be made before going full scale. The solar panel for the 12V trickle charger has been located, but more research is required for the DC-DC converter. Team members have been researching the CANbus system, while gathering more materials and information from other sources. We plan to generate a system sketch soon to have an improved visual of how each component will fit together. The team has also been working on their research slides, as well as contacting sponsors. Cardboard is being acquired for mock fabrication of components and component covers. The interior of the Jimmy was vacuumed, and the seats were loosely placed in their positions, in order to obtain measurements for the interior divider panel. Dustin is researching thermoplastics for the interior divider panel. Ryan Bittel is looking into obtaining a trailer hitch for the Jimmy, as we are still in the process of reassembling the body. Kim is looking into finding potential sponsors for painting the Jimmy. We are still working on contacting Mid-America to schedule a visit to see their electric vehicles. Additionally, part catalogs for the Jimmy were found and printed. The team also has access to a nearly identical Blazer for photographing, which will assist with the placement of components into the vehicle.
Team || Hybrid Much of this week was spent divided into our separate groups, finishing the K-16 RC builds. However, along with the completion of these projects, several other major steps forward have been made. Power requirement estimates have been completed for both the combustion and electrical systems. We are still waiting to find out whether or not some of the donated materials will function, but if not, we have selections made for parts to order. We are continuing research on braking and steering, as well as some preliminary chassis designs. A rear-wheel chain drive design has been selected, and we are looking into implementation of a multiple freewheel clutch system for the drive train. In the upcoming weeks, we will be focusing on continued design research, rolling resistance and drag tests, as well as acquiring or starting the ordering process for our power sources.
HVAC and Heart Attacks We came up with a design for a parabolic trough that can be easily modified in order to compare different materials, curvatures, and working fluids. A site at the barn for the trough was located. Materials were searched for in store and online and a bill of materials with estimated cost made. It looks to be around $200 without the temperature data loggers. Online materials were purchased. We finished our K-16 cars after much trial and error. We will purchase the rest of the materials at home depot and are still looking at data loggers. We will build the trough this week.
Field Station Team Last week we met to discuss the additional materials each group member was to bring to build our homemade solar cells for the K-16 development project. The following day, we built our Grätzel solar cells mainly following the instructions given to us, but with a few minor changes. We decided to change the dye on one of the two layers within the solar cells which simulated a change in the p-layer of the cell. This allowed us the freedom to experiment with different dyes and find which would produce the greatest output in terms of voltage across the cell. We also discovered that the energy data that we ordered from LJEC was just now being shipped to us, so the amount of output we need from our solar cells is yet to be defined. In the meantime, we are about to order our solar cells for our prototype and we remain in contact with LJEC to ensure the inverter and grid-tie systems we are looking at are consistent with the LJEC regulations and standards.
Greenhouse Team This week, the greenhouse team took dimensions of the greenhouse. This will not only aid in determining the physical sizing and placement of the collector, storage and thermal mass units but will also aid the team in evaluating the heat transfer rates of the structure and of the potential system design. A few types of testing have been outlined. As maximizing the passive solar potential is ideal, initial testing will focus on the effects that thermal mass alone has on temperature change in a controlled scale-greenhouse environment. The scale environment will be placed next to the greenhouse and will be constructed of the same type of lexan that was used for the walls of the greenhouse itself. The thermal mass will consist of black plastic containers filled with a water-based solution. The team has also begun sourcing temperature probe systems so that it will be possible to monitor the inlet and exit temperatures of the solar trough as well as the temperatures inside the thermal mass prototype boxes. The exact type of solar trough collector to be used as a prototype is being discussed but has not, as of yet, been determined.
CAES Turbine Team We are attempting to scale our prototype according to our budget constraints. Compressors and air tanks with high pressure capabilities in the 300 to 4500 Psi range are being sourced. This is not an easy task considering that compressors with these Psi ratings generally vary in cost between 1,000 and 50,000 dollars. One solution has been found in utilizing a compressor produced for paintball enthusiasts that reaches 4500 Psi with a price tag of 550 dollars retail. At this point the air tank of choice is a K size welding cylinder rated at 6000 Psi for less than 300.00. We are contacting the providers of this equipment in order to acquire these components at a discounted rate allowing us to squeeze the overall cost of the CAES system to 1000.00. The idea that is circulating is keep it simple and inexpensive at this stage.
