Systems Design Review

P14471 Vibration Testing Apparatus IIDetailed Design Review12/10/2013Brett BillingsJacob Gardner Nick Greco Ron JimboClaire KobalRyan SeligAshley Waldron1Brett1AgendaProject SummarySelected DesignPreliminary AnalysisFrameMotorElectrical / Control SystemSafetyImprovements from P13471Test PlanBOMProject PlanConcerns/IssuesAppendix

2Brett2Project Summary3Brett3Problem StatementUpdate companys vibration test apparatusMeet UL 844 StandardContinue progress started by Team 13471Done: the eccentric drive mechanism Still needs:FrameMotorControl system

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5House of QualityEngineering MetricsCustomer RequirementsCustomer WeightsDisplacement of luminaireVibration of luminaireDuration of vibration testLow soundMachine won't operate if moving parts are exposed Completely stop machine with Emergency StopMinimize pinch pointsMinimize number of operatorsVoltage of motorMount pendant configurationMount stanchion configurationMount yoke configurationMount trunnion configurationVisually display settings and status of testOperation documentationSteps required for Set-upIsolate motor from oil spillsMaintenance documentationMax weight of mounted luminaireTotal materials costTime to Set upMachine footprintAdherence to UL844 testing standard5555Apparatus is safe5355331Motor must be compatible with available voltage5533Ability to test multiple configurations35555111Easy to use3513313Easy to maintain23153Visually display test information/feedback to operator333351111Ability to test a range of luminaire weights455551115Cost under $400035Long service life411531Similar dimensions to existing machine15Technical Targets (Specifications)1/32 in.2000 cycles/min35 hours< 85 dBAyes< 10 seconds< 3 2< 240 V ACYesYesYesYesYes80% via survey (easy to follow)< 10 stepsYes80% via survey (easy to follow)> 150 lbs< $4000< 120 seconds< 34X48 in2Raw score6969691525251521253577718331645442015165Relative Weight11%11%11%2%4%4%2%3%4%6%1%1%1%3%5%3%7%7%3%2%3%1%6Crux of MSDI6Engineering RequirementsNumberRequirementRaw ScoreUnitsIdeal Measure1Displacement of luminaire69in1/322Vibration of luminaire69cycles/min20003Duration of vibration test69hours354Isolate motor from oil spills45BinaryYes5Maintenance Documentation44Survey (easy to follow)80%6Mount pendant configuration35BinaryYes7Operation Documentation33Survey (easy to follow)80%8Machine won't operate if crankshaft enclosure is open25BinaryYes9Completely stop machine with Emergency Stop25seconds< 1010Maximum voltage of Motor25V AC24011Minimize number of operators21people212Max weight of mounted luminaire20lbs> 15013Visually display settings and status of test18BinaryYes14Steps to set up16steps< 1015Setup Time16seconds< 12016Low Sound15dBA< 85 17Minimize pinch points15Count< 318Total materials cost15$< 4,00019Mount stanchion configuration7BinaryYes20Mount yoke configuration7BinaryYes21Mount trunnion configuration7BinaryYes22Machine footprint5in2< 34X4877Selected Design8Selected DesignInterchangeable ConduitsMotor with V-beltVFDDigital Dial GaugeEncoderLCD, MicrocontrollerPolycarbonate GuardsE-stopPaint for Rust Protection

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Brett9Preliminary Analysis10

Maintaining DisplacementER #1: Displacement must be 1/32Clamping force:Provided by 2 x A574 screws - 5/8-11 M = torque on screws= 168.9 M ft-1Frictional force:2 possible locations:= 33.8 M ft-1 (worst case)Maximum force applied:1.68 ft-lbs. (motor) at 1/32= 645 lbs.Required screw torque:= 38 ft-lbs. (Safety factor of 2)Max recommended A574 torque = 220 ft-lbs*Detailed calculations in Appendix1211Engineering Analysis: ForcesER # 12 Maximum Luminaire WeightForce on collar/conduit = 1641.3N (368.979lbf)Force from connecting rod = 2822.68N (634.564lbf)Calculated friction forcesWorst case = 297.68N (66.921 lbf)Torque on connecting rod = 2.13667Nm (1.575 lbft)Torque on block = 2.399Nm (1.769 lb ft)Torque on crankshaft = 2.399Nm(1.769 lb ft)*Refer to Appendix12Should probably go by the motor stuff12Engineering Analysis: FatigueConduita =15456.9psi so m =0psia < 0.5*0Therefore Infinite LifeFactor of Safetyar =15,5229psi < 0.5*0Infinite life

