BIRDIE: Biologically-Inspired low Reynolds number Dynamic Imagery Experiment

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BIRDIEBiologically-Inspired low Reynolds
number Dynamic Imagery Experiment
Critical Design Review

• Jeff Baxter
• Jeff Silverthorn
• Matt Snelling
• Courtney Terrell
• Blake Vanier
• Keith Wayman

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Briefing Overview and Content

• System Architecture
• Design Elements
• Mechanical Design Elements
• Electrical Design Elements
• Software Design Elements
• Integration Plan
• Verification and Test Plan
• Project Management Plan

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System Architecture

• Overview of Objectives
• Motivation
• Overview of Requirements
• Goals
• System Design
• Prototype- Visualization Experiment Results

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Overview of Objectives

• To create an experimental apparatus that can
  trace out a given wing motion similar to a
  hummingbird in hovering flight
• Design a system to capture the aerodynamic
  structures created by this wing motion

http//www.ae.utexas.edu/design/humm_mav/
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Motivation

• Study low Reynolds number unsteady flow of
  hovering flight
• Application for highly-maneuverable MAVs
• Single system for thrust and maneuver

Ref. 10
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Overview of Requirements

• Wing Range of Motion
• 80 in horizontal plane
• 60 in vertical plane
• 110about length of the wing (pitch)
• Achieved By
• Measuring geometry
• Collision detection

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110
80
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Overview of Requirements

• Wing tip motion must follow a given path
• Within 20, of the maximum amplitude, spatially
• Within 20, of the period, temporally
• Pitch motion must follow a given rotational mode
• Within 20, of the maximum angle, rotationally
• Within 20, of the period of rotation, temporally
• Achieved By
• Design of Wing Mechanism
• FEM analysis
• Software
• Control motion

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Overview of Requirements

• Frequency
• 0-10 Hz with a resolution of 1 Hz
• Achieved By
• Variable speed motors
• Wing Variation
• Simple interchange of wings 5-10 cm in length,
  within 30 minutes
• Achieved By
• Chuck and collet system
• Removable chamber panels

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Overview of Requirements

• Visualization of Aerodynamic Flow
• View Area gt30 cm2
• Minimum Resolution 96 x 96 pixels
• Minimum Frame Rate gt200 frames per second (fps)
• Achieved By
• Camera position and capability

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Goals

• Create three different wings with varying
  stiffness for testing
• Achieve frequency of 20 Hz
• Synchronize visualization with collected
  three-axis dynamic loading data
• Beyond project scope

10 cm
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System Design
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System Design
Units in meters
Wing Mechanism Test Structure Visualization Suppor
t Structure Servos






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System Electrical Connections
Ethernet
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Prototype- Visualization Experiment Setup

• Light Sources
• 150 mW Laser (532 nm)
• 1.3 kW Lamp
• Particle Sources
• Dry Ice
• Water-based Smoke
• Oil-based Smoke

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Prototype- Visualization Experiment Results
CO2
Fog Machine
Oil Smoke
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Prototype- Visualization Experiment Results

• Light Source
• Aixiz Service and International LLC
• 1000 mW Laser (532 nm)
• Particle Source
• Dry Ice
• Water Vapor

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Design Elements

• Mechanical Design Elements
• Wing Rotation Prototype
• Mechanical Assembly
• Structural Analysis
• Electrical Design Elements
• Wing Mechanism
• Visualization
• Software Design Elements
• Wing Mechanism
• Wing Motion Verification

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Design-To Specifications- Mechanical

• Wing Mechanism Location
• Centered for flow visualization
• Containment Chamber
• Clear for flow visualization
• Impact resistant
• Wing Beat Frequency
• High in the air medium
• High friction possibility

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Wing Rotation Prototype

• ITLL Rapid Prototype
• Demonstrates wing rotation
• Strings pull back and forth to produce rotation

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Mechanical Design Elements

• SolidWorks Animation
• Integrated model
• Slowly explode the assembly
• Rebuild from the most basic component
• Green components are either purchased or have
  minimal machining

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BIRDIE Assembly
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Support Beam Cross Section

• Thickness .25 Base 2
• Material Hot Roll (Steel)
• Supplier onlinemetals.com
• Cost 20.33