EcoFreakos Last week’s progression consisted of the early stages of our first set of decision matrices to advance further on the project. We did research and came up with options and criteria for our sub-systems. Dr. D informed us of his 4 most important criteria for this project, so these will be criteria for each decision matrix, along with other specific criteria. Jon covered steering systems and braking systems, Kyle created accelerator set-up, Steven compared battery and motor, Will chose wheels and chassis, and I assessed engine and the axle set up. These preliminary matrices were posted to our wiki for later revisions when making final decisions. Also, each team member is continuing contacting sponsors and Kyle Volle found a discounted engine (11 hp Briggs and Stratton). Both sub-teams designed and fabricated electric hill climbing cars to find out both teams motors are not strong enough to power the car up the hill.
9/26/11
Team || Hybrid As of right now, estimated power calculations are setting a basis for our design decisions. Using various assumptions for gearing, wheel size, rolling resistance, and drag, it appears a 5hp engine could give us a top speed around 40 mph, which would be more than enough for a preliminary design. One option is to specify a speed range for the electric motor (<15mph or so), which would allow for a less powerful motor to be used along with a high gear ratio. A simple battery pack composed of AGM deep-cycle batteries could be used to power the motor, and could easily be charged using existing EcoHawk facilities with the purchase of a charger (~$50). Planetary gearing and freewheel clutch systems are being considered for the drive train, and the chassis will be designed and fabricated by our team. Powering only one axle will allow for simple implementation of a front-wheel steering system. The team is currently focusing on choosing and/or obtaining a usable engine and motor for the vehicle, as other design decisions depend heavily on the vehicle's power sources.
EcoFreakos Last week’s progression consisted of various things. Steven, Will, and I have continued contacting sponsors, and I will compile a team sponsor spreadsheet, as well as update the EcoHawks master sponsor spreadsheet. Also, everyone has been assigned a decision matrix or two comprised of the options, criteria, and weighting factors, of which, we will ask Dr. D’s opinion of the weighting factors during our bi-weekly meeting with him on 9/26, and fill out the matrices as a team next week. Jon has done more organizational work on the team wiki. Also, Steven/Jon and Will, Kyle, and I have begun constructing the small scale electric hill climb car. Will, Kyle, and I have gotten the axels coupled for a solid shaft and need to mount everything and connect the motor to the drive axle. Steven and Jon need a more powerful motor as their selection is not powerful enough to climb the hill. As far as donations go, Kyle has gotten two golf carts donated that seem to be mostly complete and I have gotten a 5 HP, vertical shaft engine donated, but it does have a bent output shaft. This can be used to tear apart for educational use. In terms of research for the K-16 project, Will has reviewed some old research books and intends on performing a rolling resistance test on the chosen tires in the near future.
HVAC and Heart Attacks In the biweekly meeting with Dr. D, we decided to focus on solar thermal and put geothermal on the back burner. Geothermal will require KU permission which could easily become a quagmire. Basic thermodynamics calculations were improved upon and we are comparing them to the current kerosene space heater. We met in our car teams, purchased parts and began building the cars. We decided to build a prototype solar parabolic trough; and after researching them more we came up with a supply list and how to build an experimental prototype. We could not find information on the curvature of the parabola, so we want to be able to change this easily. We will make half a plywood box and bend a piece of poster board inside it. Mylar (98% reflectivity for low cost) will be attached to the poster board to make the reflective parabolic trough. We will use screws and clips inside the box to be able to adjust the curvature. A closed pipe will be placed at the focus and temperature or irradiance measurements made on it. This will allow us to begin testing and can be easily modified for comparison studies.