C-ChannelMax stress = 7181.27psi = aa < 0.5*0Infinite Life

Refer to appendix0 =35,000psi; u =58,000psi

13Frame 13Engineering Analysis: Fatigue/BucklingExtension Rod:Buckling:Pcr = 4576.61lbf368.9 lbf < 4576.61lbfNo bucklingFatigue:a =469.698psia < 0.5*0Infinite Life

Threaded ConnectorBuckling:Pcr = 13800.8lbf368.9 lbf < 13800.8lbfNo bucklingFatigue:a =2855.26psia < 0.5*0Infinite Life

Refer to appendix

0 =35,000psi; u =58,000psi

14frame14Frame15Brett15Final Frame Design

16Frame Halve Views

Front and Back Views of Full AssemblyFront and Back Views of Crankshaft17Analysis Overview18Frame Analysis at 0.015625 in. Displacement

19Frame Analysis at 0.0144 in. Displacement

20Motor21Motor Selection

ER #2 Vibration of LuminaireER #10 Max Motor VoltageER #12 Maximum Luminaire Weight2222Motor Performance Data:Baldor M3545

Updated cost from Volland Electric Equipment Corp: $237.51*This is a saving of almost $235.00 from the original estimateWe chose a 1 HP motor with a full-load torque of 1.5 LB-FT23V-Drive SelectionAll information was gathered from the Dodge catalogFor the given gear ratio of 1.75, Type A, 1-Groove

Driver Datum Diameter: 3.4 Outer Diameter= 3.4+.37= Approx. 3.75 Driven Datum Diameter: 6.2 Outer Diameter= 6.2+.37= Approx. 6.55

Driver Taper Lock Bushing (1210), .5 Shaft DiameterDriven Taper Lock Bushing (1610), 1 Shaft Diameter

Distance from center shaft to center shaft using donated belt guard: 9.5*Unable to locate actual Dodge belt. A very similar belt will be purchased through AutoZone.ER #2 Vibration of LuminaireER #4 Isolate Motor from Oil Spills24Motor Mount to Frame

25Encoder Placement The current shaft has to be machined down to a smaller size at the very end to add a coupling for the encoder.

*Encoder to be discussed further in electrical systems26Electrical / Control System27Component Placement at CCH28

Ask CCH where they would like the display to be?28Flow Diagram

29Power Connection Schematic

30Power SupplyVGS-25-525 Watt 5V AC-DC converter5A max delivered current 3.1 x 1.11 x 2.03 inches

*Refer to appendix for power calculations31Encoder TRD-N1024-RZWDER #2 Vibration of LuminaireER #13 Display System StatusResolution: 1024 Pulses Per Revolution (PPR)Max frequency: 100 kHzMax RPM detection: 100 kHz / 1024 PPR * 60 = 5859 RPM32

33ER # 10 Max voltage of MotorEnclosureAMP1426CCLFPolycarbonate enclosure with metal snap latch14 x 12 x 6 inches

34Control System Pseudo CodeInitial delay to allow sufficient startup time for motorRepeat (loop) the following until Timer_A value reads 35 hrsWait for appropriate delay time to avoid overworking MCU CPUUse Timer_A capture from pin 11 of MCU to retrieve digital encoder signalRead and store timer value upon rising edge of signal into var "A"Read and store timer value upon next rising edge into var "B"Period = B - AFrequency = 1 / PeriodResolution = 1024Speed of vibration in RPM = Frequency / Resolution * 60; Dimensions = (rev / min) = (pulses/sec) / (pulses/rev) * (60 sec/min)Send RPM and elapsed time (also from Timer_A) to LCD display via pinoutsif RPM exists above safety threshold (2000 RPM + threshold)exit loop with error code set highUpdate VFD with new RPM information to step up or down accordinglySend signal to alert VFD to bring motor to a complete stopif error code set highWrite "Test Ended Abruptly: High RPM" to LCD displayelseWrite "Test Completed Successfully" to LCD display35Launchpad and Display EncasingER # 3 Duration of Vibration TestER #13 Display System Status

36Safety37Brett37Polycarbonate GuardsER # 8 Crankshaft Enclosure is GuardedER # 17 Minimize Pinch PointsTop and rear guardClear, Polycarbonate Excellent impact resistanceWarning labels

