Team Hyperlynx SpaceX Hyperloop Pod Final Design
- 2. OVERVIEW Team Hyperlynx will design, fabricate, and assemble a pod to win the wheeled vehicle category of the SpaceX Hyperloop Competition. We intend to win by reaching the egress area as fast as possible without crashing. Our design is tailored to achieve this goal while featuring scalable, real-world Hyperloop applications such as a modular payload.
- 3. John K. Bennett, PhD Heather M. Underwood, PhD RJ Duran Mech. Engineering Mech. Engineering Mech. Engineering Mech. Engineering Design Comp. Science Architecture Business Mech. Engineering Mech. Engineering Mech. Engineering TEAM HYPERLYNX Connor Catterall Ben Cooper Nicole Garcia George Kemp Andres Lazo Richard Michalka Jack Nelson Richard Paasch John Spinelli Mark Urban Susan Waruinge Chandler Lacy Mech. Engineering Team Captain CU Denver Advisors Ron Rorrer, PhD Doug Gallagher Mech. Engineering Mech. Engineering Inworks Advisors Sponsors Supporters Comp. Science Comp. Science Indust. Design
- 5. TOP LEVEL DESIGN The Hyperlynx Pod will be an aluminum framed, rail-guided wheeled vehicle. An ultralight foam shell shapes the ten-foot long, two-foot max profile, three-hundred pound pod. A 12VDC battery powers networked sensors and actuators, hydraulic disk brakes, and real-time control systems. A modular payload is featured accommodating multiple passenger/cargo configurationsExploded View
- 6. Exploded Component View Modular Payload Body Rotary Actuator Master Cylinder Brake Actuator High Speed Wheel Assembly Secondary Propulsion Motor FrameSpaceX Propulsion Interface Brake Wheel Assembly Acrylic Canopy
- 7. DIMENSIONS / MASS The pod will have a tip-to-tail length of 10.5 ft. The largest cross section occupies 2.77 ft2 with a maximum height of 2.2 ft and width of 1.7 ft. The pod encloses and interfaces to the central I-beam, traveling 1 inch above the aluminum sub-track. 10.5 ft 1.7 ft 2.2 ft Pod Mass by Subsystem Total Mass: 300 lbs Pod subsystems are designed to be as lightweight as possible. Several methods realize this goal: lean manufacturing techniques reduce part count and complexity, ultralight composite materials create structural support at minimum weight cost, and system positioning leverages natural strength points of the assembly.
- 8. MATERIALS Aerospace Grade Low Density Foam 1” x 2” 6061 Aluminum Bar Acrylic Stainless Steel Linkage Rubber Wheel Aluminum Brake Rotors 6061 Aluminum Wheel Mount Assembly Steel Mounting Fixtures Aluminum Wheel with Polyurethane Tread Aluminum Propulsion Interface
- 9. STABILITY 20 custom machined wheels will hug the rail to keep the pod laterally and longitudinally stable. The aluminum hub and polyurethane tread will enclose a ceramic bearing rated up to 50,000 rpm. The design of these wheels was inspired by technology found on high speed roller coasters. Four vertical wheels on the flange and one horizontal wheel on the web will be mounted to an aluminum assembly then attached to the frame. Four of these assemblies, two mounted in the front and two in the rear will ensure the pod safely traverses the tube while traveling at high speeds.
- 10. BRAKINGA modified scissor jack linkage system will press four 10 inch diameter wheels outfitted with hydraulic caliper disk brakes against the web of the central aluminum rail. A rotary-actuated power screw drives the linkage system, allowing the desired compression force between the braking wheels and rail to be adjusted in real time. The disk brakes will receive pressurized hydraulic fluid from an electrically actuated master cylinder. The master cylinder actuator is spring loaded, requiring power to disengage the brakes, making the system mechanically safe. Braking Assembly
- 11. AERODYNAMICS The profile of the body is designed to accelerate the air flowing around the pod. The nozzle geometry created between the front of the pod and the tube will increase the velocity of the air around the maximum cross sectional area of the pod. The diverging shape at the rear allows the high velocity air to expand more rapidly, further decreasing drag. Diffuser Nozzle
- 12. PAYLOAD The middle section of the pod will accommodate a fully removable modular payload system capable of housing the SpaceX test dummy. A modular payload system in a full scale Hyperloop design will significantly reduce the cost of construction and operation of the pods, support multiple configurations, control weight distribution, and allow rapid turnaround of the pods at the station. Modular Payload
- 13. PAYLOADThe payload will feature accommodations to support the SpaceX dummy during its journey through the Hyperloop. Payload Canopy with Graphic User Interface Features include integral lighting, restraints and a graphic user interface featuring real-time pod data projected directly onto the canopy.
