About The Design Lab - Rensselaer Polytechnic Institute

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12 The Design Lab at Rensselaer Students on the Hamilton Sundstrand team presenting designs for measuring the volume inside devices within a space station.
Measuring Volume In Outer Space Quantity Sensor Redesign Craig Eaton (MS&E), Burton Francis (MECL), Richard Grebe (MECL), Adam Jankauskus (ELEC), Lukas Leinhard (MECL), Jeffery Musante (ELEC), Arvind Ramachandran (MS&E), Michelle Santospirito (MGMT) Background Information The Hamilton Sundstrand Bellows Accumulator is a tank used for storing liquid in aerospace life support systems applications. Inside the accumulator, a quantity sensor determines the volume of the liquid present by measuring the displacement of the bellows. The current device, a string potentiometer, fails too frequently because of launch vibrations. A new measurement device is needed. Measurement Results Figure 1 shows a simulation of ideal experimental output. Figures 2 and 3 show actual laser and ultrasonic measurements, respectively. Note that the laser most closely resembles the ideal system. Figure 1 Figure 2 Figure 3 Systems that are used in space applications must be stable and reliable while deployed for up to 30 years. It is necessary to measure the volume of fluid in the various systems on the space station platforms. For approximately ten years the sponsor had been considering various technologies but had not selected an alternative. One student team successfully identified promising technologies that could be used to replace the current measurement technology. The second student team then found workable and readily available hardware for two of the potential technologies and performed a gage reliability and repeatability analysis on a prototype system they designed and constructed. As a result, they were able to prove that both selected technologies were viable for the application. Loop Fluid (Water, Urine, Coolant) Results: • The laser is a more precise measuring device. • The ultrasonic sensor is a more accurate, robust, and reliable measurement system. • Both sensors work in the system and greatly surpass the sponsor’s standards in terms of percent error of full scale. Recommendations: • Hamilton should re-evaluate their error standards. • The sponsor should choose laser for immediate use and precision. • The sponsor should choose ultrasonic and research a calibration method for a more accurate and reliable measurement system. Hamilton Sundstrand Bellows Accumulator Bellows Gas Charge (Air, Nitrogen, Helium) Our Working Prototype (a.) 4” x 48” hydraulic cylinder (a.) 3/8” threaded rod (b.) Ruler mounted to piston (c.) 3/8” threaded rod actuation of piston driven by power drill (d.) Cylinder mounted on 80 x 20 struts (e.) Sensors mounted directly to cylinder, radially constrained by cap fitted in cylinder bore (f.) Spring braces used to consistently reproduce holding pressure of sensor caps to cylinder Project Objectives: 1) Create a working prototype of a Hamilton Sundstrand Bellows Accumulator. 2) Test the performance of laser and ultrasonic distance sensors in the accumulator for use as a replacement for their current sensor. 3) Decide which technology best suits the sponsor’s needs and recommend which technology to move forward with. (b.) Power drill attachment position (c.) Socket ratchet attachment position (d.) Intermediate block connecting linear actuator to piston Project Engineer: Mark Anderson (The Design Lab), Chief Engineer: Daniel Lewis (Dept. of Materials Science & Eng.) Students meeting with the mentors at Hamilton Sundstrand. 2010 Project Portfolio 13
Page 1 and 2: SCHOOL OF ENGINEERING O.T. SWANSON
Page 3 and 4: Copyright © 2010 Rensselaer Polyte
Page 5 and 6: Dear Friends: Thanks to a generous
Page 7 and 8: Purpose Current Balance System Medi
Page 9 and 10: Smart Grid - PHEV Impact Study Robi
Page 11 and 12: Project Goal Design a one of two fe
Page 13: Vision and Scope Develop models for
Page 17 and 18: Effects of Stray Currents on Bearin
Page 19 and 20: Purpose Identify a particular font
Page 21 and 22: Erika Schnitzler (MECL), Jeremy Bet
Page 23 and 24: Computer Science & Communications S
Page 25 and 26: Improving The Lives Of The Elderly
Page 27 and 28: Biometrics Team: Jesse Herrmann1 ,
Page 29 and 30: Design for Sustainability Kate Biag
Page 31 and 32: Percent Floorspace Necktab 702 Vest
Page 33 and 34: Accomplishments LabVIEW Controls Ca
Page 35 and 36: Energy For Global Impact KNUST Univ
Page 37 and 38: Wild Animal Detection and Repellant
Page 39 and 40: DESIGN LAB STAFF Mark Steiner, Ph.D
Page 41 and 42: About The Design Lab Our Mission Th
Page 44: ev. 02152011 Rensselaer Polytechnic

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