p14471 vibration testing application - rochester...

P14471 Vibration Testing

Application

Team Introductions Name Role Major

Brett Billings Team Leader Industrial Engineer

Nick Greco Lead Engineer Mechanical Engineer

Ashley Waldron Scribe Mechanical Engineer

Claire Kobal EDGE Master Mechanical Engineer

Jacob Gardner Mechanical Engineer

Ron Jimbo Electrical Engineer

Ryan Selig Electrical Engineer

Agenda

Background

System Analysis

Alternatives considered

Selected system

Test Plan

Engineering Analysis

Next Phase

Problem Statement

Update company’s vibration test apparatus Meet UL 844 Standard

Vibration RPM

Displacement

Duration

Continue progress started by Team 13471

Done: the eccentric drive mechanism

Still needs:

Frame

Motor

Control system

Project Deliverables

Completed frame

Appropriate motor selection and implementation

Motor speed control alternatives

Visual display

Frequency of oscillation

Displacement

Documentation

User Manual

Maintenance Manual

Test data verifying the operation of the apparatus

Customers Needs Requirements Importance

Adherence to UL 844 standard 5

Apparatus is safe 5

Motor must be compatible with available voltage 5

Ability to test a range of luminaire weights 4

Long service life 4

Ability to test multiple configurations 3

Easy to use 3

Visually display test information/feedback to operator 3

Cost under $4,000 3

Easy to maintain 2

Similar dimensions to existing machine 1

Engineering Requirements Number Requirement

Raw

Score Units

Ideal

Measure 1 Displacement of luminaire 69 in 1/32

2 Vibration of luminaire 69 cycles/min 2000

3 Duration of vibration test 69 hours 35

4 Isolate motor from oil spills 45 Binary Yes

5 Maintenance Documentation 44 Survey (easy to follow) 80%

6 Mount pendant configuration 35 Binary Yes

7 Operation Documentation 33 Survey (easy to follow) 80%

8

Machine won't operate if crankshaft enclosure is

open 25 Binary Yes

9 Completely stop machine with Emergency Stop 25 seconds < 10

10 Maximum voltage of Motor 25 V AC 240

11 Minimize number of operators 21 people 2

12 Max weight of mounted luminaire 20 lbs > 150

13 Visually display settings and status of test 18 Binary Yes

14 Steps to set up 16 steps < 10

15 Setup Time 16 seconds < 120

16 Low Sound 15 dBA < 85

17 Minimize pinch points 15 Count < 3

18 Total materials cost 15 $ < 4,000

19 Mount stanchion configuration 7 Binary Yes

20 Mount yoke configuration 7 Binary Yes

21 Mount trunnion configuration 7 Binary Yes

22 Machine footprint 5 in2 < 34X48

Engineering Requirements:

The Design Drivers

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

0

10

20

30

40

50

60

70

80

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Cu

mu

lati

ve %

Weig

ht

of

Imp

ort

an

ce

Engineering Requirement

1 Displacement of luminaire

2 Vibration of luminaire

3 Duration of vibration test

4 Isolate motor from oil spills

5 Maintenance documentation

Top 5

Benchmarking Current Model Our Design

Displacement Mechanism Open Encased

Motor Mounting Below shaft Offset

Brake None Between shaft and motor

Display None Digital

Displacement measurement None +/- .5µm

Functional Decomposition

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

14Project deadline is not

met

Customer is dissatisfied,

Students receive poor course Correction of mistakes 3 2 6

Participate in milestone design

reviewsALL Ongoing

2Vibration is not 2000

cycles per min

Apparatus doesn't meet

UL844Crankshaft slipping 3 2 6 Evaluate previous teams design Ashley 10/7/2013

1Displacement is not

equal to 1/32in


UL844Mechanical Failure 3 2 6 Make it adjustable Jake 10/30/2013

7 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6Design guarding, enclosure,

and/or warning labelsBrett 10/30/2013

12 Over budgetCustomer is dissatisfied,

engineering requirements Unforeseeable expenses 2 2 4

Proper budgeting/compare

prices/buy standard sizesNick Ongoing

14Can't mount all

configurations types

Customer is not able to test

some configurationsProject scope 2 2 4 Use current fixtures Claire 10/7/2013


cycles per min


UL844Speed reducer slipping 2 2 4 Splash guard/maintenance Jake 10/30/2013

8Apparatus is not

ergonomically safe to Operator injury could occur

Setup requires awkward

positioning2 2 4

Evaluate setup with ergonomic

lifting equationsBrett 10/30/2013


met


Students receive poor course

Materials are delivered

late2 2 4 Order before Christmas Nick 12/20/2013


met


Students receive poor course Delay in Tool Shop 2 2 4

Schedule machine time 1 week

in advance with Tool ShopNick MSDII

11Apparatus can not

support luminaire Fixture falls, Test fails Poor material selection 3 1 3 Analysis and testing Ashley 10/30/2013