- 14. PAYLOAD CONCEPT Conceptually, the payload modules would support multiple configurations and a variety of user types. Single Person / ADA Sleeper Two Person Group / Family / Economy Cargo / Luggage / Freight Controlling the arrangement of the modules will allow for optimization of weight distribution according to the loads, improving the pod’s overall stability and performance.
- 15. PAYLOAD CONCEPT A modular payload system would drastically improve turnaround time once a Hyperloop pod arrives at the station. This reduces the number of pods required to maintain the operating schedule of the route, thereby reducing overall cost. These modules will also optimize maintenance and upkeep of the system by allowing time for the modules to be maintained between use in the system while keeping all pods in circulation. Hyperloop Station Concept
- 16. POWER Component Power (Ah) Linear Actuators 0.5 Rotary Actuator 3.1 Electric Motor 7.5 Controls and Sensors 1.9 Total 13.0 One Power Stream 12V 22AH Lithium Iron Phosphate battery outfitted with a quick-clip terminal will interface into the modular payload. This terminal will clip into the control board on the pod, providing power to all components. Battery Pack Mounted to Modular Payload
- 17. COMPUTING Navigation Data Environmental Data Microprocessor LCD Display Brake Actuation Output Command Signal Light Gyroscope Accelerometer Temperature Barometer Sensor Input Signals Network Access Panel External Command Center SPM Control Functional Block Diagram State Diagram The embedded computer system will continuously assess and manage the condition of the pod by utilizing real time data gathered by onboard sensors to control the pod’s critical subsystems. The system will also provide external communication capabilities allowing for remote control of all pod systems.
- 18. COMPUTING The BeagleBone Black microcontroller was chosen for its built in Ethernet/WIFI capability, as well as the large number of GPIO ports. The SpaceX provided communication board, an LCD screen, accelerometer and gyroscope will be mounted inside an acrylic control box. This box will be placed underneath the modular payload, connecting all actuators, motors, sensors, and the battery. Two antennas will be mounted at the top of the body and will interface with the communication board. Controls Systems Box
- 19. CC C ABD D E COMPUTING/NAVIGATION Position Sensor Frequency Picture A Accelerometer 5.376 kHz B Gyroscope 400 kHz C Barometer/Thermometer 3.4 mHz D Range 400 kHz E Light 400 kHz Sensor Map A network of sensors will communicate in real time with the microprocessor to dynamically control the actuators and motors. The temperature will be recorded at the front and top of the pod as well next to the battery housing. The gyroscope will measure yaw, pitch, and roll. The acceleration, light, and range sensors will feed real time positioning and speed data to the microprocessor.
- 20. PROPULSIONThe tube integrated propulsion system will interface with the frame through a machined aluminum disk fastened at the rear of the pod. This interface sits 10 inches above the aluminum sub-track. This system will provide the initial impulse and will accelerate the pod at 2.8 g’s for 800 feet. A pinned link connected to an electric actuator with a 2 inch stroke will lower a roller outfitted with an electric motor. This system will allow the pod to travel in and out of the ingress and egress holding areas. This secondary system will allow the pod to travel up to 5 mph. Propulsion Interface and Secondary Propulsion Motor
- 21. SAFETY The Hyperlynx safety package is redundant and incorporates electrical and mechanical mechanisms to prevent damage to the pod, tube, as well as avoid injury to all personnel operating the pod. A complete safety plan has been assembled to highlight safety features of the pod, both mechanically and electrically. It also explains hazardous material handling procedures in addition to safety, health and environmental considerations. The FEMA identifies several modes of failure and lists actions to mitigate failures.
- 22. SAFETY FEATURES OVERVIEW Several sensors mounted within and around the pod will monitor pressure, speed, temperature, battery life and overall pod health. If any of these become critical, the pod will execute a braking sequence to stop then enter a low power state to prevent damage to the pod or the environment. In the case of complete power loss, a spring, mounted between the rear dust cylinder and the end of the push rod, will manually actuate the master cylinder. This will apply brake pressure and slow the pod to a stop. Spring Loaded Brake Actuator
- 23. HAZMAT / STORED ENERGY Our operational pod will contain brake fluid and a single Lithium Iron Phosphate battery. Team Hyperlynx will be trained in proper handling and spill procedures of all hazardous materials. All documentation, MSDS, and a complete spill kit, will be present during all transportation and testing of systems that contain the hazardous materials. For complete hazardous material considerations see the Safety Plan.
