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Hyperloop Accelerator Design Review Hyperloop Accelerator Design Review TA: Benjamin Cahill ECE 445 February 25, 2015 Mohammad Jaber Michael Eraci Shivam Sharma Group #24 Table of Contents 1.0 Introduction............................................................................................................... 3 1.1 Statement of Purpose................................................................................. 3 1.2 Objectives...................................................................................................... 3 1.2.1 Benefits ........................................................................................... 3 1.2.2 Features .......................................................................................... 3 2.0 Design......................................................................................................................... 4 2.1 Block Diagram .............................................................................................. 4 2.2 Block Descriptions...................................................................................... 5 3.0 Schematics and Simulation .................................................................................. 6 3.1 Circuit Diagram ............................................................................................ 6 3.2 Control Flow Diagram ................................................................................ 7 3.3 Simulations ................................................................................................... 7 4.0 Requirements and Verification .......................................................................... 10 4.1 Tolerance Analysis ................................................................................... 11 5.0 Cost and Schedule ................................................................................................ 12 5.1 Cost Analysis ............................................................................................. 12 5.1.1 Labor Cost ................................................................................... 12 5.1.2 Parts............................................................................................... 12 5.1.3 Total Cost ..................................................................................... 13 5.2 Schedule ...................................................................................................... 13 6.0 Mathematical Theory and Calculations ........................................................... 15 6.1 Coil Gun Theory and Equations ............................................................ 15 6.1.1 Introduction ................................................................................. 15 6.1.2 Equations ..................................................................................... 16 7.0 Safety Statement ................................................................................................... 18 7.1 Ethics with Reference to IEE Code of Ethics ..................................... 18 8.0 References .............................................................................................................. 21 2 1.0 INTRODUCTION 1.1 Statement of Purpose The Hyperloop was an idea put forth by Elon Musk as a less expensive alternative to maglev trains. The goal of this project is to assist a Mechanical Engineering team finish the prototype that has been started but is not yet working. Our prototype Hyperloop will be a proof of concept and a starting point for future students to improve and refine. We will also act as consultants for all the electrical aspects of the Hyperloop design. 1.2 Objectives 1.2.1 Goals The goal of our project is to help a Mechanical Engineering senior design team create a working prototype Hyperloop Accelerator (Tubular Induction Motor). The previous mechanical engineering team acquired most of the parts for the project and partially assembled the linear induction motor. 1.2.2 Functions Our objective is to review and improve on the current motor design and assemble a functioning capsule accelerator. The accelerator should be able to propel a capsule around a loop of partial vacuum tubing. 1.2.3 Benefits ● A working prototype will provide a proof of concept for the Hyperloop ● A completed working prototype can serve as a foundation for future Hyperloop projects where further improvement can be made on the design by future teams 1.2.4 Features ● Sensors for average speed ● Sensors for power consumption ● Linear motion via tubular Induction Motor ● Stop/Start Capability 3 2.0 DESIGN 2.1 Block Diagram While getting the tubular induction motor to work is the central aim of this project, there are other supporting modules we can use to reduce power consumption by only turning on the motor when the travelling capsule reaches the accelerating strip. Figure 1: The induction motor receives inputs whether directly or indirectly from four other modules. As shown in Figure 1, the induction motor is the terminal module with inputs from other modules used to turn it on/off to save on power consumption. 4 2.2 Block Description 2.2.1 Sensors Module This module detects whether or not the moving capsule is inside the stretch of tube located inside the induction motor. We will probably use two IR sensors to detect when the capsule enters the tubular induction motor and when it leaves. 2.2.2 Control This module will use a microcontroller such as an Arduino Uno to accept input from the sensors and determine a control signal telling the power when to turn on or off the induction motor. 2.2.3 DC Power Source This module accepts the 120V RMS value AC output of the AC power module and creates a 5 V DC voltage +/- 0.5 V for use for logic operations and sensors. 2.2.4 AC Power Module This module provides a 120V RMS output to the AC to DC converter and a modulated signal to the tubular linear induction motor (on when the car is in the accelerator and off when the car is travelling through the rest of the loop. 2.2.5 Tubular Linear Induction Motor This module uses Faraday’s law to accelerate a capsule along a straight length of tube whenever the capsule completes one lap of the loop. The motor consists of: a. Stator: 35 turns of copper winding linearly arranged along the straight length PVC pipe using wooden and aluminum supports. Serves as an induction coil b. Rotor (capsule): An iron core Three phase AC current is passed through the coils in the stator to induce a magnetic field in them. The changing direction of the current at periodic intervals leads to a changing magnetic field in the stator in turn inducing a field in the rotor. The alternating polarity of magnetic fields between stator and motor provides linear motion. 5 3.0 Schematics and Simulations 3.1 Circuit Diagram Figure 2: Diagram for the operation of a single coil This circuit will be built for each of the 36 coils. The charging and discharging of the coils will be controlled by the Arduino through the use of thyristors. Part Part number Thyristor BT 139-600 Bridge Rectifier 583-MP154 (Mouser) Capacitor 667-EET-HC2E1220A 6 3.2 Control Flow Diagram Figure 3: Flow chart describing the eventual control structure 3.3 Simulations Figure 4: Schematic used for the PSPICE simulation of the charging up and discharge of the 1.2 mF capacitor. 7 Figure 5: It takes about 0.2 seconds to charge to capacitor to 63% of the maximal charge. Therefore the time constant is about 0.2 seconds. We will define the time to charge a capacitor as 5 time constants. As such, the capacitor charges in 1 second. Figure 6: This is the current passing through the coil. If one were to use a 250 VAC source instead of the 50 VAC source from the simulation, the current would be 25 A. This is less than the 50 A maximum so the thyristor should not have a problem with managing that current. 8 Figure 7: This shows the current leaving the bridge rectifier. If one were to use a 250 VAC source instead of the 50 VAC source from the simulation, the maximum current would be 2.25 A. This is less than the 15 A maximum so the bridge circuit should not have a problem with managing that current. Figure 8: Velocity as a function of capsule mass Assuming that the coefficient of energy transfer from the coils to the capsule is independent of the capsule’s mass, lighter capsules would have higher velocities after leaving the coil. 9 4.0 REQUIREMENTS AND VERIFICATION Requirement Verification Points 1. Induction Motor: a. The motor should be able to a. Detach straight length tube 40 make the capsule move the from apparatus. Turn on length of the motor, which is 0.9 accelerator and verify that meters. the capsule is ejected out b. The motor should be able to of the end of the tube. 10 accelerate the capsule b. Dedicate a control LED for continuously without need to displaying when the restart the system. capsule passes by a sensor. Verify that the LED flashes no less than 2 times within a 30 second interval of the hyperloop being turned on. 2. Sensors: a. There are two sensors used to a. When the capsule is 20 detect entry and exit of the directly under each sensor capsule (rotor). Sensors an output LED from the detecting white (no capsule) microcontroller should be output a high voltage. The on and when the capsule capsule is dark in color. When is not the LED output the capsule enters or exits the should be off. motor, the sensors detect black and output a low voltage. 3. The AC Power Source: 10 a. An oscilloscope trace of 20 a. Should be able to turn on and off the capacitor voltage will the
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