Design and manufacture of a model support system for a half scale Formula One Wind Tunnel. The system has a full working height of 3.4m, carrying a load of 6kN with a deflection of only 0.5mm. Positional accuracy is 0.005mm at a traverse speed of 25mm/s. This was achieved using a multi-start, ground and pre-loaded precision roller screw driven by a stepper motor with integral brake and encoder.

Design and manufacture of a high accuracy, Wind Tunnel Probe Traversing System. The requirement was to position a range of aerodynamic probes in a 3m x 4m x 6m, Mach 0.3 wind tunnel working section. The probe was constructed from high modulus carbon fibre, optimised to minimise deflection, aerodynamic loading and flutter/vibration. A positional accuracy of ± 1mm was achieved using a high accuracy calibration method and unique laser deflection measurement system. High ratio, low backlash, low weight drives were used with encoder feedback and purpose designed rotary opto-electronic electronic switches for accurate positioning. Signals and power were transferred through the rotary joints by purpose designed slip rings, the pressure signals being converted to electrical signals by an on board transducer. An integrated capacitance sensor system was used for collision avoidance.

Wind Tunnel Probes Datasheet

Design and manufacture of a Wind Tunnel Probe Traversing System, supported from the roof.

Wind Tunnel Probes Datasheet

Design and manufacture of Model Motion Support Systems for Mach 0.3 aerospace wind tunnels with, typically, 3m x 4m working sections. The system positions and moves the models to within 0.25mm of required position by electro-mechanical actuators, each with encoder feedback. Maximum loading capability was up to 20kN. Drag loads onto the external balance were reduced by the use of rotating GFRP aerodynamic fairings.

Model Supports Datasheet

Design of an aero gas turbine inlet rake assembly to measure intake pressure distortion of an engine during bench testing. The design was driven by frequency requirements, to avoid flexural and torsional modes of vibration as well as von Karman street vortex shedding. This resulted in the rakes being bolted to the outer casing, with a centre-body to give enough additional stiffness to the structure to ensure acceptable frequencies. The rakes measured both steady state and transient pressures, with two of the rakes being strain gauged for vibration monitoring purposes.

Gas Turbine Rake Datasheet

Design of a large Cartesian Probe Traversing System for a full size, automotive acoustic wind tunnel. The traversing system positions a range of aerodynamic and acoustic probes (with a mass up to 25kg) to an accuracy of 1.5mm in a working volume of 5 x 12 x 13 metres. This was achieved by designing a stiff, steel, main structure with a carbon fibre aerodynamically profiled lower strut, and fairing, to carry the probe. The design of the whole structure was optimised using a number of finite element models to obtain a critical 1^st mode frequency greater than 12Hz. The system motion control used high stiffness, electro-mechanical actuators with both incremental and absolute encoder feedback to avoid ‘skew’ of the traverse. Brakes were used to lock some of the traverse axes in position during test, to ensure the 12Hz requirement was met. Maximum traversing speed was 600mm/s and the entire assembly, nearly 20 tonnes, is hung from the roof of the main wind tunnel building when installed.

Cartesian Probe Datasheet