- 24. Pod Analysis
- 25. THERMAL PROFILE The thermal profile on the outer shell of the pod is seen below. The thermal simulation was performed after the initial acceleration impulse at a speed of 260 mph, with a tube pressure of 0.02 psi, and a ambient temperature of 100 ℉. The temperature of the pod remained under 105℉. Temperature ℉ Thermal Simulation Results
- 26. AERODYNAMICS The aerodynamic coefficients of the Hyperlynx Pod were found using computational fluid dynamics and verified with wind tunnel experiments. CD = 0.247 CL = -0.00467 CFD and Wind Tunnel Prototype
- 27. TRAJECTORY The pod will accelerate for the first 800 feet and reach a speed of 260 mph. At a distance of 800 feet from the end of the tube, the power screw and disk brakes actuate slowing the pod down at a rate of 1.7 g’s. The braking sequence will take 5 seconds. Coast Brake
- 28. Tscrew FclampFclamp FclampFclamp BRAKING The braking system will use a series of linkages and a central power screw to gain mechanical advantage and compress four braking wheels against the rail. This symmetrical system ensures equal force is applied on both sides of the rail. The central screw (Tscrew) provides up to 13 ft- lbs of force, and transfers rotary motion to a linear clamping force (Fclamp) up to 1000 lbs. Finite element analysis of the linkage system shows under maximum loading conditions, the linkage will not fail. The maximum stress is located on the center link where the power screw is threaded. This linkage will be manufactured out of stainless steel. Braking Linkage Free Body Diagram / Stress Analysis
- 29. VIBRATIONUsing software-based mode shape and frequency analysis, part features are optimized by reinforcing critical points tending towards unwanted shapes at resonance. All vibrations that do transmit through the pod will be damped using a 0.125-inch layer of natural rubber between contact points of the pod, module and frame.
- 31. ACCELERATION A stress study was performed on the frame to determine if the frame would withstand the large force applied at the rear of the pod during the acceleration phase. The brake mount cross beam had the highest stresses and will not fail or yield under maximum loading conditions. 143 lbs from Front Caster 158 lbs from rear caster 870 lbs from the propulsion interface 98 lbs from Support Beam 855 lb-in from braking torque Maximum Stress = 4,830 psi
- 32. NOMINAL DECELERATION 169 lbs from Front wheels 131 lbs from rear wheels 98 lbs from support beam 4400 lb-in from braking torque In the deceleration stress study, the brake support cross beam yielded the highest stress. This was due to the large loading on the cross beam from the torque generated by the braking assembly. This stress is within the yield strength of 6061 aluminum alloy. Maximum Stress = 24,540 psi
- 33. END-OF-TUBE NOMINAL CRASH 255 lbs from front wheels 4000 lbs on front of frame 45 lbs from rear wheels 3720 lb-in from braking torque For the end-of-tube-nominal crash a force of 4000 lbs was applied to the front of the frame to simulate the crash scenario. These force values were based on a deceleration rate of 400 ft/s². The frame stress exceeds yield in the front.
- 34. Pod Production
- 35. PRODUCTION SCHEDULE Preliminary Production Schedule
- 36. CONSTRUCTION COST Pod Construction Cost $8,455 Transportation & Misc. Expenses $9,250 Total Project Cost $17,705 Funds Raised $9,663 Remaining Funds Required for Project Completion $8,042
- 38. INFRASTRUCTURE With respect to the proposed Hyperloop route from Los Angeles to San Francisco, a longer pod outfitted with multiple payload modules would increase efficiency while traveling longer distances. The shape of the pod would be scaled to accommodate a larger tube and bigger payloads. Full-scale pods of the current design would weigh 1000 lbs unloaded. The pod design allows for easy and low cost upgrades such as a front facing compressor, rotor-stator system, or levitation system. The high speed wheel assembly offers lateral stability that non-wheeled Hyperloop pods lack. Full-scale Hyperloop pods using this design can be cost effective, with an estimated build price of under $100,000 per pod, excluding payload modules. Full Size Pod ½ scale competition pod
- 39. OPERATION / MAINTENANCE Features such as the modular payload, battery location, and material choice allow for seamless operation and maintenance of Hyperloop pods. When a hyperloop pod arrives at the station, the modules will be loaded and pre-staged with fully charged batteries, passengers and freight. This will provide fast turn around time, minimizing time in the station. . Maintenance would include periodic changing of braking wheels, calipers, brake fluid, and high speed wheel assemblies. Hyperloop Station Concept
- 40. VISION The Hyperloop has many potential crossovers with other emerging technologies, such as virtual reality, vehicle automation, and ever-growing consumer access to powerful smart telecommunication technology. These concepts, when considered as part of a larger hierarchy, could lead to a paradigm shift. The automation of transportation infrastructure allows us to envision a conceptual “physical internet” in which our ability to traverse our real world would become as effortless as browsing a web page. This system would create entirely new ways for users to live their lives.