JimmE-V The JimmE-V team now has all of the Li-Ion batteries, which currently all preside in Kurata. The cell boards for the battery sensors have also arrived and are being stored in Dr. D.’s office. After four months of delay, the America Racing wheels finally arrived. D&D Tire, Inc. mounted and balanced the tires. The team then mounted the wheels on the Jimmy, which were properly torqued. A week ago, the team also stretched the Jimmy body using ratchet tow straps anchored between a planted post and a stationary Chevy Tahoe. By hand, the team was able to stretch the body an additional ¾” closer to an ideal match. The body and chassis are still an additional ¾” apart fore-to-aft from being able to get the most damaged rear body hole fastened. Five of the ten body bolts are in place. The front quarter panels and fender wells were temporarily mounted to aid in fostering ideas for ‘under the hood’ component placement. The team met with Austin Hausmann to gain further insight on how the components will function together. The K-16 groups have been working on their cars and solar cells, and should be at or near completion by the end of this week. The team is familiarizing themselves with the CANbus guide and will select a couple of members to do more in-depth research with this system. Battery box designing began, along with the research of thermoplastics for the interior space divider. We are working on contacting Mid America to schedule a visit. During this visit, the JimmE-V team will ask questions and view their electric S-10 pickup truck. The team is also working on their research slides and contacting sponsors. Matt has located a trickle charger controller, but he is still needs the solar panel to match. Matt also researched the DC-DC converter from last year’s work, and will present his findings and possibly begin the ordering process. Manuals for the converters, controller, and CANbus system are being located. A LMC Truck catalog was ordered for the correct year Jimmy to help with body assembly. Along with our weekly Tuesday team meeting, we will also hold a bi-weekly meeting with Dr. D. on Wednesday, 9/28/11 at 5:15 PM.
Field Station Team In the past week, we learned that inverters are rated for a certain input wattage and voltage, which mean that we might need a DC-DC converter to step up the (smaller) voltage coming from the solar cells to a (higher) voltage that can be inputted into the inverter. The ability to buy an inverter at many different ratings for wattage gives us quite a bit of freedom when designing how many solar cells we can have. We got the pyranometer sensor ordered at the end of the week so we can start taking irradiance data soon. This will give us a better idea of how much energy we can produce. This week we will concentrate on our K-16 development project where we will build our own solar cell and learn about the internal components that make solar cells work. Our goal is to also look into buying one or more small solar cells by the end of the week so we can start designing a prototype of our system. Once we get our hands on the small solar cells, we can use our pyranometer in conjunction with the cells and place them at different angles of tilt and take data on which cells and which angles of tilt work the best for our application.
CAES Turbine Team We have been evaluating various methods for compressing and expanding air. These methods include adiabatic, isentropic and isothermal. It has been determined that the most efficient and practical approach for our application is to mimic a constant temperature or isothermal process. This means energy in the form of heat will be allowed to transfer from the compressed air to the surrounding atmosphere during the compression and expansion processes. The selection of potential equipment regarding air motors, compressors and air tanks is also proceeding. Manufacturers and distributors of pneumatic equipment are being contacted to aid in our knowledge and to assist us with financial and component donations.
Greenhouse Team This week the team had the opportunity to meet with John Geist, a representative from ESP, the company performing the campus-wide energy audit at KU. He volunteered to assist us in determining the wintertime heating needs of the greenhouse. Measurements of the greenhouse were taken to aid in the heat transfer calculations. The greenhouse manager was contacted in regards to obtaining manufacturer information for the honeycomb lexan, of which the greenhouse is constructed, and the daily temperature data logged by the greenhouse computer system. The temperature data will aid us in our weather station selection. The order was submitted for the solar data logger which will help us to determine the amount of solar irradiance (W/m2) that the greenhouse receives on a monthly basis. Glycerin was selected as a storage medium but, it was discovered that refining the glycerin byproduct from the biodiesel initiative may be too intensive a topic for the group to tackle at this stage of the greenhouse project. In its stead, pure glycerin will be purchased for testing purposes and recommendations will be made for the future refinement of the glycerin byproduct if it is determined to be a viable option.
