INITIAL REPORT IN THE DESIGN OF A HIGH-REACH EXTENDABLE TURRET FOR USE IN FIRE TRUCKS AT CAPE TOWN INTERNATIONAL AIRPORT

John-Henry Corbett Eben Grobbelaar Rory Hurt Ludwig Schmidt

15382532 15529932 14565102 14565102

2010

INITIAL REPORT IN THE DESIGN OF A HIGH-REACH EXTENDABLE TURRET FOR USE IN FIRE TRUCKS AT CAPE TOWN INTERNATIONAL AIRPORT

John-Henry Corbett Eben Grobbelaar Rory Hurt Ludwig Schmidt

15382532 15529932 14565102 14565102

Machine Design a314 Project Group 9

2010

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Abstract
In this report a concept is created for a High-reach Extendable Turret (HRET) to be used on fire trucks at Cape Town International Airport. The report firstly deals with the Needs Analysis for the project. In this part of the report a planning for the rest of the project is done. The design brief is analysed to define the product requirements, functional analysis, design objectives, engineering requirements, and the initial design specifications of the product. The report then defines and analyses two project concepts, weighing their advantages and disadvantages against each other, determining which one is the best concept. Finally, the report looks at the calculations used in the design of the layout of the machine. This initial report is part of a larger study.

Table of contents
Page Abstract ................................................................................................................................ i Table of contents ................................................................................................................ ii List of figures ...................................................................................................................... iii List of tables ........................................................................................................................iv 1 Introduction ..................................................................................................................... 5 2 Needs Analysis................................................................................................................. 5 2.1 Planning ...................................................................................................................... 5 2.1.1 Personnel ............................................................................................................... 5 2.1.2 Resources............................................................................................................... 5 2.1.3 Procedure and Schedule ........................................................................................ 6 2.1.4 General Responsibilities ........................................................................................ 7 2.2 User Requirements...................................................................................................... 8 2.2.1 Use Profile.............................................................................................................. 8 2.2.2 Design Brief............................................................................................................ 9 2.3 Clarify Objectives....................................................................................................... 11 2.3.1 Functional Analysis .............................................................................................. 11 2.3.2 Objectives Tree ................................................................................................... 12 2.4 Engineering Requirements ........................................................................................ 13 3 Concept Selection .......................................................................................................... 15 3.1 Concept Evaluation ................................................................................................... 15 3.1.1 Concept 1 ............................................................................................................. 15 3.1.2 Concept 2 ............................................................................................................. 15 3.2 Pros and Cons of Concepts ........................................................................................ 16 3.3 Concept Selection...................................................................................................... 18 4 Layout Design ................................................................................................................. 19 4.1 Calculations for layout drawing ............................................................................ 19 5 Conclusions .................................................................................................................... 21 6 References...................................................................................................................... 22 Appendix A: Product Data Sheets ..................................................................................... 23 A.1. Parker ET - electro-thrust cylinder Product Data Sheet, Pages 6 & 7. ............ 23 Appendix B: Drawings ....................................................................................................... 24 B.1. Concept 1 ......................................................................................................... 24 B.2. Concept 2 ......................................................................................................... 25 B.3. Layout Design ................................................................................................... 26

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List of tables
Page Table 1: Project Shedule ..................................................................................................... 7 Table 2: Engineering Requirements .................................................................................. 14 Table 3: Pros and Cons of Concept 1 ................................................................................ 17 Table 4: Pros and Cons of Concept 2 ................................................................................ 18

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1.Introduction
Crash-landing of aircraft at airports invariably creates the risk of fire, setting the lives of passengers in danger. Quick response is thus required from fire teams on standby. If a fire breaks out in the fuselage area, however, it is well shielded against water sprayed to dowse it. For this reason fuselage penetrating nozzles have been developed that sit on telescopic robot arms that can reach the fuselages of large planes. The purpose of this study is to design one such High-Reach Extendable Turret. This report has been compiled to create a concept design towards this goal. Firstly, this report looks at a needs analysis, analysing the design brief and creating a project plan, design objectives, engineering requirements, and the initial design specifications of the product. Secondly different, concepts are discussed, aiming to arrive at a final concept. A layout design is then also created, giving a more final idea of the product.

