Team RailtechDivision of LaborBlock DiagramSlide 4BudgetSafety FeaturesPower System DiagramCapacitor BatterySlide 9Basic ChargerPower PartsCylindrical Rail DesignSlide 13Slide 14Slide 15Injector Adapter DrawingBrass RailsProjectilePneumatic Kick-startInjection SystemComplete SystemElectromagnetic Solenoid ValvePressure RegulatorChassis SpecsParts List- Control SystemParts List- MCUInterfacesKeypad Pin LayoutKey EncoderKeypad & Encoder SchematicKeypad DemoSoftware- MCUMCU LogicSoftware- MatlabQuestions?CDROctober 9, 2008Mike OertliJonathan KarnuthJason RancierDivision of LaborMike O.Program MCUMatlab interfaceJonathan K.Construct railsAssist in control system design and codingJason R.Construct capacitor arrayDesign voltage sensorsBlock DiagramMSP430F169Power SupplyKeypadLCDRailgunCapacitor ArrayKillSwitchLEDsInductorVoltage SensorVoltage SensorPneumatic Starter SystemEncoderItem Qty. Needed Cost Per Total for itemBrass Rails (36") 2 58.68 117.36Garolite G-10 (39") 1 92.16 92.16Teflon (12") 6 9.21 55.26Aluminum (12") 2 17.41 34.82Capacitors 50 Donated 0.00PCB 2 33.00 66.00Microcontroller 2 0.00 0.00Air compressor 1 56.10 56.10Air tank 1 62.00 62.00Solenoid Valve 1 170.00 170.00Pressure Regulator 1 35.00 35.00Transformer 1 100.00 100.00Plastic housing 1 50.00 50.00Sensors/Miscellaneous 200.00Grand Total 1,038.70Safety FeaturesVoltage sensors on rails, cap bank, & sourceKill power if out of expected rangePlexiglas casingoKeep user isolated from high voltages and short circuited railsPressure RegulatoroAdded ability to safely release tank pressurePower System DiagramCapacitor Battery50x 450V 3.7mF CapacitorDonated by CDEArray of 3 banks of 16 in parallelOverall: 1350V ~ 20mFCapacitor BatteryBasic ChargerPower Parts2x 200KOmh @ 3W1x 800Omh @ .25 W50x 100kOmh @ 3 W3x 22KOmh @ 50 W1x 120V 15 Amp AC switch1x Fuse Holder 120VAC1x 1600v Power Diode2x High Voltage Switch(1000V)1x Microwave Transformer1x Variac Variable TransformerCopper PlatePlexiglass BoxCylindrical Rail DesignDesign Difficulties•Material Tolerances•Material Loss•Toxic materials•Difficult to machine atdesired barrel lengthEfficient Design method•Maintain physical contact despite material disintegrationMachined & Fabricated PartsCompressed Air Injector AdapterInjector Adapter DrawingBrass RailsComposite: ~70% Copper, ~.07% Lead, ~.05% Iron, Remainder ZincElectrical Conductivity: 28% IACSElectrical Resistance: 6.2µΩ/cmFriction: Very low with Most metalsMelting Point: 910oCInner/Outer Diameter: 0.87”/1”ProjectileMetal: AluminumComposite: 2011Temper: T3Part #: 88615K411Melting point: 540oC Electrical Conductivity: 45% IACSElectrical Resistivity: 3.8µΩ/cmDiameter: 7/8”Length: ~1”Pneumatic Kick-start Avoids spot welding projectileAdded kinetic energyEliminates static friction coefficientsCompressed Air systemActivated by Microcontroller post safety checksAdditional safety with inclusion of Pressure RegulatorInjection SystemComplete SystemCompressed Air TankCompressorSolenoid ValveBall ValvePressure RegulatorManufactured PartsRailgun AdapterTank AdapterCompressor AdapterElectromagnetic Solenoid ValvePressure RegulatorFeaturesHigh Pressure capabilitiesVery Low Flow1/150 Flow of the Solenoid (.06 Cv)Adjustable Pressure RangeLow leakage Value3600 Psi CapabilitiesChassis SpecsInner Support Outer SheathComposite Teflon PTFE Grade G-10/FR4Crosswise Tensile Strength3,900 PSI 35,000 PSIMelting Point335oC~384oC Max TempDielectric Strength 19.7MV/m 15.7MV/mInner/Outer Diameter.875”/1” 1”/1.375”Cost $9.21 per 12” $92.16 for 39”Part # 8547K29 8668K49Parts List- Control SystemVoltage SensorMM74C922 16 key encoderKeypad, 3-line LCDMaster kill switch“Hot” switchParts List- MCUMSP430F1692 ADC1 RS232Voltage regulatorLEDsInterfacesMSP430F169 MatlabRS232Key Encoder KeypadMSP430F169Wire-wrap/Solder Wire-wrap/SolderMSP430F169P6 I/O (ADC)Voltage Sensor3-Line LCDMSP430F169Wire-wrap/SolderKeypad Pin Layout1 2 3 4 5 6 714 13 12 11 10 9 8Key EncoderMM74C92216 KeyDebounceContinuous row scanKeypad & Encoder SchematicSoftware- MCULanguage: C++Inputs: Keypad (via encoder chip on P1), voltage sensors (1 on ADC on P6, 2nd via off board ADC), power (6V)Outputs: 3-line LCD (P2), Matlab (RS232), capacitor charging control (switch based on sensors), safety/kill switchMCU LogicSoftware- MatlabPlot time domain analysis of sensor readingsKeep test-run informationInputs: Data from MSPOutputs: GUI showing dataInterface: