progetto mesa mechatronics in energy saving application

28 Pages·2013·2.72 MB·English

ITIS G. CARDANO

PROGETTO M.E.S.A.

MECHATRONICS IN ENERGY SAVING
APPLICATION

HANDBOOK

Project realized by the ITIS “G. Cardano” students of the following classes

5 AM
5 BM
5 AE
4 BI

School years 2011-2012 and 2012-2013

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 1
ITIS G. CARDANO

INDEX

The history of MESA Project .………………………………………………… Pag. 3

The objectives of the project ………………………………………………… Pag. 3

What we have achieved ….………………………………………………… Pag. 4

The initial working group….………………………………………………… Pag. 4

How we realized it ….………………………………………………… Pag. 6

Starting the design . .. ….………………………………………………… Pag. 7

We continue the work ……….………………………………………………… Pag. 10

The machining of the components …………………………………….. Pag. 15

The electrical system of the car ………………………………………..…. Pag. 16

The photovoltaic plant ………………………………………………..…. Pag. 20

The plant for solar tracking …….……………………………...……..… Pag. 22

Conclusions and Acknowledgements .…………………………..……..… Pag. 28

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 2
ITIS G. CARDANO

THE HISTORY OF THE PROJECT

The M.E.S.A. Project was conceived in 2010 as a “Leonardo” school innovation project. In
November 2011it was approved and funded by the European Slovenian Agency.
The core foundation that has participated in the design consisted of prof. Fabrizio Maggi,
Prof. Luigi Magrelli, Prof. Nicola Muto, Prof. Marcello Gambini, Prof. Bancale Giuseppe,
Prof. Marco Magrini Polloni.
The partner schools are initially of Slovenian, Italian and Hungarian nationalities.
Subsequently, the Hungarian partner school will be replaced by a Croatian school in Pula.
The project leader is the technical Centre TSC in Nova Gorica.
In January 2012, the project work began on the first meeting in Nova Gorica.
This was followed by a second meeting in Pavia in March 2012, and a third meeting in
October 2012 in Pula.
In October 2012 the technical activities for the realization of the electrical car and the study
of renewable energy also started.

THE PROJECT OBJECTIVES

This is a project for educational innovation that, through a process of class experimentation
of new topics and through the use of new teaching methods, tends to form the spirit of
curiosity and personal initiative in the students that sometimes in frontal teaching are to be
neglected.
The study of traditional subjects is maintained on a theoretical level, but in practice, all
those work methods for the realization of the artifacts conceived and designed theoretically
are used. In particular, this project involved the design and implementation of a system of
electric charge through solar energy and the transformation of a car with a combustion
engine into a car with electric traction.

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 3
ITIS G. CARDANO

WHAT WE HAVE ACHIEVED

We worked on four key topics:
• The experimental teaching of Mechatronics, Computer Science and Electrical
Engineering;
• the electric car;
• the photovoltaic battery charging;
• the system for tracking the movement of the sun through solar panels.
We took a microcar with diesel engine and turned it into a car with electric traction.

We carried out the study, design and installation of solar panels for battery charging circuit,
we have them installed on the roof of our school and realized the complete electrical
system control and measurement of the current produced.
We carried out the study, design and installation of solar panels on a micro-mechatronic
system for an optimized tracking during the day of the sun rays through the azimuthal
movement of the panels.

THE INITIAL WORKING GROUP
The first working day, the following students are present to “take possession” of the
microcar:

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 4
ITIS G. CARDANO

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 5
ITIS G. CARDANO

HOW WE REALIZED IT

We started with a microcar equipped by a 600 cc diesel engine with front wheel drive. The
car given to us by the partner Mr. Gianini had already been separated from the combustion
engine. It looked like this:

After a series of activities which have involved the removing of the electrical system, the
tank and all the parts deemed to be unnecessary and dangerous for the realization of the
prototype, the microcar looked like this
this:
With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 6
ITIS G. CARDANO

STARTING THE DESIGN

M Ø192

B A

C

R
A
R C
B

Q

B A
240 255,5
120

Calculation of belt tension:
Departure data:

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 7
ITIS G. CARDANO

Sizing of the camshaft

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 8
ITIS G. CARDANO

In the calculations we obtain a minimum yield strength

according to which we choose a steel 36CrNiMo4 with a

Bearing selection:
Il carico che agisce radialmente sul cuscinetto è di 1288,04 N. Per questioni di spazio,
l’albero ha un diametro che non può superare i 22 mm nel punto in cui si deve posizionare i
cuscinetto. Pertanto verificheremo la durata di un cuscinetto a rulli conici SKF – 320/22 X,
che ha un coefficiente di carico dinamico C=25100 N.
.
The chosen bearing ensures a duration of 19.914 billion of revolutions, which, considering
an average operating speed equal to

allows us a duration of:

The bearing can be thoroughly verified.
With our school equipment we did not have the opportunity to realize with sufficient
precision the parts we dimensioned. We then turned to outside firms after realizing the
drawings necessary for these companies for the construction of the pieces.
With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 9
ITIS G. CARDANO

WE CONTINUE THE WORK

Once the microcar has been cleared from the superfluous we took into account the design
of the housing for the motor, the one for the batteries, the construction of cable routes and
the transformation of the pedals.
So we started the design of the cradle housing the motor which presented the following
data sheet.

The design of the engine cradle was carried out employing Autodesk Inventor Tool with
which we have made the following diagrams.

With the support of the Lifelong Learning Programme of the European
Union. This project has been funded with support from the European
Commission. 10