2 Needs Analysis
2.1 PLANNING

2.1.1 Personnel:
J.H. Corbett E. Grobbelaar R. Hurt L. Schmidt

2.1.2 Resources:
Shigleys Mechanical Engineering Design Eight Edition AutoCad Inventor MathCad Bosch Rexroth Website (www.boschrexroth.com) www.freestudy.co.uk http://www.ortrucking.org/stopping (Deceleration of truck) CRC Manufacturing website (www.crcmfg.com) Parker Hannifn Corporation website (www.parker.com) Prince Manufacturing Corporation website (www.princehyd.com) HYTEC website (www.hytec.co.za)

2.1.3 Procedure and Schedule:

Meetings: Monday: 10:00 12:00 Tuesday: 11:00 13:00 (First quarter) Wednesday: 9:00 10:00 Friday: Will be scheduled as necessary Table 1: Project Schedule Date Description 1 Feb Start work on needs analysis.

8 Feb

Needs analysis to be completed. Start working on concept selection.

9-12 Feb

Do concept selection.

13 Feb

Start with layout design.

18 Feb 19 Feb 19 Feb- 13 March 14 March 15 March 15-25 March 26 March

Complete layout design and finalise report. Hand in initial report. Complete subsystem report and start with drawings. Finalise subsystem report. Hand in subsystem report. Complete subsystem drawings. Hand in subsystem drawings. Start with final design report and drawing pack. Work on final design report and drawing pack. Finalise final design report and

Responsible member Brainstorming (Group) Planning (E. Grobbelaar) Use profile (R. Hurt) Design brief (J.H. Corbett) Functional analysis (R. Hurt) Objectives tree (Group and R. Hurt) Engineering requirements (Group and R. Hurt) Each member of group will do their own research on possible concepts and report back on 9 Feb Select concept, Analysis of pros and cons (Group) Typing of analysis (R. Hurt) Calculations ( E. Grobbelaar and J.H. Corbett) Typing of calculations (L. Schmidt) Finalise report layout (L. Schmidt) L. Schmidt Group Finalise report layout Schmidt) E. Grobbelaar Group Group Hand in (R. Hurt) Group Finalise report layout (L. (L.

27March17 April 18 April

drawing pack. 19 April Hand in final design report and drawing pack. Start work on machined parts. Hand in machined parts. Start work on welded assemblies Hand in welded assemblies. Start work on cast parts. Hand in cast parts.

Schmidt) Finalise drawing pack (Group) Group Hand in (J.H. Corbett) Group Hand in (L. Schmidt) Group Hand in (E. Grobbelaar) R. Hurt

23 April 30 April 7 May

2.1.4 General responsibilities J.H Corbett

Will be responsible for overseeing all drawings and for collecting them from the various group members. Will also be ensuring that the necessary drawings are completed by the designated group member in time for deliverables.

E. Grobbelaar
Will be responsible for general administration and for ensuring that the members of the group adhere to the project schedule. Will also be responsible for informing each group member of his responsibilities for the next part of the project as well as monitoring each members progress concerning his present task.

R. Hurt
Will be held responsible for informing all group members of meetings that need to be attended as well as for typing the parts of the project that was completed as a group activity.

L. Schmidt
Will be responsible for collecting the different parts of the project from the various group members and then finalising the report. Will also be responsible for typing most of the calculations.

2.2 USER REQUIREMENTS

2.2.1 Use Profile
The High-reach Extendable Turret (HRET) has the main objective of aiding the fire fighting on a landing strip once an aircraft has crash-landed. The machine will be mounted on a fire truck, used by trained emergency rescue workers on airport runways. The purpose of the turret is to manoeuvre around an aircraft which is on fire and to spray water onto the burning aeroplane. It must also be capable of piercing the fuselage of the airplane using a specially designed nozzle, which can then spray water and a fire fighting agent into the airplanes cabin if necessary. It must be able to reach and pierce the fuselage of any plane using the airport. This device must be able to quickly and accurately extinguish fires, which will help to save the lives of passengers. It may also be used to put out general fires, and as such must be able to reach down to the ground level as well. The HRET will be used on fire trucks, and as such must be able to withstand sudden acceleration, relatively high top speeds, and braking. This must be withstood while retracted. When extended, however, the HRET will still be subjected to lower speed movement of the fire truck. The fire trucks using the HRET do not have outriggers. The HRET must thus be relatively lightweight.

