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Preliminary Design Review (PDR) Lunar Wormbot (LW) Team 1

Preliminary Design Review (PDR) Lunar Wormbot (LW) Team 1. MAE 490-02: Introduction to Engineering Design- Product Realization Instructor: Dr. Christina L. Carmen, Ph.D. Technical Advisors: Mr. Ben DiMiero Dr. Jessica Gaskin Mr. Michael Kuhlman Mr. Blaze Sanders Dr. Michael Tinker

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Preliminary Design Review (PDR) Lunar Wormbot (LW) Team 1

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  1. Preliminary Design Review (PDR)Lunar Wormbot (LW)Team 1 MAE 490-02: Introduction to Engineering Design- Product Realization Instructor: Dr. Christina L. Carmen, Ph.D. Technical Advisors: Mr. Ben DiMiero Dr. Jessica Gaskin Mr. Michael Kuhlman Mr. Blaze Sanders Dr. Michael Tinker Mr. LafeZabowski Customers: NASA NSSTC Team Members: Charles Boyles Ben Gasser Josh Johnson Ben Long Nathan Toy

  2. Overview • Purpose of the PDR • Mission Statement • Top Level Requirements • Selected Design • Design Drawings • Technical Analysis

  3. Overview • Safety Considerations • Material Selection • Cost Analysis • Manufacturing Processes • Problems and Solutions • Activity Plan • Summary

  4. Purpose • Establish that the preliminary design meets the technical requirements • Demonstrate that the design can be produced with acceptable risks • Establish the operability and producibility of the selected design • Refine cost and scheduling to ensure that planning, production and testing are feasible

  5. Mission Statement Ultimately it is the hope of this team to lead to knowledge enabling a burrowing robot to operate on the lunar surface to gather soil samples. Leading to that goal, and staying within the scope of the time period of this project, a single, prototype LW will be produced for earth based testing. This robot will be considered successful in its mission if it offers the ability to burrow through a fine particulate soil simulant, return testing data leading to improvements in design, and exhibits the robustness necessary for space based soil sampling.

  6. Top Level Requirements • Top-level Requirements • Burrowing through fine particulate matterutilizing peristaltic motion • Prototype built for Earth-based testing • Ability to acquire 50 one gram samples at various depths • Segment power consumption of 4 Watt maximum

  7. Top Level Requirements • Skin material capable of insulating internal electrical and mechanical systems from fine particulate matter • Space to integrate a sensing and navigation package • Production of at least 66 N of force directed perpendicular to the segment’s longitudinal axis

  8. Designs Considered NASA/NSSTC Initial Concept Utilizes AX-12 servo motors as well as hinged plates

  9. Designs Considered Modified NASA/NSSTC design utilizing linear actuators and hinged plates

  10. Designs Considered Linear actuators with pressurized flexible sidewall

  11. Selected Design Linear actuators with unpressurized springy sidewall

  12. Evaluation Matrix

  13. Selected Design • Advantages of Selected Design • Smaller cross section • Less mass • Relatively low complexity • Allows 3-D motion

  14. Design Drawings Firgelli L16 Linear Actuators

  15. Design Drawings Aluminum bulkhead with 3-bolt pattern

  16. Design Drawings Wiring bus conduit

  17. Thermal Analysis Thermal Analysis Basic Equations* (1) (2) (3) (1) From table 4.1, pg. 209, shape factor for a vertical cylinder in a semi-infinite medium. (2) From table 4.1, pg. 209, heat transfer by conduction using a shape factor. From equation 3.27, pg. 117, heat transfer by radial conduction through a cylindrical wall. *Fundamentals of Heat and Mass Transfer, 6th Edition, Incropera, DeWitt, Bergman, Lavine

  18. Thermal Analysis Heat Transfer and Internal Temperature Analysis: Earth Based Testing – Using Dry Concrete Mix and Three Skin Materials: Fiberglass: 77.4 F Kevlar: 79.0 F Carbon Fiber: 77.4 F Summary: The internal temperature will be approximately 80 degrees Fahrenheit, and the skin materials evaluated show no clear benefits or problems in this testing environment.