5Machine operates

when moving parts Operator injury could occur Interlocks fail 3 1 3 Use multiple interlocks as backup Ron 11/20/2013


cycles per min


UL844Motor inefficiencies 3 1 3 Accept Risk --- ---

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

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

Morph Chart Overview Attach Luminaire

Measure Vibration Displacement

Measure Vibration Frequency

Measure Elapsed Time

Display Feedback

Protect Operator - Hearing

Protect Operator - Moving Parts

Rust Protection

Move Crankshaft

Alternatives Considered: Design Element:

Evaluation Criteria Paint Electroplate Anode Stainless

Technical difficulty - - +

Cost - 0 -

Durability + 0 +

Maintenance + - +

Time required - + -

Total + +2 +1 +3

Total - -3 -2 -2

Net 0 -1 -1 +1

Rust Protection

DATUM

DATUM

Design Element:

Evaluation Criteria Screws Pins Socket Magnet

Setup time required + - +

Durability - 0 -

Cost - + -

Compatibility with luminaires 0 - -

Total + +1 +1 +1

Total - -2 -2 -3

Net 0 -1 -1 -2

Attach Luminaire

DATUM

DATUM

Design Element:

Evaluation Criteria Vertical Direct Speed Reducer Vertical w/ Belt Horiz. w/ 90°

Rotational capabilities - + -

Motor life + + +

Technical difficulty - - -

Safe to operate 0 - 0

Cost - + -

Maintenance - - -

Lubrication isolation + + +

Total + +2 +4 +2

Total - -4 -3 -4

Net 0 -2 +1 -2

DATUM

DATUM

Move Crankshaft

Consider Systems Level

Consider Systems Level

Design Element:

Evaluation Criteria Dial Gauge Laser Electrical Contact Magnify Ruler

Connection difficulty + - -

Cost - - 0


Accuracy + + -

Durability + 0 -

Dual purpose + + -

Total + +4 +2 +1

Total - -2 -3 -4

Net 0 +2 -1 -3

Measure Vibration

Displacement

DATUM

DATUM

Alternatives Considered:

Design Element:

Evaluation Criteria Stopwatch Software Egg Timer Hourglass

Technical difficulty - + +

Cost - 0 0

Durability + 0 -

Accuracy + - -

Expandability + - -

Total + +3 +1 +1

Total - -2 -2 -3

Net 0 +1 -1 -2

Measure Elapsed

Time

DATUM

DATUM

Design Element:

Evaluation Criteria Tachometer Laser Electrical Contact Pedometer

Cost - - +


Accuracy + 0 -

Connection difficulty + 0 -

Dual purpose + + 0

Durability + 0 0

Total + +4 +1 +2

Total - -2 -2 -2

Net 0 +2 -1 0

DATUM

DATUM

Measure Vibration

Frequency

Design Element:

Evaluation Criteria Seven Segment LED iPhone Dial

Expandability + + -

Cost - - +

Technical difficulty 0 - +

Ease of data relay 0 - -

Lifespan 0 - +

Display accuracy 0 0 -

Total + +1 +1 +3

Total - -1 -4 -3

Net 0 0 -3 0

Display Feedback

DATUM

DATUM


Design Element:

Evaluation Criteria Guard Plate Robot Enclosure Light Curtain

Safety + 0 -

Cost - - -

Interference with apparatus - - +

Technical difficulty - + -

Durability - 0 -

Dual purpose 0 + 0

Total + +1 +2 +1

Total - -4 -2 -4

Net 0 -3 0 -3

Protect Operator -

Moving Parts

DATUM

DATUM

Design Element:

Evaluation Criteria Damping Pads Earplugs Damp. Enclosure

Area of effect - 0

Cost + -

Safety 0 0

Interference with apparatus + -

Durability 0 0

Technical difficulty + -

Dual purpose 0 +

Total + +3 +1

Total - -1 -3

Net 0 +2 -2

DATUM

DATUM

Protect Operator -

Sound


Consider Systems Level Consider Systems Level

Attach Luminaire




Display Feedback



Rust Protection

Move Crankshaft

Morph Chart (Option 1) Screws

Vertical Motor

with Belt

Laser

Laser

Software

LED Screen

Ear Plugs

Belt Guard

+ Guard Plate

Electroplating

Attach Luminaire




Display Feedback



Rust Protection

Move Crankshaft

Morph Chart (Option 2)

Screws

Vertical Motor

with Speed Reducer

Laser

Laser

Software

LED Screen

Ear Plugs

Guard Plate

Spray Paint

Attach Luminaire




Display Feedback



Rust Protection

Move Crankshaft

Morph Chart (Option 3)

Screws

Horizontal Motor with

Flexible, Speed

Reducing Coupling

Laser

Laser

Software

LED Screen

Enclosure

Enclosure

Spray Paint

Option 1 Option 2 Option 3 Design Element

Screws Screws Screws Attach Luminaire

Vertical Motor with Belt Vertical Motor with Speed Reducer Horizontal Motor with 90° Coupler Move Crankshaft

Laser Laser Laser Measure Vibration Displacement

Laser Laser Laser Measure Vibration Frequency

Software Software Software Measure Elapsed Time

LED LED LED Display Feedback

Ear Plugs Ear Plugs Enclosure Protect Operator - Sound

Guard Plate + Belt Guard Guard Plate Enclosure Protect Operator - Moving Parts

Electroplate Paint Paint Rust Protection

Evaulation Criteria Option 1 Option 2 Option 3Time required + -Cost efficient 0 -Safe to operate + +Easy to setup 0 -Technical difficulty + 0Maintenance required - -Range of luminaires 0 -Appearance - 0Expandability 0 -Accuracy 0 0

Total + +3 +1Total - -2 -6

Net +1 -5

DATUM

System Pugh Chart

Why?

