Team Members: Nolan Cmerek David Haverlah Jeffrey Bell ASE 463Q 12/06/2006

Team Organization
Dr.

Ronald Stearman
Sponsor

Project

Nolan

Cmerek

Team

Manager Website Designer Software/Remote Access

David

Haverlah Bell
Nolan Cmerek
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Personal

Relations Cost and Analysis

Jeffery
Wind
Team Org. Outline Prev. Work

Tunnel Specialist
Tunnel Specs Goals Remote

Team Schedule

Nolan Cmerek Team Org. Outline Prev. Work Tunnel Specs Goals Remote
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Outline

Previous Q Project Work Wind Tunnel Specifications Project Goals Remote Control Need for Wind Tunnels Pickle Wind Tunnel History User Manual Other Wind Tunnels AC Variable Frequency Drives (VFD) Anti-Turbulence Screen Interview with Eddie Zihlman Cost Proposal Work Completed Recommended Future Work
Nolan Cmerek
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Team Org.

Outline

Prev. Work

Tunnel Specs

Goals

Remote

Previous Q-Project Work

BAA

Research (2003)

Included

background on the wind tunnel Purpose of this project was to improve the condition of the continuousflow type subsonic 5 x 7 wind tunnel at Pickle Research Center (PRC) Researched a semi-circular inlet screen which would be added to the mouth of the wind tunnel to dissipate turbulent eddies and ensure laminar flow Sting control system code is currently in the process of being converted from Rocky Mountain Basic to LabView Recommended the purchase and installation of the inlet screens to dissipate turbulent eddies throughout the tunnel

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Previous Q-Project Work

Joshua

Foxworth Thesis
BAA Research sting control system 4 7
Foxworth Thesis Report

Completed Chapter

General Test Procedure Cessna 208B

Start Procedures
Chapter

Sting Operations LabView Controls Math Behind Control

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Wind Tunnel Specifications (1)

5x7 by 50 long test section Powered by four 200 hp fans Designed for a maximum speed of 200 mph

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Wind Tunnel Specifications (2)

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Project Goals
Main

Objectives

Develop

a comprehensive users manual for the tunnel and data acquisition system Develop a cost proposal for a feasible upgrade to the wind tunnel
Turbulent Screens AC Controllers Re-shell and Structure Patches
Develop

outline for possible remote access

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Aeolus-Remote Control

ME Wind Tunnel Simplistic Approach Robust to handle multiple users while maintaining real-time interactivity Integrated real-time video
Security

Axis 2100 ActiveX control

User

Token server application ran as an embedded application on the FieldPoint unit

interface

Compiled application-Aeolus

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Dr. Phillip Schmidt Interview

Lent

us old ME Tunnel Reports Had to set up controls for sting in LabView Speed control working in FieldPoint FieldPoint is commercial hardware for remote data acquisition and control
Creates

a node on the internet

Worked

on a scheduling algorithm Aeolus system is not operational in the production sense. Never used it with a large class only demonstrated it.
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FieldPoint(1)
A

small rugged, easy to use, highly expandable, measurement and control device
Solid

metal backplane Removable compact flash drive Ethernet and serial ports
I/O

Boxes
modular

Expandable

architecture

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FieldPoint(2)

Real-Time LabView embedded control Developcompose application using graphical blocks Downloadtarget FieldPoint controller Deployreliable long-term execution

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Remote Access to Pickle

Use FieldPoint system from National Instruments Allow only restricted access No need for password changing system Axis 2100 for easy video integration

Total 0 -4 -4

Device Axis 2100 USB Web-Cam IEEE 1394 Webcam

Access Rate (fps) Required Hardware Ease of Integration Quality of Video 0 0 0 0 1 -2 -1 0 1 -3 -1 1

Maintainability 0 -1 -1

Security 0 -1 -1

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Need for Wind Tunnels

Airflow simulation over aircraft and structures is a complex and involved process. A few common methods of flow analysis used today; scaled wind tunnel testing, full size wind tunnel testing, and computational fluid dynamics (CFD)

Basic Needs; Safety, Economics and Education Proof of design prior to test flight which puts life and prototype at risk Education, hands on learning and observation of fluids (modeling can only be as accurate as ones perception and understanding of nature) Flows around complex structures are presently difficult to model with CFD. Scaled model wind tunnel testing is comparatively easy to setup and research Scaled testing is more economic than full size testing simply because a full size capable wind tunnel is a few orders of magnitude more expensive than a scaled wind tunnel (simultaneity with Reynolds numbers) CFD was used entirely for the design of Scaled Composites SpaceShipOne prior to test flights. However, during one of the initial test flights, flight threads were attached to the surface of the wings in order to augment the computational model

http://en.wikipedia.org/wiki/Wind_tunnels

Jeffrey Bell Need for Tunnels Pickle History User Manual Other Wind Tunnels
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History of the Pickle Research Center Wind Tunnel