9/19/11
JimmE-V This week, everyone on the JimmE-V Team has passed the machine shop test. All members can now work at the barn and the Learned machine shop. Our team had their first bi-weekly meeting with Dr. Depcik. Josh Petty, from the JimmE-V team of 2010-2011, also attended and offered assistance. The team created a general list of goals to accomplish on the Jimmy this semester and year. We would like to solve the issues with the body-to-frame bolts, determine where the motor controller and other components will fit under the hood, build the battery packs, connect wires, set up controlling, and get the interior back into shape. The team also decided that a better weekly meeting time would be on Tuesdays at 6:00pm. Dr. Depcik ordered the remaining half of the batteries needed for the Jimmy. We also requested a large battery charger through the first-quarter FAC funding. The team is to hear back from D&D pending the arrival of the Jimmy wheels. D&D will be contacted again this week if no response. The tires are already on hand. During Monday’s team meeting, the JimmE-V team split into smaller groups to tackle the K-16 project. Two groups are doing the battery powered car, and the other group is doing the homemade solar cell. Everyone is still researching from last year, and it will likely be an ongoing task. As research continues, members are finding areas of interest. Matt is looking into the solar trickle charger. Kim, Josh, and Ryan O. expressed interested in the battery pack on the Jimmy. We should be able to split into groups based on areas of interest on the Jimmy. Ryan B. is also going to look into a trailer hitch (purchasing vs. fabricating) for the Jimmy to allow us to pull the Genset trailer. Some students have begun contacting sponsors to look into further funding for the EcoHawks. Sunday, 9/18, we are meeting at the barn to do some work on the body and other various components of the Jimmy. In the weeks to come, the smaller K-16 groups will be ordering parts and beginning fabrication of their project, reporting back to Dr. D. by the end of the month on progress.
EcoFreakos After yet another week of progress, we have divided K-16 parallel hybrid into sub-systems and assigned leaders and co-leaders to each of these sub-system. We have begun to think about these sub-systems and are, hopefully, documenting our findings and research on team wiki. Jon Collins has kept the team wiki up to date with meeting minutes and organization. William Marshall and I have taken and passed the machine shop competency test. Jon Collins and Steven Callen have begun work on their K-16 electric hill climb car. Kyle Volle, William Marshall, and I will begin working on the electric hill climb car this next week. The team has also met with the other K-16 parallel hybrid team to bounce ideas between us two teams. We plan to meet every two weeks with the other group. We are all continuing project and sub-system research and contacting sponsors in attempt to get donations. Kyle Volle has roughly computed the minimum power requirement to maintain top speed. From there, we can preliminarily choose a motor, engine, and batteries. Once we choose tires, we can find the rolling resistance and re-compute the power required to maintain top speed and see if we can still theoretically meet the power requirement. Decision matrices and more research of previous years testing procedure is necessary at this point.
Team || Hybrid Research is ongoing, but the design process has started. Realistically, lead-acid batteries will probably end up being used, with the research more intended for future designs. Though lead-acid are not the most efficient and energy dense, they are probably the easiest to deal with, and the most readily-available. Still, donations and/or pricing must be looked into further, as deep-cycle batteries would be required for extended use. A meeting with the other parallel hybrid team has given both teams some more focus, and will allow for comparisons between different designs. In the upcoming week, a decision must be made regarding a chassis. We need to decide whether to continue looking for a golf cart, or just to design our own chassis around other design parameters. Estimated power requirements are being calculated, which will help in choosing an engine and motor. Once these basic design decisions have been finalized, we will be able to start working more on specific details regarding the battery charging process, drive train, steering, safety, and other important aspects of the project.
CAES Turbine Team We are continuing our research of compressors and air motors along with developing decision matrices in order for us to best evaluate the strengths and weaknesses of these two critical components. We are investigating the possibility of using compressed air tanks that have adjustable baffles in order to keep the tank pressure at a constant. The thermodynamic analysis is making headway with the implementation of excel spreadsheets which are comprised of the most important thermodynamic relationships governing heat loss and required work input associated with the compressed air cycle. This will allow us to optimize the system once particular components have been chosen. The physical structure of the shrouded wind turbine is being analyzed and the individual components of previous designs are being modeled with Autodesk Inventor to give a preliminary shape and configuration for our design to catapult from.
Field Station Team We held a team meeting last week and decided to draw straws so we could split into two groups within our team for the K-16 development project. Our K-16 development project will involve building our own (small) solar cells so we can gain a better understanding of how photovoltaic solar cells work on a small scale before we start using them on a large scale. We also decided on a pyranometer sensor that suits our needs the best, which we hope to have on the roof of the Berm and operational within the next couple of weeks. In addition to the pyranometer and the K-16 development, we contacted the electric company that the Field Station uses, LJEC, and found that we need to find an inverter that is approved by the company. We also looked into the electric company’s application process and fees for tying a “small” renewable energy generation facility (<10 kW) into the grid. Next week we have our 2nd bi-weekly meeting with Dr. Depcik, by which time we want to have the solar cell kit for the K-16 development project ordered, as well as the pyranometer sensor ordered. Continuous communication with the electric company looks necessary at this point so that we can ensure we comply with their codes and regulations with regard to every component of the system.
