high speed lanyard release test fixture

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MULTIDISCIPLINARYMULTIDISCIPLINARYENGINEERINGENGINEERING

@ R I TSenior Design Senior Design

MEMERITRITMULTIDISCIPLINARYMULTIDISCIPLINARY

ENGINEERINGENGINEERING@ R I T

Senior Design Senior Design

MEMERITRIT

HIGH SPEED LANYARD RELEASE TEST HIGH SPEED LANYARD RELEASE TEST FIXTUREFIXTURE

PROJECT NUMBER 05423PROJECT NUMBER 05423

Michael Amos, Project ManagerMechanical Engineer

Aaron BrechkoMechanical Engineer

Joshua CarmerElectrical Engineer

Dr. Benjamin Varela, Faculty MentorMechanical Engineer

Justin GrigonisIndustrial & Systems Engineer

Lindsay LaRoccaMechanical Engineer

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OverviewOverview Project OverviewProject Overview The ProcessThe Process Desired OutcomesDesired Outcomes Key RequirementsKey Requirements Major Design ChallengesMajor Design Challenges ConclusionsConclusions

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Amphenol Aerospace Amphenol Aerospace Operations (AAO)Operations (AAO)

““Accepted leader in providing quality Accepted leader in providing quality connectors… to the Industrial, connectors… to the Industrial,

Military, and Aerospace markets” Military, and Aerospace markets”

www.Amphenol-Aerospace.comwww.Amphenol-Aerospace.comSidney, New YorkSidney, New York

http://www.amphenol-aerospace.com/

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Project OverviewProject Overview Mission StatementMission Statement

• To design a drive system, with supporting To design a drive system, with supporting documentation, for an actuation method documentation, for an actuation method to test the separation of AAO’s lanyard to test the separation of AAO’s lanyard release connectors.release connectors.

Executive SummaryExecutive Summary• WhatWhat• WhyWhy

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Lanyard-Release Connector Lanyard-Release Connector AssemblyAssembly

Main Components Main Components • LanyardLanyard• Operating SleeveOperating Sleeve• Plug ShellPlug Shell• ReceptacleReceptacle

Main electrical Main electrical interface between interface between aircraft and its aircraft and its storesstores

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The ProcessThe Process Needs AssessmentNeeds Assessment Concept DevelopmentConcept Development

• Many conceptsMany concepts Feasibility AssessmentFeasibility Assessment

• Several ConceptsSeveral Concepts Preliminary Design ReviewPreliminary Design Review

• One design conceptOne design concept

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Desired Outcomes / Desired Outcomes / RequirementsRequirements

For AAO’s Selected Concept:For AAO’s Selected Concept:• Complete bill of materialsComplete bill of materials• Component and assembly drawingsComponent and assembly drawings• Provide detailed analysis of fabricated componentsProvide detailed analysis of fabricated components

Meet new Military Specification MIL-DTL-38999/31DMeet new Military Specification MIL-DTL-38999/31D• High speed separation of connectorHigh speed separation of connector

30 ft/s ± 10%30 ft/s ± 10% Variable Test VelocityVariable Test Velocity ReliableReliable RepeatableRepeatable EconomicalEconomical Low-Cycle TimeLow-Cycle Time SafeSafe

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Major Design ChallengesMajor Design Challenges Motor SelectionMotor Selection

• Torque vs. RPMTorque vs. RPM• AC Performance CharacteristicsAC Performance Characteristics

Overall System DynamicsOverall System Dynamics Component SelectionComponent Selection

• Clutch/BrakeClutch/Brake• ControlsControls

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DescriptionDescription

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Major ComponentsMajor Components MotorMotor

• 7.5 HP, 3 Phase AC Induction 7.5 HP, 3 Phase AC Induction 230 V SmartMotor 230 V SmartMotor

Sprockets (6)Sprockets (6)• DriverDriver

5.123” diameter, 24 teeth (1)5.123” diameter, 24 teeth (1)• Driven:Driven:

9.911” diameter, 48 teeth (5)9.911” diameter, 48 teeth (5) ChainChain

• Size 50, 5/8” pitchSize 50, 5/8” pitch• Two-Single Strands for Upper Two-Single Strands for Upper

System (US)System (US)• One-Single Strand to connect One-Single Strand to connect

motor shaft to USmotor shaft to US

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Major Components – Cont’dMajor Components – Cont’d Mounting Block Linear Bearing -

Track

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Component Selection Component Selection ProcessProcess

