MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

DESIGN PROJECT
PART III
MEEN 3250 S101

Greg Schellinger
Gregory.schellinger@marquette.edu

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

DESIGN PROJECT: DELIVERABLE #3

Executive Summary:
This technical report is to explore the redesign of the Burke Brise Soleils
mechanical system. The purpose of the redesign is to eliminate the use of hydraulic
cylinders by replacing the driving components with an alternate mechanical system. The
new design will be able to cycle each wing through 90 of radial motion within 3.5
minutes and will accommodate winds up to 23 mph. It consists of two wings, each with
30 hollow cylindrical fins ranging from (100ft-30ft) in length. Each fin is made of a
carbon fiber reinforced polymer (CFRP) and has an inside/outside diameter of 6 inches
and 12 inches accordingly. The fins have a yield strength of 60,915 kpsi (420 Gpa). For
the largest fin (100ft) the maximum moment was calculated to be 67,003.83 lbin which
results in a factor of safety of # . The maximum deflection of the longest fin was
calculated to be .8 inches. The fins where sectioned into 5 groups with regards to the total
torque required to overcome the moment cause by the distributed mass of each fin. To
provide sufficient torque to operate the each section simultaneously, the wings where
coupled together in each section with a with a carbon fiber connecting rod. With the rigid
connecting rod the sections can be raised and lowered by a strategically placed
connecting rod that raises and lowers each section. The drive systems including the
motor, primary gear box, and secondary geared wheel system is mounted on the
underside of the central spine of the structure. The power from the primary gear box is
transmitted through several intermediate geared wheels and arms that swing the
connecting arms up and down within a predetermined angular range on a pivotal point.
The output pair of driven wheels reduces and simultaneously transfers the rotational
motion of a single electric motor. The two gear systems use splined shaft profiles where
needed to seat and secure each gear. The high output rpm of 1,800 is reduced to 9.88
giving the system an over all geared ration of 182:1 to generate the required torque of
roughly or 1,800 to the
The wing sections were grouped in such a way that the total moments caused by
each coupled section requires equivalent power to raise and lower each section. Each
wing section is powered by a 75 hp AC motor. The transmission system for each section
will consist of an AC motor and a primary and secondary gear system that will step down
the rpm and increase the torque of the motor. The pinion shaft of the motor (dia-2.75 in)
is connected via key connection to an input shaft of the first gear box. The key was
designed with a factor of safety of .. in order to protect the larger shafts down the line
in the transmission from yielding. The motor output shaft was chosen to be a critical shaft
because of its high risk for fatigue as well as its integral position in the system. Located
on the underside of the central spine it will be press fitted on either end to two roller
bearings. By means of DE-Goodman the diameter of . was chosen for the Xft long
shaft in order to endure the high cycles and torsional loading it is subject to.

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Introduction:
The task of redesigning the Burke Brise Soleils wing system had its challenges.
The design of a robust reliable system needed to be created to replace the current 90 ton
hydraulically actuated system. The new system had to be resistive to the corrosive
environment of Milwaukees weather as well as reliably provide high torques to the 30
fins on each of the two wings. With the output motion in mind a four bar linkage similar
to the linkage found in Ornithopter (Flying machine powered by flapping wings) was
used to flap the wings offering a mechanical advantage and allowing the cycling
forward and backward by simply reversing the rotation of the driving shaft. The starting
position of each fin is 45 off the negative Y axis and swinging 90 all the way to 45
degrees of the positive Y axis. Some of the challenges that needed to be overcome related
to the high torques required to overcome the moments created by each fin as well as the
task of transmitting power the entire length of the central spine. The calculations in this
report are of the fifth and final section of the building located the closest to shoreline.
The design of the new system is broken into 3 main parts. The first if the design of the fin
and fin connections and the related calculations. The second is the transmission system
including gear boxes as well as . The last part is the design of the critical shaft
as well as a keyed shaft that is designed to yield in the case of a malfunction. The keyed
connection was used to seat the first gear in the first gear box.
on the A UNS G10350 steel output shaft leaving the motor A UNS G10350 steel
shaft

