Mechatronics

1
Mechatronics
MENG 483 Project
Hall-Effect Linear Position Array for Flap
Transition
Group 5 Derek Doyle Porter Smith Jeff
Paige Fall 2006
2

• Outline
• Introduction
• Overview Diagram
• Mechanical Design
• Electrical Design
• Software Design
• System Assembly
• Testing
• Material Cost and Total Expense
• Conclusion

3
Introduction
Eclipse would like to redesign current flap
actuator system to reduce stress, save time, and
improve overall function. This can best be
achieved by making the activation system a
modular design so that the wing doesnt have to
deal with actuator stresses. Possible sensor
ideas -LVDT -Cable Drawn Potentiometer -Hall-Effec
t Sensors Hall-Effect Sensors will be used to
accurately spot the location of the gear-motor
assembly.
4
Overview Diagram
Hall-Effect Sensor
MRK Board for Data Acquisition
Magnet
Stepper Motor
Materials -Serial Communication Cable -Stepper
Motor -Power Adapter -Multimeter -Permanent
Magnet -Erector Set -Breadboards and
miscellaneous wires, resistors and a
capacitor(.1µF) -MRK Controller
Board -Microcontroller -Hall-Effect
Sensor -Eclipse Platform -MRK Terminal
5
Mechanical Design
-Eclipse Aviation requested a proof of concept
design be built -Show that the sensor system
would work properly. -No budget. -No
specifications for this design -Final design
will have to be able to withstand 1000 pounds
tension and 800 pounds compression. -These
figures will effect the motor, gearbox, and track
used for the system.
6
Electrical Design
The Stepper motor needed a controller chip to
function properly shown to the right. The
hall-effect sensor is shown to the right here
wired for uni-polar readings and the pin-out for
the chip is directly below it.
7
Software Design
8
System Assembly
Experiences -Building a system that incorporated
Electrical, software, and mechanical design had
many challenges -Theory was rarely seen to be
consistent -Lots of time was needed for
coding Success/Failure -Learned a lot about
programming and shortcuts. -Learned how fragile
the MRK boards are. What Works/ What
Doesnt -Sensors work great for digital behavior
but not for analog -Stepper motors ability to
count steps works great for comparison -our
first board doesnt work since a loose wire
touched 5V Recommendations -Check everything
before powering anything on -Take advantage of
resources
9
Testing
Test 1 Sensor Function
Test 3 Sensor Continuity
Test 2 Sensor Readout
Test 4 Sensor Operation -proved successful based
on Terminal readout from Software Design slide
10
Material Cost and Expenses
-Nothing had to be bought for this design that
wasnt already available
Current Flap Design -1200 per
actuator -Several man hours to get access to
actuator location in wing Theoretical
Costs -Hall-Effect sensors lt10 each including
shipping -Standard DC motor with gearbox
attachment lt 500 -Redesign current Tracks to
house gear track MRK Board300
11
Conclusion

• Purpose was to design a Mechatronics system that
  could be used as a proof of concept design for a
  prototype for Eclipse Aviation.
• The system had to be innovative and solve the
  problems that the current design has.
• Achieved by making the system a modular concept
  and going against conventional design used in the
  aerospace industry.
• Over the course of the design, the team learned
  the practical aspects of the concept and how it
  would function in a real setting as opposed to in
  theory.
• The system showed to function as necessary with
  few problems.
• We had to re-evaluate goals of the operation of
  the system to account for unanticipated problems
  with the sensors.
• Still, when the system concept is further
  developed into a large scale model, caution will
  need to be used in the design and system elements
  will need to be revisited and refined to meet the
  strict regulations of both the sponsors and the
  FAA.