1970, design was started on an open circuit 5 x 7 foot 200 mph tunnel to accommodate aeronautical, meteorological and architectural needs 1971, construction initiated using State funds available to the College of Engineering

Used to purchase and erect four main drive fans and construct the test building

1980, tunnel construction completed and testing started

1995, Joshua Foxworth performed lift, drag and moment coefficient testing on the Cessna 208B
Other testing includes a cable mounted Cessna Caravan aerodynamic testing, skeleton sled drag coefficient optimization, and this semesters aerodynamic damage team

Future testing includes the Design Build Fly and UAV projects

Jeffrey Bell Need for Tunnels Pickle History User Manual Other Wind Tunnels
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Users Manual Summary General Test Procedure: Force and Moment Measurement

The following steps must be performed in order to safely and properly perform a general force and moment measurement test on a model in the wind tunnel.These sections were summarized, condensed and/or directly copied from Foxworths Chapter 4 thesis, and the Wind Tunnel Startup Procedures manual authored by Eddie Zihlmans work study students. Call 1-3600 on the day of a run to inform grounds keepers, etc. and page Bobby (grounds crew supervisor) at 625-8145 and leave a call back number.

Jeffrey Bell Need for Tunnels Pickle History User Manual Other Wind Tunnels
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Summarized Steps(1)

Step 1: Perform Safety Checks

Sting Force Balance Safety Check Fan Motors and Wind Tunnel Preparation and Safety Checks
Check hydraulic system for proper fluid levels Turn on water cooling system Sting is controlled with Main_controller_code.vi in Labview Measure and input sting rest angle into sting control window to zero the AoA of the sting Zero the force load on the sting to eliminate DC bias errors Mount model when sting is at 0 degrees AoA Check for clearance during range of AoA Measures and records forces for each angle of attack with no wind load Jeffrey Bell

Step 2: Prepare the Sting for Use

Step 3: Move Sting to Zero Degrees Angle of Attack

Step 4: Take Initial Force Balance Readings

Step 5: Mount the Model

Step 6: Run Tare Test Using Automated Testing Function

Need for Tunnels

Pickle History

User Manual

Other Wind Tunnels

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Summarized Steps (2)

Step 7: Turn on Fans and Achieve Proper Tunnel Speed

Measure airspeed via airspeed indicator box or digitally with the scanivalve interface
Press the Run Automated Test Sequence button

Step 8: Run Force Test Using Automated Test Sequence

Step 9: Take Timeline Data

Measures and recorded force data for 6 axes Dynamic force measurements allow frequency content to be analyzed
Press the Calculate Coefficients / Plot Data button Calculates lift, drag and moment coefficients

Step 10: Reduce Tare and Force Files to Proper Coefficients

Step 11: Calculate Frequency Content of Timeline

To view the frequency content of a recorded timeline, the Plot Frequency Spectrum of Timeline button

Step 12: Remove Model, Lower Sting, Power off all Equipment

Make sure floor inserts do not obstruct the sting when it powers off
Pickle History User Manual

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Average Lift Coefficient Plot Example

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Other Wind Tunnels

9

x 15 Low Speed Wind Tunnel at NASA Glenn Research Center Aerodynamic and Aeroacoustic Research Center Automotive Wind Tunnel (Italy) of Washington Kirsten Wind Tunnel

Pininfarina

University

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9 x 15 Low Speed Wind Tunnel at NASA Glenn Research Center

Characteristics and Performance

Flow Visualization

Test Section Size: 9 ft high by 15 ft wide by 28 ft long Mach Number Range: 0 to 0.2 Fan Drive Rigs: 1000, 2000, and 5000 shp 1024 channel pressure measurement system Pressure sensitive paint Both conventional and focused Schlerien systems Sheet laser Oil flow visualization High speed video - up to 1000 full screen frames/s Real-time remote access to all data Online calibration Video conferencing in real time Workstations supplied for remote site Secure network connections provided

http://facilities.grc.nasa.gov/9x15/9x15_desc.html

Remote Access Control Room

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Pininfarina Aerodynamic and Aeroacoustic Research Center Automotive Wind Tunnel (Italy)

Characteristics and Performance

Test

http://arc.pininfarina.it/english/index_en.html

Section Size: 4.20 m high by 9.60 m wide by 8.00 m long Max Flow Speed = 56 m/s DC Motor Power = 1.1 MW

Flow Visualization, Acoustics, and Other Instrumentation

Hot

wire,14 pressure tab probe, smoke, laser light sheet 3 component Laser Doppler Velocimeter Acoustic field measurement inside and outside of the vehicle Brake Disk and Radiator Cooling flow measurement

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University of Washington Kirsten Wind Tunnel