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Assumptions:
Beam Theory: Each fin is modeled as a simple cantilever regarding the calculations of
Max stress and factor of safety for each fin. It will disregard the pin connection 3ft from
the end of each fin which has negligible effects values in order to simplify the static load
Power loss: Power loss and friction within the gear train were neglected because with the
simplicity of the parallel axial transmission negligible power is lost.
Coupled Fins: the design requires that each section of fins is to be coupled together and
it is assumed that the motion of coupled beams is essentially identical because they are
rigidly attached to each other and pinned to a ridged structure.
Effects of wind: Wind load was modeled as a uniform load over the length of each fin
and was only used in the calculations of static situations. The effects of the wind where
considered negligible when calculating total moment on each crank arm. .
Motor Efficiency: An efficiency of 95% was assumed to be accomplished by each motor.
With the efficiency in mind a 75 hp motor was selected power the sections ranging from
66 hp to 53 hp in required power.
Dimensioning: Only key components of the system will be considered and discussed in
order to get a general idea of the system without having to dive into great detail. Design
components like fasteners, bearing type, and transmission of power will not be elaborated
on.
Mechanical Analysis: The system described was broken into 5 sections each requiring
roughly the same power to operate. Five identical drive systems will be used to power
each section so for the sake of simplifying the calculations only the calculations for
Section 1 will be discussed because it required slightly more power than the other four
Sections.
Radial Load of Shaft: The appropriate approximation of 30% of the tangential load was
used to calculate the radial load carried by the shafts in this design.

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Proposed System Design

In order to better organize the redesign of the new system it is broken into three
subsection. The first is relating the design and material selection of the each wing section
and the fins that compose them. Part two will discuss the design of the drive system
including the primary gear box, secondary gear assembly, connecting shafts, and motor
selection. Part three will provide more details and design decisions regarding the shafts
and reliability of critical components.
Part I
referencing figure 1, the new wing design will consist of two wings with each wing being
made up of 30 individual fins pinned perpendicular to the central spine of the
building(Overhead drawing of lifting mechanism and wind orientation is shown on page
# of the appendix)..
The new drive system and of five sections of fins each powered by an identical
Blue Max 2000 Vector Duty Y516 75 hp AC motor. The AC motor is able to supply
constant torque from startup which is essential for a system that operates inconsistently
and at such high torques. The AC motor is completely enclosed and offers the durability
needed to work in Milwaukees harsh weather. It also has the important feature of being
electrically reversible which means that it can be reversed in direction which allows the
power transmission system to simple be run in reverse direction to lower the wings. The
The Motor Pinion shaft with the diameter of 2.75in will be rotation at a speed of 1,800
rpm and will needed to be slowed down in order to increase the torque of the output. This
is accomplished through a primary gear box shown in in the Appendix part X connected
with an intermediate shaft to the geared mechanism that lifts each wing section
(mechanism shown in appendix page ) . Together the geared transmission accomplishes
velocity step down of 182:1 or 1,800 to the 9.8823 rpm. (dia-2.75in) will be joined with
the Double Flex Composite Disc Coupling to the input of the gear box (dia-2.75in).
Inside the gear box the first three shafts will have a 2.75in diameter hole in the center to
appropriately seat on the spline. Each shaft with in the gear box will be mounted via press
fit onto the gearbox housing. Figure 3 shows the shaft components talked about above
(Not to scale with actual sizes).
The power here are 5 identical transmission systems controlled by a single switch
to raise and lower the wing sections in unison. Section 5 will be analyzed because it
consists of the largest wings and is a good representation (as far as torque required to
rotate) of the 4 other systems located before it. The section of the building this report is
analyzing id circled in Figure 2 below and further detailed in Figure 1.