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FEM Analysis of Displacement
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Design-To Specifications Electronics

• Force 6 N maximum
• Increased force based on updated control arm
  length
• Velocity 1.15 m/sec maximum
• Increased velocity based on updated control arm
  length
• Torque Requirement 0.0572 Nm maximum
• Based on designed string pulley diameter of 0.75
• Rotational Requirement 690 RPM maximum
• Based on designed string pulley diameter of 0.75

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Electrical Design Elements
Galil Controller/ Amplifier
Wing Mechanism Subsystem
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Electrical Design Elements
Visualization and Wing Motion Verification
Subsystems
Ref. 8
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Design-To Specifications- Software

• High Frequency
• Controls
• Data Acquisition
• Suspended Particulate Imagery
• High-Speed Camera

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Software Design Elements

• Requirements
• Command wing motion with rotary motors
• Verify wing tip location
• Galil controller software
• Three-axis control software
• Able to ramp up motors to desired motion
• Open loop control with encoders
• IDL/ENVI
• Image manipulation software
• Capable of batch processing
• Ideal for computing location of wing tip marker

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Software Design Elements-Wing Mechanism
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Software Design Elements Wing Mechanism

• Function Translation to Rotation/Rotation to
  Rotation
• LABVIEW
• Vertical Motion Sinusoidal
• Horizontal Motion Affected by vertical motion
• Controller Software
• Galils DMCWIN
• Drivers for interacting with
• controller
• Galils WSDK Servo Design Kit
• Real-time velocity, error, and
• torque display
• Used to determine control
• gains

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Software Design Elements-Wing Motion Verification
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Integration and Verification

• Assembly Flow Diagram
• Functional Software Test
• Functional Hardware Test
• Verification and Test Plan

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Assembly Flow Diagram
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Functional Software Test

• Verify translational to rotational program
• Using encoders and string
• Verify IDL code
• Generate test image

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Functional Hardware Test

• Servo Test- No Load
• Built into Servo Design Kit software
• Using encoders
• Test pulleys and string setup with software
• Design test software
• Wing Mechanism
• Measure max range of motion
• Test Bed
• Mass test

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Verification and Test Plan
Requirement Verification Method
Wing Range of Motion Visually, angle measurement
Wing Tip Motion, within 20 spatially IDL/ENVI Software, distance measurement
Wing Pitch Motion, within 20 spatially IDL/ENVI Software, angle measurement
Wing Tip Pitch Motion, within 20 temporally Elapsed time and position based on frame rate
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Verification and Test Plan
Requirement Verification Method
Frequency, 0-10 Hz, resolution of 1 Hz Variable speed motor Elapsed time based on frame rate
Wing Variation in 30 min Time interchange of wing
Minimum View Area, 30 x 30 cm Visually, use grid system
Minimum Resolution, 90 x 90 pixels Camera Settings
Minimum Frame Rate, 200 fps Camera Settings
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Project Management Plan

• Organizational Responsibilities
• Work Breakdown Structure
• Project Risk
• Schedule
• Cost Estimates
• Specialized Facilities and Resources

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Organizational Responsibilities
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Work Breakdown Structure
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Project Risk
5 Inadequate power Eye damage from illumination Inadequate software
4 Linkage breaks Resource scheduling
3 Data storage Low illumination Component friction
2 Turbulent flow
1
1 2 3 4 5
Consequence
Likelihood
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Risk Mitigation

• Inadequate Controls Software
• Repetitive loops
• Component calibration
• Component Friction
• Friction tested Teflon to aluminum interface
• Further friction reduction with lubricant
• Motors can produce excess torque