2.2.2 Design Brief:

Client: Airport fire and rescue services Water turret for fire truck Turret to be used on airfield Must have 2 arms that are hydraulically actuated(pistons) The maximum weight of the turret is 2 tons Must reach 15m above ground level when fully extended Position nozzle and pierce from ground level to 15m elevation Fire truck is 3,5m high The upper boom must be telescopic The telescoping boom should extend at least half the length of the (unextended) upper boom Max horizontal reach >10m with telescoping boom extended Must be able to reach ground level The upper boom must stay horizontal while the turret is moving forward The nozzle can move 180 in the x-y and x-z plane ?

There must be no excessive oscillation or vibration of the turret The turret is mounted behind the front wheels, approximately 2,5m from the front of the truck End of boom must not overhang end of cab when un-extended Design starts at the base plate of the truck and end at the mounting point for the nozzle The nozzle will rotate 30 CW and CCW The weight of the nozzle is 150kg Must calculate/estimate the force needed to pierce fuselage

The truck must not tip over during use (no outriggers on truck) The truck must be able to move at a certain speed while turret is extended The weight of the truck is 40 tons The truck accelerates from 0 80km/h in 25s The top speed of the truck is 140km/h Must estimate/calculate braking distance of the truck Truck min turning circle: 30m Truck climb capability: 30 The wheelbase of the truck must be determined The water pressure in the hose is 15 bar(1500kPa) The maximum water flow rate is: 4000l/min (main nozzle)

950l/min (piercing nozzle) Max throwing range should be approx. 80m Max hydraulic pressure: 200 bar Do not have to put actuators inside structure Cost limitations?

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2.3 CLARIFY OBJECTIVES

2.3.1 Functional Analysis

Inputs Force Pressurised Water

Outputs Put Out Flames

Force

Extend/ Manoeuvre Turret

Pierce fuselage

Spray water into/onto fuselage Deliver water to nozzles

Put Out Flames

Pressurised Water

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2.3.2 OBJECTIVES TREE

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2.4 ENGINEERING REQUIREMENTS

Table 2: Engineering Requirements
Material and Dimensions D D D D D D D Upper and lower boom: Rectangular steel alloy tube Telescoping inner boom: Rectangular aluminium alloy Water hose nominal diameter: 80mm Connection to Truck: Flange Connection Connection to Nozzle: Flange Connection Vertical Reach Range: 0 - 15m above ground Telescopic extension boom should extend at least half of the length of the un-extendable upper boom: Length of un-extendable Upper Boom: 6.5 m Length of telescopic extension piece: 4.5 m Length of Lower Boom: 4m Reach of Telescopic Boom: > 10 m fully extended Maximum Total Weight: 2 000kg Maximum deflection of booms: <100 mm

D Demand W Wish

D D D D

Operating Conditions D D D D D D D D D Temperature Range: 0 - 80C Rotation Angle: -30 to +30 Rotational Speed: 0.14 rad/s Must be able to withstand a force of 1.78kN due to acceleration of truck. Must be able to withstand a force of 8.74 kN due to deceleration of truck. Extension speed: 0.5 m/s Maximum nominal pressure of hydraulic cylinders: 20 MPa Manoeuvring speed with boom extended: 4.17 m/s (15 km/h) Withstand Force of Approx. 490 N while fully extended 13

Life Expectancy and Maintenance D D W 20 years with regular maintenance Service After every 100 hours of use Can Be Serviced By Non-Specialist

Explanation of Calculations for Engineering Requirements

1. Rotational Speed
The rotational speed of the turret was derived from estimating a time of 45 seconds for the turret to complete one revolution. This gives a time of 7.5 seconds for the turret to move from -30 to +30 degrees.

