Friday, September 30, 2016

Electric Toothbrush Aircraft - Part 2 - The Propeller

Youtube video:



Continuing development of the Electric Toothbrush Aircraft using a high power rechargeable compact motor drive from a budget supermarket electric toothbrush.
Exploring the potential for educational value in getting that running a polystyrene glider kit flying "around the pole" on a tether line. Lessons can include feeling the torque effect then choosing the direction around the circle so the torque effect to maintain the line tension. Other lessons include a micro switch held on by line tension so cutoff happens if the line breaks.
Aiming here for a low cost kit - the motor unit, switches, propeller (and optional micro video camera) can be re-used for each group of learners. The aircraft and some accessories probably need to be new for each group project at a cost of about USD 10

Well performing fixed wing aircraft typically need to have a maximum thrust (weight force) of 25 percent of the weight. The measurements here are 35gram-force for an all up estimated weight of 100g - that includes carrying a micro video camera. So the maths says that this should be a good performer - 35 percent - too good to let loose on free flight - this will need a tether!

Low cost electric toothbrush is "Expert" sold by Countdown Supermarkets here in New Zealand. Cost is NZD 25 which is approx equivalent to USD 18
http://shop.countdown.co.nz/Shop/ProductDetails?stockcode=749862

Propeller is "THO 387" from Acorn Models, Christchurch, New Zealand:
https://www.acornmodels.co.nz/products/aircraft-accessories/propellors-electric-rubber-powered/78684/

The next exciting episode will be the aircraft. So far after checking out a variety of kits, the best value I can find is this one:
http://www.dx.com/p/fx-fx-702-hand-throwing-hand-launch-glider-airplane-toy-w-sticker-white-black-420328

Note that links are working as at 01 Oct 2016 but designs and supply can change quickly.


Monday, September 26, 2016

Electric Toothbrush Aircraft - Part 1 - The Motor

I lost my electric toothbrush so my wife bought me a low cost one from the local supermarket. This was remarkable for how powerful it was. Big noise and big brushing action. Then I found the previous more gentle one. And I thought - what to do with a spare high powered electric motor? Try powering a model aircraft with it! Maybe there is good STEM education value in here somewhere.

I cut around the case to remove the top and bottom. I needed to cut vertical slots in the middle section of the case to get it off. See photo below. After removing the interesting and possibly educational gearbox arrangement there is a compact motor drive unit with a rechargeble 2-cell NiMH battery. The cells are of miniature size so it delivers 2.4 V from half the usual NiMH battery weight.
I kept the bottom 5cm as a handy vertical stand. It also holds the unit nicely in the battery charger.

The toothbrush is "Express". Here in NZ it sells for NZD 20 in "Countdown" supermarkets. My checking suggests that this remarkably high power motor plus rechargeable battery plus charger for that price in one handy unit competes very well with the equivalent from gadget and hobby shops. Now .. can this thing fly?

Youtube Video:



Photos: I added the red insulation tape around the motor to tame its wild array of wires.


Friday, May 27, 2016

Rocket Post 13 - We are not alone! This exists and its name is "Resistojet".

What a difference a keyword makes!  I was wondering if it was a new idea to model a nuclear thermal rocket in miniature with an electric heater coil? What I named "SteamFlash Rocket" has a history as "Water Resistojet" going back to 1906. It is normal for it to provide a very low thrust. NASA experimented with it for many years as a possible small control thruster for satellites and spacecraft. Resistojets have been successful but with working fluids other than water. The one flying "Water Resistojet" I can find was on the experimental no-budget "STRaND-1" satellite where the working fluid was water with alcohol antifreeze added.
http://www.sstl.co.uk/Missions/STRaND-1--Launched-2013/STRaND-1/STRaND-1-FAQs

"STRaND-1" has a lot of "hitechfromlotech" in it. Including another idea we are interested in which is to use a cell phone to provide computing power for robotics.

Why did we miss this at first?
Excuses excuses! The word "Resistojet" does not appear in the Zuppero et al article[1]. The article does have the related term "Thermal Rocket" but that did not stand out for me because I thought all rockets were "Thermal" except the odd ion or laser experiment. Turns out "Thermal Rocket" means heat not coming from combustion - IMO not clear to newbies. The word "Resistojet" does not appear in the Wikipedia article "Steam Rocket". I am a Wikipedia member so adding it is on my TODO list. I did ask around model rocket enthusiasts about what I was doing and none of them had ever heard of it. One of my helpers said "they are just into whizz-bangs so they will not get this". The audience for this blog and related posts is about 300 and none of you said anything. It was only after getting a very low thrust result that I headed into Google for a long search session and eventually teased out "resistojet".

So is it a good thing to build and test one?
YES! Satisfying to discover that working from isolated innocence, our "resistojet" is remarkably close to the NASA experiments. Similar physical size, coil resistance, voltage and current used. I kept it simple so it has been quicker and more interesting to build and run this than to spend hours passively reading papers on the subject. We appear to have done something new in building a transparent plastic resistojet and videoing what is happening inside. We may have some useful findings coming out of that. Sigh of relief that I did not buy the expensive lithium battery and its expensive charger, safety and support gear. Going through static tests run by utility batteries was a good move. The biggest effort was the thrust measuring mount which is going to be useful for tests of other flight propulsion options like ducted fans.

Where are we at with STEM inspiration for High School students?
(or should I say "inspire STEM with Steam"?!)
Very unlikely that this can lift off a rocket from the ground. The only NASA proposal that is even close is Zuppero et al proposing lift off from The Moon with the advantages of low gravity and operating in a vacuum. Powering a model aircraft may be possible, otherwise this is a static test activity. Makers can go for an efficiency challenge - how many watts to produce 1N of thrust. Smaller is better, About 10000 so far for our Resistojet. About 2000 for equivalent NASA experiments [2]. To fly a model rocket needs about 200 so that design would need to be 10 times better than NASA's research results or taking a very different approach.

