P14471 Vibration Testing Apparatus II Subsystems Design Review

10/29/2013

Brett Billings

Jacob Gardner

Nick Greco

Ron Jimbo

Claire Kobal

Ryan Selig

Ashley Waldron

Agenda System Design Selection

Subsystem Selection

Frame

Motor

Displacement Measurement

RPM Measurement

Display and Control System

Test Plan

Risk Analysis

BoM / Cost Estimate

Next Phase

System Design Selected

Vertically mounted motor with v-belt offset for maximum

torque and speed control

Dial gauge to confirm displacement and verticality

Encoder and VFD to read and control speed

LCD Display of RPM and time elapsed

Safety: belt guard, polycarbonate guards, E-stop

Multiple diameter conduits with dedicated flanges and collars

for quick change-overs

Spray paint to prevent rust

System Design

Selected

Frame Design

Frequency Analysis Vibration frequency:

33.3 Hz (2000 RPM)

Natural frequency of apparatus:

42.3 Hz

Maximum deflection

.853” (shown in red)

Structural Analysis of Cantilever

Maximum stress:

= 6897 PSI

Maximum deflection

= .046 inches

Overall System Analysis

Motor Selection

Maximum Load= 150 lbs

Torque Necessary= 1.68 ft-lbs

We will be running the motor at full load torque to allow for a longer life.

𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =𝑖𝑛𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑

𝑜𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑=

3500

2000= 1.75

Motor Continued

Total Cost: $472.00

Motor Performance Data:

Baldor M3545

V-Drive Selection All information was gathered from the Dodge catalog

For the given gear ratio of 1.72, Type A, 1-Groove

Driver Datum Diameter: 3.4”

Outer Diameter= 3.4”+.37”= Approx. 3.75” P/N 118190

Driven Datum Diameter: 6.2”

Outer Diameter= 6.2”+.37”= Approx. 6.55” P/N 118204

Driver Taper Lock Bushing (1210), .5” Shaft Diameter: Keyway P/N 119191

Driven Taper Lock Bushing (1610), 1” Shaft Diameter: Keyway P/N 117159

Distance from center shaft to center shaft using donated belt guard: 9.5”

P/N A33

Belt Life: 25,000 hours (714 testing cycles)

Cost of V-Drive

Driver:

Sheave: $10-20

Bushing: $10-20

Driven:

Sheave: $30-35

Bushing: $10-25

Belt: $10

Total: $70-110

Dial Gauge Selection

Digital Dial Gauge can

connect to final display

More reliable and less

expensive than a laser

$150

½” range

0.0005” resolution

Maintaining Displacement Clamping force:

Provided by 2 screws - ½’’-13

M = torque on screws

Screw vs. T-Block (u=.2)

210 M ft-1 (see Appendix)

Frictional force (prevents slipping): 2 possible locations:

Adjustment Base vs. Adjustment Slider (u=.8)

Adjustment Base vs. T-Block (u=.2 to .8)

Assume worst case, u=.2

42 M ft-1

Maximum force applied (causes slipping): 1.68 ft-lbs. (motor) at 1/32’’

645 lbs.

Required screw torque: Safety factor of 2

31 ft-lbs.

Control System

Encoder Selection: TRD-S100-VD

Inexpensive incremental (quadrature)

encoder

Capable of sending (depending on exact

model) 100-1024 pulses per revolution

Speed of motor can be determined based on

number of pulses received and time elapsed

Hardware allows for maximum of 6000 RPM

– well above 2000 RPM expected

Micro-Controller

Firsthand objective: proof of concept

TI Launchpad

Comes pre-equipped with on-board emulation and simple

outputs for ease of testing & debugging

Control procedure can be implemented using pseudo-inputs

and pseudo-outputs to prove feasibility of concept

In final design encoder sends signal to controller, which is

interpreted and fed in through VFD for feedback

After concept is proven a permanent microcontroller can be

selected to optimize system integration

Test Plan

Test Displacement

Tighten adjustment screws to proper torque

Measure displacement with dial gauge during setup

Validate 1/32” total displacement

Test Vibration Cycles

Measure RPM with encoder and display for feedback

Validate 2000 cycles/min

Test fittings

Do they fit the frame?

