Table Of ContentDepartment of Mechanical and Materials Engineering
Florida International University, Miami, FL
EML 4905
A SENIOR DESIGN PROJECT
PREPARED IN PARTIAL FULFILLMENT OF
THE REQUIREMENT FOR
THE DEGREE OF
BACHELOR OF SCIENCE
IN
MECHANICAL ENGINEERING
Design of an Operational Turbojet Data Acquisition
Console – TURBODAC
Submitted by:
Dan Becker
Ivan Darias
Dwayne Gordon
Michelle Heethawakage
Kin Ng
November 28th, 2007
FACULTY ADVISOR
______________________
Dr. George S. Dulikravich
This report is written in partial fulfillment of the requirements in EML 4551. The contents represent
the opinion of the authors and not the Department of Mechanical and Materials Engineering.
Team Signature Page
This report was prepared by the following team members:
_______________________ November 28th 2007
Dan Becker
_______________________ November 28th 2007
Ivan Darias
_______________________ November 28th 2007
Dwayne Gordon
_______________________ November 28th 2007
Michelle Heethawakage
_______________________ November 28th 2007
Kin Ng
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Table of Contents:
Team Signature Page ...................................................................................................................... 1
Ethical Design Statement: ............................................................................................................ 4
Environmental Impact Statement: .............................................................................................. 4
Background: .................................................................................................................................. 5
Problem Statement: ...................................................................................................................... 6
Goal Statement: .................................................................................................................... 6
Objectives: ............................................................................................................................ 6
Form and Functionality: ....................................................................................................... 6
Challenges: ........................................................................................................................... 7
Intended Clients: ................................................................................................................... 7
Constraints:........................................................................................................................... 7
Functional Analysis: ..................................................................................................................... 9
Function Means Diagram: ......................................................................................................... 10
Conceptual Designs:.................................................................................................................... 11
Part Specifications: ..................................................................................................................... 12
Rigid Frame: ....................................................................................................................... 13
Load Cell: ........................................................................................................................... 14
Turbo-Jet Mounts: .............................................................................................................. 15
Engineering Analysis .................................................................................................................. 17
Theory of Operation ................................................................................................................... 22
Gas Turbines:................................................................................................................................ 22
Pressure Ratio: ................................................................................................................... 24
Combustion Chamber Shape: ............................................................................................. 25
Turbine Efficiency:.............................................................................................................. 26
Nozzle Efficiency:................................................................................................................ 27
Sensory Equipment and Placement: ......................................................................................... 28
Compression Fittings: ........................................................................................................... 30
K-Type Thermocouples: ...................................................................................................... 31
Pressure Transducers: ........................................................................................................ 33
Pressure and Temperature Sensor Insertion: ..................................................................... 34
The Load Cell: .................................................................................................................... 38
Electrical Circuitry and Fuel Delivery: .................................................................................... 41
Electrical Distribution: ....................................................................................................... 41
Fuel Delivery: ..................................................................................................................... 44
Quick disconnect fuel adapters: .......................................................................................... 45
Complete Schematic: .......................................................................................................... 46
Throttle Control: ......................................................................................................................... 47
Throttle System Structure: .................................................................................................. 48
Data Acquisition and Software Interface Techniques: ............................................................ 50
Sensor Transfer Functions:................................................................................................. 54
Front Panel: ........................................................................................................................ 55
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Data and Results: ........................................................................................................................ 57
Full Run: ............................................................................................................................. 61
Appendix A: Software Walkthrough ........................................................................................ 69
About Labview 8.0: ............................................................................................................. 69
Intercept the Data: .............................................................................................................. 72
Data Types: ......................................................................................................................... 74
Signal Splitting: .................................................................................................................. 75
Configuring Turbo-DAC for Acquisition: ........................................................................... 78
Appendix B: Familiarizing yourself with Turbo-DAC........................................................... 82
Appendix C: Start-Up Procedures ............................................................................................ 88
Appendix D: Failure Modes and Effects Analysis ................................................................... 93
Appendix E: Bill of Materials .................................................................................................... 95
Appendix F: Instrumentation .................................................................................................... 97
Appendix G: Project Timeline ................................................................................................... 99
Appendix H: Literature Review .............................................................................................. 100
Mechanics and Thermodynamics of Propulsion ............................................................ 100
Fundamentals of Gas Turbines ....................................................................................... 100
Principles and Applications of Electrical Engineering .................................................. 100
Fundamentals of Heat and Mass Transfer ..................................................................... 100
Microcomputer Design and Construction ....................................................................... 101
References:................................................................................................................................. 102
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Ethical Design Statement:
This is to certify that this project will be in accordance with the National Society
Professional Engineer’s Code of Ethics for all purposes of design and prototyping. The
designers consider the safety of the public to be paramount and have addressed this issue
throughout the design and implementation of this project.
