Eddy Current Break System Mechanical Project Report - Part 2

Get Our Latest Interview Questions: Aptitude, Reasoning, English, GD, HR-PI

2. Problem Statement:  
A disconnect system on a high-speed generator serves as a safety device.  The disconnection occurs between the gear box and the generators drive shaft in order to prevent further propagation of failure.  A disconnect system has already been developed and now needs and activation system.    So, basically we are facing a task of designing activation system along with design.  A preference has been set in terms of function in the design of our innovative disconnect system.  The problem with the current Honeywell proposed setup occurs with multiple disconnects.  With the current design disconnection can happen once, then must be repaired before the generator and it’s disconnect will function again.  We must design a reset able and reversible activation system that operates at variable speeds while remaining maintenance free.

3.1.Operational Conditions

Angular Velocity
We must design a gracing system that will operate at a minimum angular velocity of 3000 rotations per minute and a maximum angular velocity of 7200 rotations per minute.  This constraint will have an effect on each of the concepts in its own way and was a major factor in determining a final design.  The Final Design section will discuss how the range of angular velocity will affect the Final Design.

Power Source
Our design will operate with a limited power source of 12-14 volts DC.  This constraint operates with the power supply allowed by the generator.  On top of operation at this power input we must develop a test rig that simulates the power supply.
Reliability

Our final design and product must have a reliability of 90% operational readiness.  Our product must work when triggered.  Late activation or no activation may cause irreversible damage to the gearbox, generator, or both.  It has to work with NO uncertainty.
 
Weight
Our test rig needs to be portable to allow the demonstration at Design Day as well as for presentation to Honeywell.  If it is too heavy we will not have the ability to transport the test rig in order to demonstrate our product.

Housing
The test rig needs to accurately model the design envelop established in the Functional Conditions.

Budget
We have been given a budget of 8000-9000 Rs.  We may not go over that amount and no additional funding will be allotted.

3.2. Final Design
Our final design is an Eddy Current Brake System.  In the following sections we will discuss how an Eddy Current Brake System works the reasons why we chose an Eddy Current Brake design, and how we will analyze an Eddy Current Brake System.  We will also discuss the different failure modes, stresses and fatigue that we took into consideration for our final design.  After establishing an understanding of our final design we will state how our design will fulfill all requirements. 
                                                      Remain You Get In Our Previous Post.