Optical Mounting System for Laboratory Research

1
Optical Mounting System for Laboratory Research

• Group Members
• Nicholas Hamilton
• Michael Kukla
• Melissa Martin
• Michael Mastin
• Academic Advisor
• Dr. Raul Bayoan Cal

2
Introduction

• PSU Mechanical Engineering Department is
  installing a wind tunnel on the first floor of
  the Engineering Building.
• It is essential to be able to image the airflow
  moving past fixed objects in the test area to
  study boundary layer effects, turbulent kinetic
  energy, and heat transfer effects.
• A system is required to mount the imaging
  components.

3
Design process and specifications

• Customer interview
• Problem Statement
• Provided basis for PDS
• Operable by a single user
• Travel the entire length of the wind tunnel
• Hold an array of optics and imaging equipment
• Enable varied focal depths through the test
  chamber

4
Design process and specifications

• Brainstorming session
• Identified key components (base, frame, and
  materials)
• Design ideas reviewed after two minute intervals
• Individual ideas for components were critiqued
• Best design features were implemented in initial
  designs
• External search
• Modified single-mirror off-axis schlieren
  photography configuration was selected
• Patent search
• Potential fabrication materials researched

5
Design process and specifications

• Solid models of each design were generated and
  compared using SolidWorks
• A decision matrix was used to determine the best
  aspects of each design

6
Design process and specifications

• Designs were streamlined
• Upon review by the customer, design
  specifications
• changed

7
Schedule and milestones
Optical Mounting System Optical Mounting System Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d) Weekly Start Dates (m/d)
Task Number Task Name 1/4 1/18 2/8 2/15 2/22 3/1 3/8 3/15 3/22 4/5 4/19 5/3 6/7
1 PDS Development                          
2 Initial Design                          
3 External/Internal Search                          
4 Design Evaluation and Selection                          
5 Progress Report                          
6 Materials Testing                          
7 Detailed Design Development                          
8 Prototype Building                          
9 Prototype Testing                          
10 Finish Documentation                          
8
Imaging Setup
Modified single-mirror off-axis Schlieren
photography configuration
9
Prototyping

• Required orientation of optical components was
  determined through experimentation
• This data was paramount in determining the
  dimensions of the optical mounts

10
Material selection and fabrication

• Material decision based on data collection in
  ME411
• Engineering analysis included
• Measuring deflection with strain gages
• Modeling members with Abaqus, an FEA software
  program
• A decision matrix was used to compare materials
  using the following criteria.
• Strength
• Weight
• Cost
• Manufacturability

11
Material selection and fabrication

• Brackets were fabricated from 10 gage mild steel
• Flat patterns were laser cut from one solid piece
• A hydraulic break press was used to create the
  desired geometry
• Edges were welded for structural integrity

12
Fabrication

• Double Convex Collimating Lens Holder
• Milled from 1 thick 6000 series aluminum using a
  CNC end mill
• Holes drilled and tapped using an end mill
• Orbital sander (220 grit) was used to create the
  final finish

13
Obstacles and lessons learned

• Largest obstacle was in the ordering the
  materials.
• Response time from manufacturer and distributor
• Wind Tunnel delivery delayed
• Designs were based off technical drawings
• Changing design specifications
• The customers priorities changed, altering the
  PDS
• Budget constraints
• Creative design changes were made to lower cost
  and maintain functionality detailed in the PDS.

14
Final Design

• The final design was determined by adhering to
  the PDS and customer feedback.
• Mounts to the legs of the wind tunnel
• Operable by a single person.
• Optical components can be adjusted easily to
  improve image quality

15
Questions
Photo generated during testing of Schlieren
imaging configurations