Growth Innovations Kite Group

1
Growth InnovationsKite Group

• Final Project Presentation
• 6 April 2006
• Chris Boven
• Trever Carnes
• Brandon Henley
• Emmanuel Zoubovsky

2
Introduction
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Design a System to Control a Traction Kite for
  Sailing Applications

3
Kite Background
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Upper Level Winds
• More Stable
• 3 Lines
• Sides Turning
• Middle Pitch
• Each Line Controlled by a Crewmember

4
Specifications
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Line Speed 5 ft/sec (turning)
• Line Loads 1500 pounds
• Section Weight lt 200 lb
• Power Source 12-volt batteries
• Controlled using one hand

5
Concepts
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Ideas
• Electric Capstans
• Hydraulic Motors
• Individual Gearboxes
• Planetary Systems
• Why Planetary Systems?
• Collective Control
• Turning Advantage
• Stress Distribution

6
Calculations
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Gear Selection
• Turning Line Speed 5.1 ft/sec
• Gear Stresses 1.2 Factor of Safety
• Power Consumption
• In/Out 10.6 HP
• Pitch 2.1 HP
• Does Not Consider Friction

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Final Design - Gears
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Planetary Gearsets
• Multiple Inputs
• Sun Gear
• Outer Ring
• Single Output
• Planet Carrier
• Worm Gears
• Speed Reduction
• Backfeed Prevention

8
Final Design - Gears
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Inputs
• Turning
• Differential
• Pitch
• Angle of Attack
• In/Out
• Kite Orientation Unchanged

9
Final Design - Frame
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Welded Steel Frame
• Angular Members
• Prevent Collapse
• Allow Motor Access
• Larger Members
• Support Main System

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Final Design - Electronics
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Off-the-Shelf Components
• RC Transmitter
• RC Receiver
• RC Interface
• Motor Controller
• Motor

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Manufacturing - Lathe
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Turned on Lathe
• 11 Shafts
• 3 Spools
• 15 Round Plates
• 36 Spacers

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Manufacturing - Mill
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Machined on Mill
• 30 Plates
• 3 Keyways
• 31 Gear Mods

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Manufacturing - Welding
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Total Shop Time 590 Hours

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Assembly
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Used 400 Fasteners
• Broke20 Allen Wrenches
• Time Spent 60 Hours

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Testing Fit Testing
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Fit Shafts in Bearings
• Size Spacers to System
• Align Bearings
• Adjust for Oversized Material
• Compensate for Bowed Plates
• File Damaged Gear Teeth

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Testing No-Load Testing
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• All Motors Running
• Line Speed of 5 ft/sec in Turning
• In/Out Caused Slight Backfeed
• RC Interfaces Ceased to Function

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Testing Loaded Testing
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work
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Future Work
Introduction Kite Background Specifications Concep
ts Calculations Final Design Gears
Frame Electronics Manufacturing Lathe
Mill Welding Assembly Testing Fit
No-Load Loaded Future Work

• Possible Future Projects
• Lighten the System
• Make System More Modular
• Scale Down System Size
• Make Corrosion Resistant

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Questions