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Fins & Coupling rods

Building Central Spine

Roller bearings

Secondary Gear Train

/crank arms

Crank arm

Primary
Gear Box
Reduces RPM

Critical shaft

Figure 1
AC
Electric
Motor

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Wing Section 5

MEEN 3250 Spring 2015

Design Project: Deliverable #3

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Greg Schellinger

MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

The Shaft exiting the gear box will be termed the critical shaft and will be 12in in
diameter

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Figure 4. The Solidworks drawing shows the critical shaft and

keyed connection (Not to scale).

Calculations: To size Critical shaft to keep tortional deflection to < 1

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Calculations: sizing key

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Greg Schellinger

MEEN 3250 Spring 2015

AC
Electric
Motor

Design Project: Deliverable #3

Gear Box
Reduces
RPM

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Greg Schellinger

MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Composite Disc Coupling

The second component of the drive train is the rpm speed reduction of 182:1 or 1,800 to
the 9.8823 rpm the secondary gear set needs to operate the wings at the correct speed
(Discussed more in calculations on P.11). The output from the speed reducing gear box is
Figure 3 by a intermediate axial to the final gear set which provides the wings with the
carried
power to open and close. The final gear set can be seen in detail on P.10 where its
components and mechanics are broken down.
Analysis and Results
Part I
Power required and motor Selection:
Equation 1 - Power [Horse power] = [ (rpm) (Torque [lbft] ) ] / 5252
Calculated power required for every Fin as shown in Figure 4 below.

Fm=(l) (l/2)
3ft

L/2

L/2

A.

Fr=(3ft)(x)

Figure 4

Moments at A = 0 Fr (Force Reaction) = Fm (combined weight moment)

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

This calculation was done for every beam and combined in the Excel table below

Table 1: Shows Fin lengths and densities which were needed for calculations

Table 2: Shows Individual torques for North and South fins

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

With the in order to have the fins lift 90 degrees in 3.5 minutes an rpm of .142857 was
calculated and explained in further detail later in the report. Knowing the rpm along with
the torque allowed the horse power to be calculated for each section through equation 1.

Selection of motor:

Shafts are splined to seat gears

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

Discussion of Results:
Considering the torques the motors have to overcome I think the four 75 hp motors
are the best fit for my design because they are still light enough where they could
possibly be mounted onto the spine of the building. The first parallel speed reduction
(gear box) reduces the rpm on a scale or 182:1. The secondary mechanism works on a
reduction of nearly 20:1 in order to slow the speed down enough to create enough torque
to raise and lower the fin section. To lower the wings, the motor will reverse direction
and the gears will return to their original position. Rather than rotation each fin at its base
the design utilizes the mechanical advantage of the crank arm mounting 3 ft. from the pin
which lowers the net torque of required to overcome the moment. Lastly each section will
be coupled with a custom fiber glass component that is perfectly rigid to ensure a uniform
motion on each wing section powered by the secondary mechanical mechanism.
Conclusion:
In conclusion, the Drive system converts the 1,800 rpm of the each of the five 75 HP
motors into the .1429 rpm and 2,461,061ftlb or torque required to lift each section of the
North and South wings. The overall Reduction of rpm is 1:3,600 in order to produce the
torque needed for each section. Several concerns will have to be addressed in the next
deliverable regarding the systems reliability. First something will likely need to be done
to help evenly distribute the crank arms force to each fin rather than the fiberglass
coupling (possibly having more than five secondary mechanical systems). Secondly the
assumption of zero power loss will likely require a closer look to ensure that there are no
major factors being overlooked that could create inefficiencies. Lastly it would probably
be a good idea to implement some sort of a clutch to the drive system to insure the initial
phase of the rotation goes smoothly.

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MEEN 3250 Spring 2015

Design Project: Deliverable #3

Greg Schellinger

APPENDIX:

Intermediate

Pin/Shaft connection of each fin section

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Greg Schellinger

MEEN 3250 Spring 2015

Design Project: Deliverable #3

b
Checked
y

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Greg Schellinger

Dat
e

MEEN 3250 Spring 2015

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Greg Schellinger