Test User Interface

Check connections

Ease of use

Safety Evaluation

Risk Analysis ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due

1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844 Poor design 3 2 6 Make it adjustable Brett DONE

1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844 Disp. changes during test 3 2 6Calculate torque required on bolts so

displacement won't slip.Brett DONE

2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844 Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE

2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844 RPM changes during test 3 2 6Design closed loop feedback and VFD

to adjust RPMRyan DONE

12 Frame falls apart Test fails, costly to fixVibration is same as natural

frequency3 2 6

Perform ANSYS Analysis, add supports

to change natural frequencyNick DONE

12 Frame falls apart Test fails, costly to fix Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE

12 Frame falls apart Test fails, costly to fix Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE

10 Can't mount all configurations typesCustomer is not able to test some

configurationsProject scope 2 2 4 Use current fixtures Claire DONE

15 Project deadline is not met

Customer is dissatisfied, Students

receive poor course grade, RIT's

reputation is negatively impacted

Materials are delivered late 2 2 4 Order before Christmas Nick 12/20/2013

18Unable to integrate measurement devices

with display

Machine is just as difficult to setup

and monitor as beforeLack of knowledge 2 2 4

Research integration requirements

and prepare LabView backupRyan 11/20/2013

19Can't get items (Motor, VFD, etc.) from

Eaton in available time

Need to purchase items instead,

increased cost of projectLead time is too long 2 2 4

Request items by specified date from

CCH and ask for delivery date. Have

backup supplier prepared.

Ron 11/20/2013

3 Motor burns out Costly to replace, test fails Motor burns out 3 1 3Calculate required torque and RPM,

select appropriate motorRon DONE

Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe

Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely

BoM & Costs

Item Cost Item Cost

Materials for Frame $700 Rust Protection $200

Materials for Conduits / Flange / Collar $250 Welder Fees $200 (est.)

Digital Dial Gauge $150 Electrician Fees $0

Motor $470 Shipping Costs (for testing) $200 (est.)

VFD $480 Upgraded displacement adjustment $50

Encoder $100 Polycarbonate Sheet ¼’’x36’’x24’’ $70

LCD Display $100 Belt Guard $0

Micro-controller & components $100 Electrical Lockout $40

Electrical Box $200 (est.) V-Drive $90

Total $3400

Next Phase

Questions for Cooper-Crouse Hinds

Electrical wiring done by students and checked by CCH?

Questions?

Appendix

More Motor Information

V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-pt.com/products/pt_components/belts/belts.html

Safety Checklist

Item Safety Item Yes No N/A Owner Due Date

1 Is lockout/tagout procedure posted?

2 Can all energy sources be locked out? (electrical, air, hydraulic, water, etc.)

3 Are all electrical devices labeled with voltage and power source?

4 Are all machine controls labeled?

5 Are all machine hazards adequate guarded to prevent bodily contact? (motion, heat, light, ejection, etc.)

6 Do machine interlocks/light curtains inhibit motion?

7 Are E-Stops located at all operator stations?

8 Are utilities routed to avoid trip hazards?

9 Have any potential waste materials been identified? Do they have a disposal procedure?

10 Is there adequate egress from area?

11 Is a fire extinguisher located within 75 ft?

12 Is there adequate access for all operations? (maintenance, setups, operation, etc.)

13 Is machine designed to minimize overhead and extended reaching, pulling, bending, and twisting?

14 Is all required training complete and documented? (LOTO, maintenance, setup, operation, etc.)

Functional Decomposition

Full Risk Analysis ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due

Poor design 3 2 6 Make it adjustable Brett DONE

Disp. changes during test 3 2 6 Calculate torque required on bolts so displacement won't slip. Brett DONE

Poor calibration 2 1 2 Define calibration procedure and schedule Jake MSDII

Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE

RPM changes during test 3 2 6 Design closed loop feedback and VFD to adjust RPM Ryan DONE

Belt slips 2 2 4 Use v-belt and belt guard (for oil drip) Ashley DONE

Motor inefficiencies 3 1 3 Accept Risk --- DONE

Belt is too loose 1 2 2 Design motor mount to be adjustable Ashley 11/20/2013

Frame misalignment 2 1 2 Write procedure to verify conduit is 100% vertical Claire 11/20/2013

3 Motor burns out Costly to replace, test fails Motor burns out 3 1 3 Calculate required torque and RPM, select appropriate motor Ron DONE

Crankshaft improperly lubricated 3 1 3 Define maintenance procedure and schedule Ron MSDII

Motor is too loud 2 1 2 Add motor enclosure, sound damping, hearing protection Brett MSDII

Vibration of frame 2 1 2 Add sound damping, add hearing protection Brett MSDII

Luminaire breaks and rattles 2 1 2 Accept Risk - test will be ended early --- DONE

Operators don't wear earplugs 1 2 2 Accept Risk - exposure duration is still low --- DONE

Fixed guard not in place 3 1 3 Place warning labels on apparatus Brett MSDII

Machine not properly guarded 3 1 3 Install polycarbonate guard and belt guard Brett MSDII