2. Force on Turret due to Acceleration and Deceleration of Truck

The truck accelerates from 0 to 22.222 m/s in 25 seconds. A constant acceleration was assumed which gives a value of 0.88 m/s2. A truck with a weight of 40 000 kg has a braking distance of 82.296 m when travelling at a speed of 26.8 m/s This gives a negative acceleration of 4.37 m/s2 (Stopping distance chart,[S.a.]). Using the mass of the turret this corresponds to a force of 1.78 kN acting on the mass centre of the turret during acceleration and a force of 8.74 kN acting on the mass centre of the turret during deceleration.

3. Force required to puncture fuselage

A pressure of about P = 172.4 kPa is sufficient to puncture the fuselage of most commercial planes (c. Leeham, 2009). Assuming a thin blunt strong pipe is to be used to penetrate the plane, a force of 487N is required for a pipe of diameter 2 cm.

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3 Concept Selection

3.1 CONCEPT EVALUATION

3.1.1 Concept 1 Concept 1 consists of two separate pin-connected booms with the lower boom mounted to a base plate on top of the truck. The lower boom has a fixed length of 4 m while the upper boom is a telescoping mechanism with an unextended length of 6.5 m and an extended length of 11 m. This concept is hydraulically actuated and uses three cylinders to control the movement of the turret. One cylinder is used to raise and lower the lower boom while a second cylinder is mounted parallel to the lower boom. The second cylinder enables the angle of the upper boom to stay constant, for a certain range of motion, when only the lower boom is moved. A third cylinder, mounted inside the upper boom, is used to extend the telescoping boom. 3.1.2 Concept 2 Concept 2 consists of four pin-connected booms. Two booms, of equal length, are mounted to the base plate on top of the truck and are connected to a third boom in order to form a parallelogram. This configuration enables the angle of the upper boom to remain constant when only the lower boom is moved. This concept uses linear actuators (electric motor driven worm gear drives) to enable movement of the turret. One actuator is used to control the movement of the lower boom while a second actuator controls the vertical movement of the upper boom. A third linear actuator, mounted on top of the upper boom, controls the extension of the upper boom.

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3.2 PROS AND CONS OF CONCEPTS

Table 3: Pros and cons of concept 1. Pros Cons Structure Minimal number of parts: consists of High cost of hydraulic components only two booms and three actuators Weighs less due to less material used High forces needed to move booms for construction of booms due to compact design Able to be manufactured in normal workshop Easy to repair, replace parts Actuator of telescoping boom is mounted inside upper boom, which results in better weight distribution Actuation Can produce very large forces for their Hydraulic fluid needs to be maintained size and contained Actuators can be mounted remotely Heavy actuators from the hydraulic power supply Actuators length of motion(stroke) is relatively long Telescoping cylinders are available that can extend several times their length Actuators are rugged, they will not overheat or burn out due to over loading Actuators are more economical and the same cylinder can move at various speeds (The Advantages of Hydraulic Cylinders,[S.a.])

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Table 4: Pros and cons of concept 2. Pros Cons Structure Able to be manufactured in normal Larger number of parts: needs four workshop booms and three actuators Actuators are relatively light Higher manufacturing cost due to larger number of parts used and more expenses on tolerancing of mating parts Easy to repair and replace parts Actuator of telescoping boom is mounted on top of the upper boom Actuation Actuators have high mechanical Actuators are more expensive, efficiency (up to 90%) and smooth especially when non standard sizes are operation required Actuators have long life, requires low Limited stroke (only up to 2.4 m maintenance, have low wear and high available) precision with hardly any stick-slip effect Easy to access all actuators for Actuators have backlash of up to maintenance 0.024 mm Actuators need to be driven by electrical motors Electrical motor needs to be closely coupled to worm gear drive Actuators is limited in both power and stroke Actuators that can handle large forces are expensive due to the expensive worm gear that needs to be machined Long-stroke worm gear drives suffer from harmonic vibration problems and worm gear shaft sag