Greenhouse Team This week we formally divided the responsibilities of the project into five categories: HVAC, sun/collector position, collector, storage, solar irradiance. We eliminated the flat plate collector as an option and are currently weighing the pros and cons of a parabolic trough collector vs. evacuated tube style collectors. Between October to April, the angle of the sun ranges from 27˚- 65˚ from the horizon. Sun-tracking mechanisms are generally used with parabolic troughs to allow them to track the sun across the sky. We would ultimately like to avoid extra energy consumption and minimize moving parts because they require more maintenance. As such, we are considering placing multiple troughs fixed at different angles so as to maximize the solar collection, no matter the angle of the sun is in the sky. To further minimize the need for electricity, we would like to employ some level of passive solar heating, potentially utilizing thermal mass as a heat collector and temperature regulator that could be placed directly in the greenhouse and would not require a pump. In researching glycerin as a potential working fluid, we determined that whereas water has better heat retention properties, glycerin has a lower freezing point and the optimal ratio of glycerin to water is about 67% glycerin, by weight. Other developments include the selection of a solar data logger and the decision to procure a weather station to log both interior and exterior temps at the greenhouse.
HVAC and Heart Attacks We researched and narrowed down potential energy sources and HVAC systems this week. For an HVAC system, we decided on some sort of heat pump and not to use electric resistance heaters. We looked at whether to use air ducts or a piped fluid, either under the floor or in radiators above the floor. Air ducts tend to have more losses and be less efficient. Under the floor heating would require building a new floor: a complicated and expensive mess. Using a decision matrix, we thus determined above floor radiators would be our best bet. On energy sources, we used a decision matrix to determine that solar thermal is our best option. We will look at incorporating geothermal into this and using solar cells to power any fans, pumps, and other accessories. Wind and biomass were also considered, but both would be a hassle to get through KU and likely be more complicated and expensive. We chose to cars over the solar project and divided into teams. One team is Joe (team leader), Kris, and Josh. The other team is Eric (team leader), Tommy, and I (Ryan). We are going to start working on car designs while researching more into the chosen energy sources and HVAC systems. We are also starting a simple thermodynamic analysis.
9/12/11
HVAC and Heart Attacks Our team met with Dr. D. and discussed KU approval issues and the scope of the project. Wind energy looks unlikely. A team name of HVACs and Heart Attacks was chosen. We continued to research potential energy sources and HVAC systems. We will narrow these down to a few options and then focus in on our research, each team member finding a specific area.
JimmE-V This week, the majority of the JimmE-V team passed the machine shop test. A few students are still waiting on their results, while a couple students still need to take the test. With this large number of people now able to work at the barn, we are having a barn workday Sunday, September 11th. The purpose is to organize the barn and get to know each other and the barn better. While there, we will take inventory of what we have, what we need, and what we don’t feel we need. Measurements will also be taken for additional shelving additions. Our first team meeting will be Monday, September 12th, and our first bi-weekly team meeting with Dr. Depcik is on Wednesday, September 14th at 5:15pm. Students have continued researching last year’s presentation slides to learn more about the Jimmy. Research on the 3-phase motor and controller has begun, with further plans to research the other large components on the Jimmy. Battery pack research has also started, and we are investigating ways to test the batteries. FAC funding proposals are due next week. We decided to put a large battery charger on the proposal list. The charger will drastically cut charging times and allow small scale battery pack testing. Patrick and Dustin are investigating the wheels that were ordered at D&D Tire in May. They confirmed that the order had been placed and payment was accepted, but no wheels were ordered. Jim at D&D plans to get back with us next week when he is back in town. The team will be splitting into smaller groups to complete the K-16 project. Ryan Bittel has continued researching Genset Trailer possibilities for the JimmE-V. The team is also working on compiling a list of sponsors to begin contacting.