The fact that "resistojet" has a story and some interesting practical applications could be a plus for the target audience.

Where to from here?
Look again at the Robert Truax Steam Rocket concept, This works on a different principle of storing energy in superheated water under pressure. This beast gets us concerned about safety for the young target audience but a very small capacity unit may be safe using the same safety rules as educators use with solid fuel rockets. Refs:
Robert Truax – Patent US 3029704 A – Steam powered rocket and launcher therefor. 1959.
http://www.google.com/patents/US3029704
Good ideas and information here some of which could apply to a Resistojet.

AQUARIUS Hot Water Rockets. German Student Project. Similar to Truax 1959 with use of electric pre-heater.
https://www.youtube.com/watch?v=457DSAxuwBY
http://www.aquarius-aerospace.de/index-e.html

Gets me thinking - Hybrid? Truax concept superheated water tank provides feed pressure into a Resistojet chamber where the resistance heater adds some extra energy to the wet steam just before it exits the nozzle.

Robert Truax and the NASA papers emphasise that nozzle design can make a big difference. The expansion bell, even as a simple cone, receives a lot of reaction force from the exiting wet steam. Our Resistojet currently has a 1mm exit hole. NASA's equivalents range from 0.15mm to 0.3mm which is going to build more pressure and give faster exit velocities. Greater temperature and pressure will demand a stronger and more temperature-resistant flash boiler.

An interesting option is the "Super Capacitor" for electrical energy storage. This stores less energy than the same weight lithium battery but it can release that energy in a much more rapid burst which means more power for a short time which is what a rocket or aircraft needs. The "Super Capacitor" also looks like a safer and lower cost option than lithium. A set of capacitors would have a similar cost to a lithium battery but would not need the special charger and safety electronic controllers. The capacitors do have a disadvantage in that the voltage drops as the current flows which may need something like a coil in sections that run in series to start with then switch to parallel during the run.

Where to from here also means looking away from a rocket as an attractive robotics application and finding other robotic activities to try with cell phone as robot brain.

---------------------------
Footnotes: Rocket Post 13 - We are not alone! This exists and its name is "Resistojet"

[1] Zuppero, A. Schnitzler, G. Larson, T. (1998). Nuclear-Heated Steam Rocket Using Lunar Ice.
http://www.neofuel.com/moonicerocket/


[2] Result of 0.17 N from 330 W input:
Manzella D., Carney L. (1989) Investigation of a Liquid-Fed Water Resistojet Plume [NASA Technical Memorandum 102310 AIAA-89-2840] Retrieved from: http://ntrs.nasa.gov/archive/nasa/casi.ntrs.nasa.gov/19890018335.pdf




Saturday, March 19, 2016

SteamFlash Rocket Motor 12 - Test 2 challenge - measuring minimal thrust

13 Mar 2016 - and a mystery. Test run gives a stubborn zero on our "force measurer"which is a luggage weighing scale. To get good performance we need 100W of electrical power to deliver a thrust force of 1N which would show on these scales as 0.1 kg force. Scale sits at zero all the way. Big under-performance challenge here!



Test 1 looked good - so there is something there.

I plan to follow-up by trying:
  1. A smaller nozzle for more of a pressure build up, 
  2. Balancing the balance beam instead of measuring reduction of the weight force of a large counterweight
  3. Measure other kinds of model thruster on this rig for comparison

Wednesday, March 2, 2016

SteamFlash Rocket Motor 11 - New static test rig under construction


Beam balance about 45cm long made of "Make-a-Bracket Carinya" steel shelving pieces.
Idea is to assemble the motor on the vertical piece at the end nearer to camera.
Rocket motor applies an up force - pivots in beam centre - giving a down force at the other end to be measured with an electronic hanging scale intended for weighing luggage.


Monday, February 29, 2016

SteamFlash Rocket Motor 10 - Preventing Burnout - the answer is in the hair dryer

A challenge, see video below, is a risk of "burnout". Normally the energy needed to change water to steam keeps the coil at 100 deg C or a little above. If we run out of water or lose water then the coil glows and can melt nearby plastic, or worse.  I searched for fuse wire with the idea of making the coil out of a low melting point wire so it would act as its own fuse. This search found something better, the "thermal fuse". This sends current through a little bead of low-melting point metal. On temperature rise the bead melts switching the current off. This is used for a similar safety purpose in hair dryers and hair straighteners. Looks great - I am thinking of embedding this in the wall of a boiler made of epoxy resin - or in a cutout in a polypropylene tube reinforced with epoxy resin and carbon fibre.  Example ref:
http://www.jaycar.co.nz/Passive-Components/Circuit-Protection/Thermal-Switches-%26-Fuses/c/202E

Friday, February 19, 2016

SteamFlash Rocket Motor 09 - Second thoughts - I can be less like Elon Musk

I was going to keep Rocket Motor Number One as a historical treasure until I met ex student Dave who tells me he likes this blog and hurry up please to give us all Test Number 2 (This is Dave 2.0 - the number of interested people has grown to the point where there are 2 Daves)  The quickest way to Test 02 is to modify the motor from Test 01. Ordering a few goodies online - like a pressure gauge and digital hanger scales for only about 5 dollars each which is a pleasant surprise. I checked out pumps but small electric pumps only go up to about 100psi and I calculate that tension springs or rubber bands acting on a syringe plunger can do better as well as being simpler, lighter and easier. Aiming for a static test of a more complete design with thrust and pressure measurements.