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Schedule
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Cost Estimates
SUBSYSTEM ITEMS Details Details Cost
Test Bed Outer Casing Polycarbonate 1m2 Polycarbonate 1m2 310.50
  Support Beam See Drawing Tree See Drawing Tree 29.32
Wing Mechanism Materials See Drawing Tree See Drawing Tree 88.63
  3 Rotary Motors Pittman Brushed motors w/ 500 line encoder Pittman Brushed motors w/ 500 line encoder 688.59
  Controller Galil 3 axis controller Galil 3 axis controller 1,245.00
  Amplifier Galil 4 axis 200W amp Galil 4 axis 200W amp 595.00
  Cables Serial and Ethernet Serial and Ethernet 75.00
  Power Supply BK Precision 640W (borrowed) BK Precision 640W (borrowed) 0.00
Visualization Camera High-Speed (borrowed) High-Speed (borrowed) 0.00
  Laser Aixiz Laser (532nm) Aixiz Laser (532nm) 1,500.00
  Media Storage 300 GB Hard Drive 300 GB Hard Drive 210.00
  Particle Creator Dry Ice Dry Ice 10.00
Wing Motion Verification Paint 1 oz. bottle 1 oz. bottle 12.00
      Shipping 50.00
      SUB-TOTAL 4,814.04
      Uncertainty 1.25
      TOTAL 6,017.55
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Specialized Facilities and Resources

• Visible Research Phantom HS Camera
• Max Frame Rate 90,000 fps
• Max Resolution 800 x 600 pixels
• (1,000 fps)
• Color or Monochrome
• Imaging Software
• Laser Optics

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References

1. Ametek Technical and Industrial Products.
   lthttp//www.pittmannet.com/part_num_database/pdf/1
   4204S006.pdfgt.
2. BK Precision. lthttp//www.bkprecision.com/www/np_p
   df.asp?m1790gt.
3. Galil Motion Control. lthttp//www.galilmc.com/prod
   ucts/gt.
4. McMaster-Carr. ltwww.mcmaster.comgt.
5. Online Metals. lthttp//www.onlinemetals.comgt.
6. Small Parts Inc. ltwww.smallpartsinc.comgt.
7. Unistrut, The Original Metal Framing.
   lthttp//unistrut.com/gt.
8. Vision Research. lthttp//www.visiblesolutions.com/
   gt.
9. W.M. Berg. ltwww.wmberg.comgt.
10. Warrick, Douglas R, Bret W Tobalske, and Donald R
    Powers. Aerodynamics of the hovering
    hummingbird 2005, Nature, Volume 435, pages
    1094-1097

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Questions?
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Summary

• Briefing Overview and Content
• System Architecture
• Overview of Objectives
• Motivation
• Overview of Requirements
• Overview of Requirements
• Overview of Requirements
• Overview of Requirements
• Goals
• System Design
• System Design
• System Electrical Connections
• Prototype- Visualization Experiment Setup
• Prototype- Visualization Experiment Results
• Prototype- Visualization Experiment Results
• Design Elements
• Design-To Specifications- Mechanical
• Wing Rotation Prototype
• Mechanical Design Elements

• Electrical Design Elements
• Design-To Specifications- Software
• Software Design Elements
• Software Design Elements-Wing Mechanism
• Software Design Elements Wing Mechanism
• Software Design Elements-Wing Motion
  Verification
• Integration and Verification
• Assembly Flow Diagram
• Functional Software Test
• Functional Hardware Test
• Verification and Test Plan
• Verification and Test Plan
• Project Management Plan
• Organizational Responsibilities
• Work Breakdown Structure
• Project Risk
• Risk Mitigation
• Schedule
• Cost Estimates

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Supplementary Information
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Supplemental Summary

• Friction Consideration
• Motor Mount
• Support Beam
• Support Beam
• Wing Mechanism
• Wing Movement Mechanism
• Wing Gimbal and Joint
• Wing and y Gimbal

• y Gimbal
• Von-Mises Stress Analysis
• Bracket Displacement
• String Guide Displacement
• Test Bed Overall Structure
• Outer Casing
• Detailed Assembly Flow Diagram

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Friction Consideration

• mk estimated for Teflon and aluminum .36
• Lubricant will be used
• Absolute worst case scenario 9.5 N force
  increase
• Within our safety factor of motors

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Motor Mount
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Support Beam
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Support Beam
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Wing Mechanism
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Wing Movement Mechanism
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Wing Gimbal and Joint
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Wing and y Gimbal
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y Gimbal
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Von-Mises Stress Analysis
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Bracket Displacement
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String Guide Displacement
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Test Bed Overall Structure

• Unistrut Design
• Most parts provided

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Outer Casing

• Zelux W Polycarbonate from boedecker Plastics,
  Inc
• Dimensions 1/8x39x39
• Cost 51.75/sheet (310.50 total)
• Pinned to Unistrut structure

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Detailed Assembly Flow Diagram