Replace existing top guardMove mounting holes away from edgeIncreases strength, but slight overhang

Modify rear guardAdd access hole to decrease setup time38

Belt Guard

ER # 17 Minimize Pinch PointsProtects operator from 2000 RPM beltDonatedModifications required:Convert to split typeWeld existing halves togetherCut guard in half in other directionChange existing mounting brackets

39Lock Out, E-stopER # 8 Crankshaft Enclosure is GuardedLock out during maintenanceOn electrical box, after power is isolatedLock out procedure to be written in MSDIIER # 9 Completely Stop Machine with E-StopE-stopLocated on machineManually cuts power immediately

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Engineering Analysis: Sound ER # 16 Low SoundHearing Protection / Engineering InterventionTo be determined in MSD II with Test PlanBased on sound dosageDosage Calculation:L = dBA Sound LevelT = 8 hour exposure limitC = actual exposure hoursD = 100 * (C1/T1 + C2/T2 + C3/T3 +)D > 50% requires hearing protectionD > 80% requires engineering intervention

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736http://www.industrialnoisecontrol.com/comparative-noise-examples.htmhttp://www.coopersafety.com/noisereduction.aspx

41B41Safety ChecklistER # 8 Machine GuardingER # 9 Emergency StopER # 16 Low Sound

42Improvements from P1347143Brett43Setup ImprovementsER # 11 Minimize number of operatorsER # 14 Steps to set upER # 15 Setup time

44Explain this is a bitch44Setup Improvements

Current setup procedure:Measure displacement with dial gaugeLockout machineRemove top guard (8 screws)Remove rear guard (4 screws)Remove collars (2)Remove connecting plateLoosen locking bolts (2)Adjust set screwPerform 2-7 in reverseRepeat 1-9 until 1/32 reached ~ 5xApproximately 60 minutes to setup

10 minutes2x45# steps: 10 =>45Setup ImprovementsDisplacement adjustment without removing rear guard, collars, or connecting plateAlso, U-bolt prevents block from rotating

Changes required:Add 2 access holes to connecting plateAdd 4 holes total for u-boltAdd 1 access hole to rear guardDoesnt impact safety, .2

46Put in time saved46Setup Improvements

Finer set screwBefore:11 threads per inch1 turn = 290% of displacement!After:100 threads per inch1 turn = 33% of displacement

Changes required:Machine new set screw plateRequires threaded bushing for set screw47Why are we doing this?47Set Up ImprovementsSet screwAccount for excess space between conduit and collarFlange Dimensioned to be placed in same location every timeBlocks on the C channel

FlangeCollar crankshaft connectionCollar set screws

ER # 11 Minimize number of operatorsER # 6, 19-21 Mount 4 configuration typesER # 13, 14 Setup time, number of steps 4848Test Plan49Brett49Test PlanDisplacement TestDate Completed: ______________________Performed By: _______________________________

Engr. Spec. #Specification (description)Unit of MeasureMarginal ValueToleranceComments/Status1The total displacement of the Luminaire must be 1/32"inches 1/32+/- 2%1,2The adjustment screws must be tightened to the proper torqueft-lbs>=38-50Test PlanVibration TestDate Completed: ______________________Performed By: _______________________________

Engr. Spec. #Specification (description)Unit of MeasureMarginal ValueToleranceComments/Status2Vibration of Luminaire must be 2000 rpmrpm2000+/- 2%13Vibration measurement is sent back to the displaybinaryYes-12Apparatus will sufficiently vibrate a large weight luminairelb>=150-3Vibrates for 35 hourshours>=35-10Motor power is sufficient to fully run the testhp>=1-51Test PlanDimensional TestDate Completed: ______________________Performed By: _______________________________

Engr. Spec. #Specification (description)Unit of MeasureMarginal ValueComments/Status11Conduits fit the framebinaryYes22Footprint difference compared to old apparatusft^2=804Motor is isolated from oil spillsbinaryYes5Survey given says apparatus is easy to maintain%>8054Test PlanSafety TestDate Completed: ______________________Performed By: _______________________________

Engr. Spec. #Specification (description)Unit of MeasureMarginal ValueComments/Status8Machine will not run during LOTObinaryYes17Pinch points are covered# exposed016Noise is below 85 decibelsdB