Environmental Impact Statement:
The design and implementation of this project will be manufactured such that the
impact to the surrounding environment will be minimal and will have no permanent adverse
effects on the community or the environment.
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Background:
Turbo-DAC team is assigned the task of designing and constructing a testing console and
compiling all performance and efficiency characteristics of the MW-54 Mk3 Turbo-jet.
Locust USA of Hialeah Florida has contributed a complete Wren Turbo-jet model MW-54
Mk3 to Florida International University. Their contribution to our project has been a
rewarding and educational experience. The highlight of the assignment is to integrate
software and hardware into a comprehensive learning tool that will benefit future engineering
undergraduates. As with all similar assignments, a safe design is the foremost concern. As
we do not currently have this type of equipment in the mechanical and materials engineering
department and there are many unknowns with this new testing console, safety concerns are
priority one, then cost effectiveness, then ease of operation and so on. After completion, our
final design will be utilized by Florida International University for demonstration purposes in
the Propulsion Systems course. Students will learn the fundamentals of the Brayton Power
Cycle with hands on experience in advanced data acquisition and engine control.
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Problem Statement:
Goal Statement:
To design a functional, easy to use, portable gas turbine laboratory that acts as a data
acquisition console to be used by the future students of Florida International University.
Objectives:
• To acquire data from the Turbo-jet sensory equipment and record it for
engineering evaluation.
• To be as minimally invasive as possible when instrumenting the engine as to not
affect engine performance.
• To keep the operator and all personnel safe during operation.
• To teach the students how to interface using advanced data acquisition techniques.
• To teach the students the fundamentals of the Brayton Power cycle.
Form and Functionality:
The Turbo-jet will be encased in a rigid structural frame that can be easily transported.
This allows experimental showcases to be done virtually anywhere.
The senior team understands the dangers involved with a high powered device operating at
high RPM. Before the engine becomes operational, it must pass a series of safety protocols.
In the event of engine malfunction, the engine console will indicate the fault and the fuel
supply will be shut off. Microcontrollers will be incorporated into the circuit for an
instantaneous data and control delivery. In addition to the microcontroller, pure analog gages
will be present that can also be used for auxiliary data acquisitions.
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Challenges:
The biggest challenge will be to design the data acquisition software structure and user
interface. Our team intends to make this console user friendly while at the same time rugged
and fault tolerant. The system must not be too heavy or too big. It must be easy to start, run
and safe to use. It must be easy to maintain and easy for the user to assemble and
disassemble. Compilation of a clear, concise instruction manual will also be a crucial
challenge.
Intended Clients:
Florida International University’s Mechanical & Materials Engineering Department is
our intended client. This device may be appealing to any institution that has a Mechanical
Engineering department. In addition to this, any private sector that wishes to invest in an
educational device would also have an interest in this console.
Constraints:
The team recognizes our main constraints to be user safety, cost and ease of operation.
A turbo-machine that consumes a volatile fuel such as kerosene, propane or diesel that spins
at high RPM must be designed with safety as a primary constraint. The fuel lines must use
quick disconnect type fittings and the design will have redundant shut off mechanisms that
are easily accessible.
The cost per unit is a concern. If the cost per unit is too high, the design will not be
appealing to any educational institution on a strict budget. The unit must be easy to use; thus,
proper user interfacing is essential. The switches, gages and dials must all be located at
proper ergonomic locations. The console must use up-to-date software such as LabView 8.0
or DASYLab for proper data recording.
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Noise level is also a constraint the team is concerned with; the turbojet is a screeching
device. Ear protection will be available to students and faculty that are in the vicinity of the
engine.
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Functional Analysis:
The project architecture is illustrated using a drawing tree. Four major branches of the
project will be the main focus of the Turbo-DAC project and they are the structural housing,
user safety, user controls and data logging capability.
Design of an Operational Turbojet Data Acquisitions Console
“TURBO-DAC”
Strucural User User Data
Housing Safety Controls Logging
Rigid movable Explosion Propane control Analog gauges
steel frame resistant Lexan for the user to
panels view
Caster wheels Digital throttle
and stops Fuel shut-off control Labview data
Emergency acquisition
switch
Glow plug
Separate
control
computer Omega
Emergency siren Hardware
station adjacent
and diagnostic
to turbojet
lights All controls are
mounted on the
main control
Electronic fuel panel
shut-off with
safety logic
gates
Logic gates are dependant Engine mounted
on RPM and EGT. on linear
Fuel will not flow unless all bearings.
gates are satisfied. All force is to be
absorbed by the
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load cell.