Energy source not isolated 3 2 3 Install location to lockout machine Brett MSDII

Lockout not observed 3 1 3 Accept Risk --- DONE

Button is broken 3 1 3 Define maintenance schedule Ryan MSDII

Electrical failure 3 1 3 Use certified electrician Ron MSDII

8 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6 Guard all pinch points Brett DONE

Setup requires awkward positioning 2 2 4 Design conduit to be assembled first, then attached all at once Claire DONE

Luminaire is too heavy 2 1 2 Specify use of lift assist or 2nd operator, Design for use Brett 11/20/2013

10 Can't mount all configurations typesCustomer is not able to test some

configurationsProject scope 2 2 4 Use current fixtures Claire DONE

11 Oil spill on motor connection Motor failure/smoke Leakage 1 2 2 Offset motor so oil can't drip on it Ashley DONE

Vibration is same as natural frequency 3 2 6 Perform ANSYS Analysis, add supports to change natural frequency Nick DONE

Improper construction 3 2 6 Use certified welder Nick MSDII

Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE

Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE

13 Project runs over budget

Customer is dissatisfied,

engineering requirements must be

sacrificed

Unforeseeable expenses 2 2 4 Proper budgeting/compare prices/buy standard sizes Nick Ongoing

14 Apparatus is larger than existing one Customer is dissatisfied New holes must be drilled in concrete floor 1 2 2 Accept Risk --- ---

Correction of mistakes 3 2 6 Participate in milestone design reviews ALL Ongoing

Delay in Tool Shop 2 2 4 Schedule machine time 1 week in advance with Tool Shop Ashley MSDII

Materials are delivered late 2 2 4 Order before Christmas Nick 12/20/2013

16 Electrical shock from apparatus Operator injury could occur Improper wiring 3 2 6 Use certified electrician Ron MSDII

17 RPM can't be measured accurately Apparatus doesn't meet UL844 Tachometer vibrates too much 3 1 3 Add damping Jake MSDII

18 Unable to integrate measurement devices with displayMachine is just as difficult to setup

and monitor as beforeLack of knowledge 2 2 4 Research integration requirements and prepare LabView backup Ryan 11/20/2013

19 Can't get items (Motor, VFD, etc.) from Eaton in available timeNeed to purchase items instead,

increased cost of projectLead time is too long 2 2 4

Request items by specified date from CCH and ask for delivery date. Have

backup supplier prepared.Ron 11/20/2013

Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe

Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely

Customer is dissatisfied, Students

receive poor course grade, RIT's

reputation is negatively impacted

Project deadline is not met15

Operator injury could occurApparatus is not ergonomically safe to setup9

12 Frame falls apart Test fails, costly to fix

Operator injury could occurMachine starts during maintenance6

Operator injury could occurEmergency stop doesn't work7

1

2

Machine is too loud4

Operator injury could occurMachine operates when moving parts exposed5

Hearing conservation or

engineering intervention is

required

Apparatus doesn't meet UL844Vibration is not 2000 cycles per min

Apparatus doesn't meet UL844Displacement is not equal to 1/32in

Architecture

Central System

Power supply Motor system

Sensors

Display/user

interface

Luminaire

connection

Crankshaft

connection

Safety features

Conduit Pipe Size Considerations

• Concept: each conduit size will

have its own:

• Flange

• Collar

• This concept allows for easier

usage by operator

• Plan:

• Provide the 1st and possibly

the 2nd most used size

conduit

• Provide the drawings/files

necessary for the fabrication

of the remaining conduits

Flange

Collar –

crankshaft

connection

Collar – set

screws

Conduit Verticality

Attempt to keep the conduit as vertical as possible

Based on conversations with an operator – verticality is not

very critical

Very basic method:

Place a vertical level in the same place every time and using the

adjustable crankshaft to make minor adjustments

Safety Features Fixed polycarbonate guards on drive system

Clear, light-weight

Excellent impact strength, ¼’’ thick

“Split” type belt guard

Left and right half for easy removal

Lock-out on electrical box for maintenance

http://www.eriecustomproducts.com/beltguards/

Adjustment Mechanism

Additional holes in connecting plate

Access to adjustment bolts

U-bolt to lock system in place during adjustment

Finer set screw

3x finer than current

8-32: ¼’’ turn ~ 1/128’’ displacement

Setup Improvements

New Connecting Plate

UL844 Vibration Test Standard

Maintaining

Displacement

Calculations

Maintaining

Displacement

Calculations

Maintaining

Displacement

Calculations

Design characteristics for VFD

HP : VFD must be rated for the appropriate HP.

Full Load Amps : Motors Full Load Amps must not exceed

VFD’s continuous amp load.

Voltage : number of phases and voltage must be matched as

well with the VFD.

Load Type: Constant vs. variable Torque during operation.

Programmability: programmable parameters of a VFD