Eco-Freakos After a week of hard work, William Marshall came up with and we all signed a team work agreement for additional accountability. Also, we all came up with a few team names and have mutually agreed on the team name of “Eco-Freaks”, a weekly team meeting time of Wednesday at 5:30 p.m. in Spahr Library, and an additional weekly team meeting time of Friday at 10:30 a.m. in Spahr Library. With the K-16 Electric Car Project deadline approaching rapidly, we have reviewed rules and planned to begin the project this week. Kyle Volle and Steven Callen have done more research on Parallel Hybrid systems. Steven Callen has taken and passed the machine shop test. William Marshall also reviewed Autodesk for future use. We have also chosen to divide the team into roles: leader, scribe, quality assurer, scheduler, and treasurer. Finally, we divided the Parallel Hybrid project into sub-systems and figured out who was interested in what sub-system(s).
Greenhouse Team We had the opportunity this week to tour the Hayworth greenhouses. With the guidance of Katie Sadler, the greenhouse manager, the team identified several possible locations for the solar collector and solar storage unit. Supplemental heating becomes necessary in the winter months when the hours of sunlight are truncated and the sun sits lower in the sky. This, coupled with the somewhat restrictive layout of the surrounding architecture, made the team realize that proper positioning of the collector and storage must be one of our top priorities. Tasks have been identified and divided among the group members. Efforts are underway to identify potential methods for collecting, storing and measuring solar energy that will lend themselves efficiently and effectively to our application. Every effort is being made to employ glycerin as a storage medium as it is a byproduct of the biodiesel produced on campus and was traditionally used in antifreeze. We have also obtained the contact information for John Geist, the individual responsible for the energy auditing initiative being conducted campus-wide. He is already involved in a project concerning the greenhouses and we look forward to the opportunity to apply aspects of his professional evaluation to our project.
Team || Hybrid After a few questions and a bit of discussion during the meeting with Dr. D, the goal for this project seems clear. An end result of a working parallel hybrid is the main goal, so most design decisions are open-ended. We have spent time researching chassis possibilities, and much of this decision may depend on whether or not we hear back from some of the companies we have contacted. A usable golf cart or similar vehicle would save some building time, but might prove to be more difficult when trying to implement all the necessary components. We have started research on motor and engine possibilities, and hope to learn about battery ideas by reading through previous EcoHawk research. We are still waiting to hear from Pick-N-Pull and McNeese Customs about in-kind donations, which could affect design options, and have had preliminary contact with the City of Lawrence and PakTrakr. This week, we will continue our research, and divide the project into smaller categories, to allow members to specialize.
CAES Turbine Team We are in the midst of determining the various components needed for compressed air energy storage. The focus now is centered about a few key pieces. The first is a compressor that can obtain the relatively high pressures necessary. At this point a double acting two or three stage reciprocating piston compressor is the most likely candidate. Secondly we are choosing between metal or composite high pressure air tanks. Also important decisions are being made on the type of air motor used to extract and convert the compressed air into usable work. Last but not least we need to evaluate if an alternator or DC generator connected to the air motor would be most appropriate in this application. If it is determined a DC generator is required, we must incorporate a DC-AC converter.
Field Station Team We held a group meeting early in the week and were each assigned a research topic to learn more about not only photovoltaic solar cells, but also the components that connect solar cells to the grid. Once we got a grip of the scope of the project, we were able to settle into individual roles for the team. The most important component at this point is to start taking irradiance data at the Field Station with a specialized sensor called a pyranometer, which will give us an idea of how much power we can generate with our solar cells once installed. Next week, we can concentrate on buying a pyranometer and hopefully start taking irradiance data as soon as possible. Furthermore, we expect to contact the electric company for specifications regarding energy usage at the Field Station and we want to start talking to sponsors to secure donations so our project can move forward.
9/6/11
Greenhouse Team With the conclusion of the first week comes the accomplishment of several key steps in the establishment of the greenhouse initiative. All members of the team have been selected. Preliminary research efforts have been made by all team members regarding such topics as glycerin-based heat storage media, existing residential heating alternatives, including pop can heater units, and solar data logger options and venders. The greenhouse manager has also been contacted and a tour has been scheduled for the team.
HVAC and Heart Attacks Kris had the idea to have a meeting between people who would like to work together. Joe and I set up this meeting. It was decided that the people at the meeting would work on the Solar Field, the Greenhouse, and a yet to be determined project. Kris and I came up with the idea of providing HVAC at the barn using renewable sources and some sort of energy storage system. We got Josh Sharp, Eric Wittman, and Joe Lauth on board with us and had a meeting with Dr. D to propose the project. The project was accepted pending interest in the JimmE-V. We went to the barn with Dr. D on Thursday to get a feel for the place. In class, Tommy Balough joined our group. We have been and will continue looking at past research and independent research.