  19. Thermal Analysis Heat Transfer and Internal Temperature Analysis: Lunar Regolith– Using Lunar Regolith and Three Skin Materials: Fiberglass: 259.9 F Kevlar: 261.5 F Carbon Fiber: 259.8 F Summary: All skin materials and internal components will be able to withstand such calculated temperatures.

  20. Force Analysis • Column Buckling • Superposition • Point Load • Total force required from actuators • Power Required

  21. Force Analysis Simplified Analysis Method FE = 0.513 lbfPcritical=0.673 lbf NetForce = (FE + Pcritical)NS= 29.8 lbf ≈ 133N

  22. Technical Analysis Power Consumption of Actuators: Voltage – 12 V Current – 136 mA @ 133 N Output Force Power Consumption – 4.88Watts > 4 Watts Life Cycle/Durability of Actuator Analysis: Max Rated Cycles– Firgelli L16 = 20,000 cycles Estimated Stroke Length – 2 cm Burrow Depth – 15 m Life of Lunar Wormbot – 13 missions Summary: Based on the rated life of the actuators, the wormbot will be able to accomplish 13 missions of 15 meter depth (includes return to surface).

  23. Technical Analysis Bulkhead Stress (Von Mises) Finite Element Analysis

  24. Technical Analysis Bulkhead Deflection Finite Element Analysis

  25. Safety Considerations • Manufacturing • Standard Risks • Materials • Minimal • Storage • Lifting • Dropping • Mishandling • Testing • Shock threat • Pinch points • Auger Blades • Maintenance • Shock threat • Sudden movement

  26. Hazard Assessment Military Risk-Hazard Assessment Standard 882B Failure Modes

  27. Material Selection • Actuators • Firgelli L16 • Bulk heads • Aluminum 7075 • Titanium • Steel • Skin • Fiberglass • Kevlar • Carbon Fiber

  28. Manufacturing Processes • Facility Requirements • Locations • W100 Technology hall • $0 /hr labor • NSSTC Machine Shop • $60/hr Labor • Duration • 2-3 months • Auger • Rapid Prototyping • 5-axis Machining • Segments • Standard Machine Shop • CNC Capabilities

  29. Cost Analysis Segment Parts and Hardware

  30. Cost Analysis Electronics

  31. Cost Analysis Manufacturing Cost

  32. Cost Analysis Testing Cost

  33. Cost Analysis Summary of Cost Analysis

  34. Problems and Solutions • Resurfacing • Aft end equipped with auger • Power Consumption • Batteries or capacitors • Actuator limitation • Custom design • Parts Procurement • Local suppliers

  35. Future Work Analysis of sidewall members Actuator efficiency Collaboration with LA Tech concerning system integration Manufacturing prototype Testing sub-systems

  36. Activity Plan

  37. Summary • Selected Design • Size • Aesthetics • Functionality • Performance • Reliability

  38. Summary • Technical Analysis • Thermal properties • Stress analysis • Force analysis • Life-cycle analysis • Cost Analysis • Materials utilized • Manufacturing • Overhead • Future Work

  39. References • Software Packages • Solid Edge ST and v20 • SolidWorks • X-TOOLSS and MS Visual Studio • Mathcad v14 • MS Excel • MS Project

  40. References • Books • Incropera, DeWitt, Bergman, Lavine, “Fundamentals of Heat and Mass Transfer 6th Edition” • Juvinall, Marshek, “Fundamentals of Machine Component Design 4th Edition ”

  41. Acknowledgements • Adam Burt • Kirk Biszick • Dr. Christina Carmen • Steve Collins • Ben DiMiero • Dr. Jessica Gaskin • Michael Kuhlman • Blaze Sanders • Dr. Michael Tinker • LafeZabowski • Dr. Francis Wessling

  42. Questions Hail Mary Plan

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