Team Members & Role:
Joseph Ruck: Team Lead
Christian Fuehr: Analysis Lead
Sampson Cohen: Design Lead
Trish McGinty: Evaluation Lead
Liam Weschrob: Fabrication Lead
Abstract: The objective of this project is to design a mechanism to secure and apply pressure to a new design of modular electrical transformer called a Power Electronic Building Block (PEBB). The need for PEBBs is becoming increasingly common in the electronic infrastructure designs of the US Navy’s fleet of ships, as the share of power requirements shifts away from a near 95% dedication to sustaining propulsion, to a near equal distribution of power among the propulsion, and various sensor and weapon systems. The result of this expansion and diversification of energy needs is a complex network of cables that stretch the length of the ship, creating concerns in efficient routing methods and subsequently longer ship building times. Functioning similar to a power substation, the PEBB integrates with a central power corridor to manage and distribute power more efficiently. Fundamental to the design of the PEBB, is its advanced thermal management system, which relies on indirect liquid cooling to keep operating temperatures low and prevent failure of the entire electronic infrastructure of the ship. This is accomplished by maintaining high contact pressure between the interface of the PEBB and the liquid cooled ‘cold plates’. Previous designs for a ‘latching mechanism’ to maintain pressure were either too complex, requiring a separate pneumatic system, or not compact enough given the constrained space of the power corridor. This new latching mechanism design proposed by Team 1506 took the failings of these previous designs into account. By prioritizing high latch pressure without compromising compactness or simplicity, a block and tackle design was selected. Originally inspired by the ‘BOA’ tensioning systems on many ski boots and cycling shoes, the block and tackle design utilizes a dual, tensioned pulley and cable system to apply a large amount of force to the surface of the PEBB with only a small input torque required from the user. A condensed bill of materials, large mechanical advantage, and compact package all add to the benefits of this design and prove the potential that this latch mechanism has in meeting the expectations of the project sponsor.