Team || Hybrid Part of last week was spent researching topics and choosing a project, and at this point, all EcoHawks teams have all been finalized, and specialization has begun.The K-16 hybrid team 1 members have all read through the Shell Eco-Marathon rules, and the next week will be spent discussing and considering design decisions. A major decision that must be made is whether to design according to the Prototype or Urban Concept specifications, as they are slightly different. The combustion, electric, and hybrid categories have different specifications, and decisions also need to be made regarding the extent to which the EcoHawks design will follow the Shell parameters (for example, the hybrid vehicle's motor must be run off a Super Capacitor, NOT a battery). One potential sponsor has been contacted, and a follow-up will take place this week. An update meeting will take place at 5:15 on Friday, 9/9.
Greening the KU Field Station At the beginning of last week, the group was jockeying for position as to who was going to which group. Once the teams settled down into core groups of students, there were fewer uncertainties as to the composition of the Field Station group. Four of the current six team members took a trip to the Berm at the KU Field Station North of town so we could start thinking of ideas and get a physical image of the building in mind as we start the process of ascertaining the scope of the project. Once our team was set in stone, we scheduled our first official team meeting to clearly define team roles and start the research process. Next week, we plan on researching certain topics relevant to our project. One of our group members will take notes on the previous year’s Research Books, and the other group members will start extensively researching Thermal Source/Sink, Earth Sheltering Methods, Energy Storage Methods, Additional Energy Generation Methods (outside of solar), as well as other topics potentially deemed fit to the team as decided in the team meeting. We also intend to start talking to Westar for metering options and to start talking to our de facto customer, the Biology Department. In the later part of the week, we will meet with Dr. Depcik to further define the direction of our project.
JimmE-V During the beginning weeks of ME 640 for EcoHawks, the JimmE-V team members each looked at a variety of project options before finally selecting the JimmE-V. The JimmE-V project was officially combined with the Genset Trailer project during class. The main focus of the team will be to complete the JimmE-V. As we progress, some focus will shift to the Genset Trailer. The trailer will be closely related to the JimmE-V, which is why we combined the projects. A few students have already passed the machine shop test. The remaining students plan to take the test this week so we can begin working at the barn. Team contact information was gathered on the discussion board. Students have begun reading last year’s research book and presentation slides. We need to get more people reading the information provided from last year so that everyone knows the project status, and why last year’s team made the decisions they made. We also need to organize the team into areas so everyone has a specific focus. Before jumping in on the JimmE-V, the team has been discussing further shop organization by putting up shelves for added storage, which also improve appearance and makes for more efficient work time. For the JimmE-V, we need to figure out what all we have in possession, what we need, and what we can remove. We also need to determine and contact potential sponsors, along with existing sponsors.
Eco-Freakos Now that the semester is gaining momentum quickly, we have split the K-16 Parallel Hybrid into two teams; Shane Gooden being the leader of our team (Team Name TBD). We have chosen the Wednesday, September 14th time slot for meetings with Dr. D. At this point, this project has been mostly team work, excluding individuals researching and choosing the project. Will, Jon, and Kyle have done some preliminary research on the Shell Eco Marathon – Urban Design Challenge; and its rules, regulations, etc. At this instant, all tasks have been met and exceeded.
CAES Turbine Team This last week we formed our team which now consists of four members and have spent the week getting to know each other on a personal and technical basis. We have begun by narrowing in on what is achievable and how to proceed. Specific tasks have been doled out to one another based on individual strengths and interests. The thermodynamic aspects of compressed air storage are being assessed currently with Chenaniah and Daniel heading that aspect. Tank design is being looked into by Colin and he is also analyzing the business side of how viable this project may be which will include manufacturing costs. Tyler is compiling his previous research on compressed air to share with the group. We have started reading research papers on shrouded wind turbine design and philosophy. Utility scale versions of our project are also being researched to gain valuable insight into how this type of energy storage is handled on a large scale. |
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EcoHawks Weekly Blog |
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The University of Kansas School of Engineering Design Project A Sustainable Approach to Automobiles and Energy Infrastructure |
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Energy Infrastructure |