1.1. Choose MotorChoose Motor2.2. Choose SprocketsChoose Sprockets3.3. Determine force and velocity at Determine force and velocity at

mounting blockmounting block Re-iterateRe-iterate

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ConfigurationConfiguration

Requirements:Requirements: 30 ft/s30 ft/s 200 lb pull force on 200 lb pull force on

lanyardlanyard

At Motor - Driver:At Motor - Driver:• 1400 RPM1400 RPM

At Upper System – At Upper System – Driven:Driven:• 700 RPM700 RPM

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Overall System CalculationsOverall System Calculations Acceleration:Acceleration:

a=167.97 ft/sa=167.97 ft/s22

t=0.1786 st=0.1786 sd=2.68 feetd=2.68 feet3 feet3 feet

Deceleration:Deceleration:a=-434.64 ft/sa=-434.64 ft/s22

t=0.069 st=0.069 sd=1.035 feetd=1.035 feet

ClutchofTorqueBrakingTIM BTotal

2

21 mrI

FrontBackMotorEquiv IIN

II

21

MotorofTorqueIM MEquiv

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Drive MotorDrive MotorBaldor 7.5 HP, 3 Phase Baldor 7.5 HP, 3 Phase

Induction SmartMotorInduction SmartMotor SmartMotor: Integrated SmartMotor: Integrated

Control Board Saves:Control Board Saves:• $$$$$$ & Man Hours & Man Hours

Programmable Programmable Velocity ProfilesVelocity Profiles

Accuracy = Accuracy = 2.9%2.9% Breakdown Torque:Breakdown Torque:

• 69.9 ft lbs69.9 ft lbs

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Baldor KeypadBaldor Keypad Remote control (up Remote control (up

to 100 ft)to 100 ft) Indicator lightsIndicator lights Clear LCD DisplayClear LCD Display SimpleSimple ProgrammableProgrammable

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Clutch and Brake ComponentClutch and Brake Component Enclosed Uni-Enclosed Uni-

Module model 215Module model 215 One On / One Off One On / One Off

DesignDesign• 230 VAC Powers up 230 VAC Powers up

either clutch or either clutch or brake at any given brake at any given timetime

CBC-150-2 CBC-150-2 ControllerController

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Switch LocationsSwitch Locations

4. Home2. Past Test Position

1. At Speed (1400 rpm) Signal From Motor

3. Reverse Switch (user activated)

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Control ComponentsControl Components SwitchesSwitches

1.1. Emergency StopEmergency Stop2.2. TrackTrack3.3. RockerRocker

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Emergency Stop SwitchEmergency Stop Switch DPST NO/NC switchDPST NO/NC switch Efficient for control systemEfficient for control system Necessary in event of failure of Necessary in event of failure of

lanyard to disengagelanyard to disengage

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Track SwitchTrack Switch Tells control system the location of Tells control system the location of

the carriagethe carriage Makes control system logic simpleMakes control system logic simple SPST maintained contactSPST maintained contact Requires ramped contact surface on Requires ramped contact surface on

bottom of carriagebottom of carriage

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Rocker SwitchRocker Switch Manually switched after each testManually switched after each test Functions as second input needed to Functions as second input needed to

control the clutch/brakecontrol the clutch/brake Necessary due to limited motor Necessary due to limited motor

controller outputscontroller outputs Simple and inexpensive solutionSimple and inexpensive solution

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Control Logic / Power Control Logic / Power ApplicationApplication

Four SwitchesFour Switches• Signals Feed Clutch / Signals Feed Clutch /

Brake Decision Logic Brake Decision Logic based on state of each based on state of each switchswitch

Logic output control Logic output control feeds gate of Power feeds gate of Power Switching Transistor to Switching Transistor to pass 230VAC to power pass 230VAC to power up either Clutch or up either Clutch or BrakeBrake

Emergency Stop Button Emergency Stop Button included as Safety included as Safety MeasureMeasure

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Resulting Motion ProfileResulting Motion Profile

0 5 10 150

5

10

15

20

25

30

35

40Sled Speed vs. Displacement (Concept)

Vel

ocity

(ft/s

ec)

Displacement (ft)

Clut

ch E

ngag

ed, B

rake

Off

Lanyard Pull Test

Clutch Disengaged, Brake Activated

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Mounting Block DescriptionMounting Block Description Shall ProvideShall Provide

• Power transmission between chain and Power transmission between chain and lanyardlanyard

• Mounting surface for lanyardMounting surface for lanyard• Mounting surface for additional Mounting surface for additional

componentscomponents Should be light weight and rigidShould be light weight and rigid

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Mounting Block Final Mounting Block Final DesignDesign

6061 aluminum6061 aluminum Connector mounting surface is Connector mounting surface is

perpendicular to plane of motionperpendicular to plane of motion 0.25 in fillets on edges to reduce stress 0.25 in fillets on edges to reduce stress

concentrationconcentration Weight Weight 5 lb (excess material removed) 5 lb (excess material removed) Mounting points for carriage, chain, and Mounting points for carriage, chain, and

receptaclereceptacle

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Linear Bearing – TrackLinear Bearing – Track Provide supporting surface for Provide supporting surface for

mounting block movementmounting block movement Light weightLight weight Withstand acceleration and velocity Withstand acceleration and velocity

of the testof the test

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Linear Bearing Final DesignLinear Bearing Final Design INA LFL 32 Linear BearingINA LFL 32 Linear Bearing Carriage Weight - 3.5 lbsCarriage Weight - 3.5 lbs Able to withstand nearly 5g’s Able to withstand nearly 5g’s

accelerationacceleration

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Mounting Block / Linear TrackMounting Block / Linear Track