Characteristics and Performance

Flow Visualization

Test Section Size: 8 feet high by 12 feet wide by 10 feet long with 1.5 feet high (45) fillets in all four corners Max Flow Speed = 250 mph Two 500-hp dc motors 30 data channels with 2 additional for model positioning at 100 samples per second Smoke, tufts, china clay, oil, sublimation Digital and analog video capture with normal and ultraviolet lighting,

China Clay Flow Visualization

http://www.uwal.org/uwalinfo/techguide.htm

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AC VFD Control

VFD-Variable Frequency Drive

Changes the output frequency to control motor RPM

Current control is On/Off only, with shutter vane options

VFD allows total control of fan speed-needed for UAV

Remote computer control supported

http://www.clrwtr.com/Yaskawa-Drives.htm

David Haverlah AC Control Turbulent Screen Eddie Cost Work Completed Future
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Anti-Turbulence Screen

Currently there is only one anti-turbulence screen Approximate cost is $15,000-$25,000 each + installation per screen. Aerolab technician cost~$1,000 man/day + travel. Needed installation~2 men minimum for assembly and installation. Total cost for 2 screens~$30-$60K.

http://www.semguy.com/gfx/screen.jpg

Front View of Inlet

Close up of Screen

Side View of Inlet

David Haverlah

AC Control

Turbulent Screen

Eddie

Cost

Work Completed

Future

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Interview with Eddie Zihlman (1)

Discussion of tunnel operations an involved process

Safety checks and lockouts Full speed runs require shutdown of high speed tunnel

Advanced notice required to coordinate the two facilities

Measurement issues
The sting is weak in the yaw direction Measuring balance has been damaged and repaired several times The bulk of the sting creates unwanted blockage of the tunnel at low and negative AOA

Initial design changes

Found records where initial design was altered slightly in exhaust area which might contribute to tunnel fluctuations

David Haverlah AC Control Turbulent Screen Eddie Cost Work Completed Future
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Interview with Eddie Zihlman (2)

Tunnel issues

Wet rot from inadequate drainage and poor initial design

Several patches have been cut into the existing tunnel to attempt to fix, but rot is spreading

Kink or dog-leg in diffusion section that creates adverse flow fluctuations into fan Sealant material used to weatherproof outdoor sections of tunnel contains asbestos Low frequency velocity oscillations occur within test section at moderate external (atmospheric) wind speeds

This limits operations to days when winds are below 9 mph *

Exhaust flow is not contained, and can be a hazard if the experimental model is destroyed during operations

Highlights
The tunnels does work, and was built on a shoestring budget mostly by students Was used to measure drag on USA Olympian skeleton racer, who eventually won

David Haverlah AC Control Turbulent Screen Eddie Cost Work Completed Future
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Cost Proposal
Option 1 Upgrades
Item VFD AC Motor Controller Anti-Turbulence Screen Honeycomb Flow Straightener Total Cost Item Cost $8,750.00 ~$15,000 $30,000 ~$15,000 $30,000 Number Required 4 2 1 Required Cost $35,000.00 $30,000 $60,000 $15,000 $30,000

$80,000 $125,000

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Cost Proposal
Option 2 Upgrades
Item Option 1: Total Cost Item Cost Number Required Required Cost $80,000 $125,000

Enclosure Building Computer and DAQ Re-Build Tunnel Total Cost

~$25 per sq. ft + $27,500 foundation

~$1,000-$3,000

250 X 60 = 15,000 ft2 2-3

~$375,000 $403,000 $2,000 $10,000

~$50,000 $150,000 ?

~$50,000 $150,000 ?
$507,000$688,000

Consider New Tunnel ~ 1-2 Million

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Work Completed

Gathered information and prices for AC motor controllers Contacted Dr. Bragg at the University of Illinois at Urbana

Generated contacts nationwide to get turbulence screens and other items

Made several trips to Pickle facility and researched tunnel history

Learned of initial designs and construction period Obtained partial operation manual and documents that explain operations of the sting

Feasibility of remote access

Interview with Dr. Phillip Schmidt Interview with Eddie Zihlman

Comprehensive User Manual

Cost Proposal
Option 1 $80,000 - $125,000 Option 2 $507,000- $688,000

Consider building new facility for 1-2 million David Haverlah AC Control Turbulent Screen Eddie Cost Work Completed Future
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Recommended Future Work

Film

sting operations and LabView system Implement Remote Access using FieldPoint Continue search for tunnels that may be decommissioned for possible purchase Pending Funding:
Upgrade

to at least Option 1for UAV and DBF use

AC Motor Controller Anti-Turbulence Screen Flow Straightener

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Questions?

Thank You
For more information please visit

http://www.ae.utexas.edu/~cmereknd/PICKLE_WIND_TUNNEL/home.htm

Nolan Cmerek

David Haverlah

Jeffrey Bell

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