Blog 2 Capstone Project Update
Greetings Houstonians! We have come a long way from our first post. Changes have been made to our overall trajectory of the capstone project. We will no longer be doing the beach wheelchair; instead, we have proudly been sponsored by NASA to duplicate data of a fuel cell prototype.
Seeing that we are eager to leave this planet, efforts are being made here on Earth to create power plants that will work on the moon and beyond!
Our contribution will be creating a prototype that duplicates data from NASA’s fuel cell project in order to validate their efforts at increasing the feasibility of long-term space missions.
Below is a table that describes the constraints, descriptions, and challenges of the technical problem statement.
Constraint | Description | Challenges |
Size | The device must fit onto a 6in x 6in thermal interface surface [TBD] | Designing a compact system that can efficiently manage heat within this limited space is challenging, potentially requiring scaling down components and developing an efficient layout to fit the required dimensional constraint. |
Heat Rejection Range | Operation range of 30W to 520W for simulating heat flux boundary conditions | Achieving accurate simulation across this wide range of heat rejection rates requires precise control and calibration of the system, potentially involving complex electronics and programming. |
Actuation Angle | Fuel cell door actuation from 0 to 180 degrees affects heat reject rates | The device must accurately simulate changes in heat rejection as the actuation angle varies, requiring a reliable actuation mechanism that can vary the angle precisely and consistently, potentially using motors or other sensors. |
Simulation Run Time | Complete the heat rejection simulation cycle within 5 minutes | Rapidly adjusting to changes in heat rejection demand within this short timeframe demands efficient and responsive design solutions, which may require fast-acting thermal elements and data processing capabilities. |
Weight | The device must be light enough not to damage the fuel cell | Balancing the need for minimal durability and functionality with the requirement for a lightweight design can limit material and component choices. |
Budget | Aim to keep the budget as low as possible to outbid competitors | While indirectly a physical constraint, finding cost-effective solutions that meet all technical requirements without compromising quality or performance is a significant challenge. |
Before we execute our prototype phase of the project, a technical analysis will be made to refine our design. This technical analysis plan consists of three main topics; requirements for the device, design and fabrication planning for heat management system integration, and detailed engineering design analysis.
The key physical challenges that this project contains are moving heat from heat-dissipating material to the environment and creating a harness and connection that will adapt a heat-dissipating device with a hot plate and heat sink. Key parameters that will help draw specific conclusions about our design is finding a heat-dissipating material that has a high enough thermal conductivity to cycle between 30 and 90 degrees within 5 minutes and have the appropriate dimensions provided by NASA. Also, researching a heat-dissipating material that will conduct a maximum heat flux of 887.4 [W/m^2] heat input from the hot plate to the heat-rejective surface. Designing a connection between heat-generating device, heat-dissipating material, and heat sink device by making a circuit diagram and schematic as well as a CAD design for a harness. Finally, using the heat flux equations (convection, conduction, radiation) to calculate the heat dissipation of the heat-dissipating material.
A soft challenge refers to non-physical obstacles or difficulties that are not easily measurable or tangible. Unlike hard or physical challenges, soft challenges are often complex, subjective, and require thoughtful consideration and creative solutions. In the context of our team’s project, communication and project success are the two major soft challenges our team is currently aware of. Communication is a recurring soft challenge our group must address. Inter-team communication is key to a successful and uniform understanding of the project and its direction. An example of overcoming this challenge would be maintaining consistency in naming physical and conceptual items through discussions and documentation. Communication with our stakeholder has also proven difficult at times, with our group occasionally misunderstanding the information provided. We have mitigated this as much as possible by scheduling weekly meetings with our stakeholder and maintaining an open line of communication for addressing questions as they arise. The most critical, albeit challenging, soft issue to address at this moment is predicting the success of the project. Not only does the project need to be successful, but questions such as whether our stakeholder will be satisfied with the method and direction our team's design takes, or what the overall impact of our project will be on the larger NASA mission, add complexity. Our team anticipates more soft challenges to arise as this project continues, requiring ongoing solutions.
JSC ESTA 15-foot Dusty Thermal Vacuum Chamber
The cost of testing in such vacuum chambers can vary significantly depending on the longevity of the test, reaching millions of dollars. Cheaper, yet effective, simulations are often sought.
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