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Chain and Sprocket Chain and Sprocket EnclosuresEnclosures

Protect outside environment if failure Protect outside environment if failure occursoccurs

Keep drive system components cleanKeep drive system components clean Help prevent human contactHelp prevent human contact Allow air flow to cool the motorAllow air flow to cool the motor Allow for easy access for routine Allow for easy access for routine

servicesservices

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Chain and Sprocket Chain and Sprocket Enclosures Final DesignEnclosures Final Design

13 ga. sheet metal13 ga. sheet metal 13 ga. expanded 13 ga. expanded

sheet metal on sheet metal on sidessides

Maintenance / Maintenance / Access door to Access door to motormotor

Removable panels Removable panels for full system for full system serviceservice

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Chain System FrameChain System Frame Provides mounting Provides mounting

locationslocations 2” X 2” X 0.125” 2” X 2” X 0.125”

6061 Aluminum6061 Aluminum Welded Welded

constructionconstruction Length determined Length determined

using basic using basic kinematic kinematic equationsequations

192” L x 36” H x 30” D

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Polyethylene U-ChannelPolyethylene U-Channel Purpose: Purpose:

• Support upper Support upper chainschains

Mounted via Mounted via aluminum right aluminum right angle bracketsangle brackets

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Ergonomic AnalysisErgonomic Analysis Test Table Height and WidthTest Table Height and Width

• 9595thth percentile male / 5 percentile male / 5thth percentile percentile femalefemale

Motor access accomplished via side Motor access accomplished via side door in test machine framedoor in test machine frame

NoiseNoise• Ear plugs may be necessaryEar plugs may be necessary

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Safety ConsiderationsSafety Considerations Track/sprocket/chain enclosuresTrack/sprocket/chain enclosures

• Prevent entanglementPrevent entanglement Mesh covering over the motorMesh covering over the motor

• Allows heat to dissipateAllows heat to dissipate Shock absorbersShock absorbers

• Prevents carriage contact with sprocketsPrevents carriage contact with sprockets

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ConclusionsConclusions MEETSMEETS and and EXCEEDSEXCEEDS Requirements Requirements

• Velocity (Velocity (38 ft/s MAX38 ft/s MAX))• Impulsive Pull force (Impulsive Pull force (334 lbs MAX334 lbs MAX))

Strong, Durable and Accurate (Strong, Durable and Accurate (2.9%)2.9%) Easily MaintainedEasily Maintained Variable Velocity ProfilesVariable Velocity Profiles Mechanical Components Totally EnclosedMechanical Components Totally Enclosed $9,000$9,000 Total Component Cost Total Component Cost

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Special Thanks to Amphenol Special Thanks to Amphenol Aerospace for their supportAerospace for their support

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Questions or Comments?

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Acceleration/DecelerationAcceleration/Deceleration

Table 1 Front Assembly Inertia Values

Component mg r Quantity Unit

Inertia Total Inertia

lb in lb-in-s2 lb-in-s2 Sprocket 7.20 4.96 3 0.22903 0.68709

Shaft 10.46 0.63 1 0.00529 0.00529 Total 0.69238

Table 1 Back Assembly Inertia Values




Shaft 10.46 0.63 1 0.00529 0.00529 Total 0.46335

Table 1 Motor Inertia Value




Shaft/Motor 10.46 0.63 1 0.00529 0.00529 Total 0.03589

taVV xif

xaVV xif 222

FrontBackMotorEquiv IIN

II

21

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AC Motor Torque CharacteristicsAC Motor Torque Characteristics

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Frame Stresses / DisplacementFrame Stresses / Displacement

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Baldor Induction SmartMotor - Baldor Induction SmartMotor - AccuracyAccuracy

MIL-DTL-38999 allows 30 ft/sec MIL-DTL-38999 allows 30 ft/sec 10% (10% (3 ft/sec)3 ft/sec) Accuracy = Accuracy = 20 RPM (provided by factory representative)20 RPM (provided by factory representative)

sec/87.0121sec/38.10

sec/38.102

911.9sec/09.2

sec/09.2sec

min30

20

ftinftin

ininrad

radREVradRPM

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Connections Block DiagramConnections Block Diagram

high speed lanyard release test fixture

Documents

drive system

control systemnecessary

rpmat upper system

integrated control board

past test position1

phase ac induction

aerospace markets

motor shaft