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3.3 CONCEPT SELECTION

When comparing concept 1 with concept 2 it is clear that there are some distinct advantages and disadvantages to each concept. Firstly, from looking at the general structure proposed for the high reach extendable turret, it is clear that concept 1 provides a much better solution for the design of the structure. Although both concepts provide a structure that is easy to repair and maintain, the structure purposed by concept 1 consist of less individual parts. This reduction in the number of parts used contributes to a less expensive design, a reduction in the total weight of the design and in the overall fabrication time. All of these advantages make concept 1 the preferred choice when it comes to the structure of the high reach extendable turret. Secondly, taking a look at the different means of actuation proposed by each concept, both methods of actuation seem capable of accomplishing the task at hand. However the use of hydraulic cylinders, as proposed by concept 1, provides significant advantages over the worm gear drives proposed by concept 2. Hydraulic cylinders are for instance much better equipped to handle the large forces which will be required to move the individual booms of the mechanism. All though the worm gear drives proposed by concept 2 are capable of delivering the forces required to operate the extendable turret, they have a limited stroke capability, which is vital to the successful operation of the design. This, along with the bulky electric motors needed to drive the worm gears make them less practical for the application. It is thus the capability of the hydraulic cylinders to provide large forces in comparison with their compact design that makes them the preferred means of actuation for the design. Finally, both the proposed structure and means of actuation of concept 1 is much more economical and will ensure a final design of much higher quality than concept 2. Thus after careful consideration of the above mentioned facts there have been decided that concept 1 is the preferred concept to be developed further into a final design for the high reach extendable turret.

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4 Layout Design

4.1 CALCULATIONS FOR LAYOUT DRAWING

Required angle to achieve a height of 15 m above the ground when fully extended: B = 4sin(76) = 3.881182905 = 3.88 m D = 15 (B + C) = 15 (3.88 + 3.5) = 7.618 m 11sin() = 7.61 = arcsin(7.618/11) = 43.8 Thus an angle equal to or greater than 44 above horizontal will enable the turret to place the nozzle at a height of 15 m above the ground. Distance (x) from base plate where boom intersects the height of the truck cab: = arcsin*(B + C)/11+ = arcsin(7.381182095/11) = 42.1455719 = 42.15

B 11 m

x
C

E 19

E = 11 sin() = 8.155865307 = 8.16 m (B + C)/E = B/x 7.381182905/8.155865307 = (4sin(60))/x x = 3.827671872 = 3.83 m

Angle : = arctan (E/(B +C)) = arctan(8.155865307/7.381182905) = 47.85442282 = 47.9

The distance x is greater than (2.5 + 4cos(76)) = 3.47 m (the distance that the pivot point of the upper and lower boom is from the front of the truck). Thus the boom will be able to reach the ground without hitting the front of the truck.

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Conclusions

This report aimed to develop a HRET capable of penetrating the fuselage of a burning aeroplane to deliver a spray of water to douse the fire inside. A needs analysis was completed, utilising the Design Brief to create a project plan, design objectives, engineering requirements, and the initial design specifications of the product. Two concept designs were then discussed. The first concept consisted of a robotic arm driven by hydraulic linear actuators. The second concept design had an extra link, enabling the angle of the upper boom to remain constant when only the lower boom is moved. It utilised electrical linear ball-screw actuators. Hydraulic actuators were found to have numerous advantages over linear ball-screw drives. This, along with the reduced cost and complexity of design, ensured that the first option was chosen. A layout design was then created using the required envelope of movement as a guide.

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6 References
c. Leeham.net Uncertainty exists over fighting composite airplane fires [Online] Available: http://leehamnews.wordpress.com/2009/03/10/uncertainty-exists-overfighting-composite-airplane-fires/ [2010, 02 February] Stopping Distance Chart. [S.a.]. [Online]. Available: http://faces4.org/index.php/Speed/Stopping-Distance-Chart.html [2010, 20 February] The Advantages of Hydraulic Cylinders,[S.a.]. [Online]. Available: http://www.ultrametal.com/hydcyladvantages-sc.cfm?ID=19&categoryid=45. [2010, 20 February]

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Appendix A: Data Sheets

A.1. Parker ET - electro-thrust cylinder Product Data Sheet, Pages 6 & 7.

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Appendix B: Drawings
B.1. Concept 1 Drawings

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B.2. Concept 2 Drawings

25

B.3. Layout Design Drawings

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