Paint

Selected Concept

Risk Assessment of Selected

Concept

ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due

15 Laser vibratesUnable to get accurate

displacement and frequencyNot properly damped 3 1 3

Attach laser to wall to avoid

vibration of machineJake MSDII

16Laser isn't compatible

with display

Can't get feedback for

displacement and frequency

Software and Feedback

problems2 2 4

Look at software requirements

and compatibilityRon 10/30/2013

Transportation damage 2 1 2Look at other options or

possible solutionsNick 10/30/2013

Scratches 2 1 2Look at other options or

possible solutionsNick 10/30/2013

18 Belt is too lose Vibration frequency too low Motor positioning 1 2 2 Make motor mount adjustable Ashley 10/30/2013

19Operators don't wear

earplugsHearing loss

Absence of hearing

protection1 2 2

Accept Risk - exposure duration

is still low--- ---

20 Motor is too loud Hearing lossEarplugs aren't enough

alone2 2 4

Buy motor enclosure if

necessaryBrett MSDII



Electroplating is

damagedMachine rusts17

Architecture

Central System

Power supply Motor system

Sensors

Display/user

interface

Luminaire

connection

Crankshaft

connection

Safety

features

Test Plan

Test Displacement

Validate the 1/32” total displacement

Test Vibration Cycles

Validate 2000 cycles/min

Test fittings

Do they fit the frame?

Test User Interface

Check connections

Ease of use

Safety Evaluation

Engineering Analysis: Frame

Analysis

Modeling frame in ANSYS Workbench

Using Modal Analysis to determine Natural

Frequency

Next, stress and fatigue analyses will be

performed on frame

Goal: 1. Prevent resonance in the frame

2. Prevent material failure

3. Prevent fatigue at connections

Engineering Analysis: Motor A v-belt speed reducing system was selected because of its

ability to provide the torque and speed necessary to run the machine at the standard and because of cost.

A direct coupling would have needed a 3500 RPM motor to run at less than 60% speed for 35 hrs at a time. This just isn’t possible with most motors.

Most speed reducing apparatuses are used to drastically increase torque output and don’t provide the speed ratio needed to run the crankshaft at 2000 RPM. They are also much more expensive than the belt system.

Concept: Because of an increase in the

radius, the driven pulley will be able to

rotate at 2000 RPM while the driver pulley

rotates at 3500 RPM when the proper ratio

of radii is selected.

Engineering Analysis: Control

System

Open Loop

System

Closed Loop

System

Engineering Analysis: Open Loop

Control System

Two component system:

User input

Motor speed control

Multiple methods to control speed output:

Vary input voltage to the motor

Alter frequency of input signal to the motor

Change the number of stator poles

Engineering Analysis: Closed Loop

Control System

Cycles per minute directly proportional to RPM

Three core components required for control:

Vibration speed sensor

Motor speed correction

Motor speed controller

Laser distance sensor to simultaneously measure

vibration speed and displacement

Variable-Frequency Drive (VFD) to adjust speed

Microcontroller to accept sensor output measurement

and feed corrected motor speed into VFD

Digital display for reading back measurements

Engineering Analysis: Closed Loop

Feedback

Laser Feedback System

Accuracy & precision on order of microns

Measurement frequency on order of kilohertz

Line of sight coincident with linear motion

Accurately sense each 1/32" displacement

Two consecutive changes in distance = 1 cycle

Analog output to feed into corrective circuit

Engineering Analysis: Control

System Comparison

Open Loop System

Requires user input to adjust motor speed

Does not self correct with changing loads

Does not require a feedback system

Simple design to implement

Closed Loop System

Self correcting (no user input required)

Higher design budget

Integrates measuring devices with control system

Engineering Analysis: Sound

L = dBA Sound Level

T = 8 hour exposure limit

C = actual exposure hours

Dosage Calculation: D = 100 * (C1/T1 + C2/T2 + C3/T3 +…)

D > 50% requires hearing protection

D > 80% requires engineering intervention

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736

http://www.industrialnoisecontrol.com/comparative-noise-examples.htm

http://www.coopersafety.com/noisereduction.aspx

Maximum 8 Hour Exposure:

dbA hours Comparison

40 8192 Library

50 2048 Conversation at home

60 512 Conversation at restaurant

70 128 Radio or TV

80 32 Average Factory

85 16 Hearing protection required

90 8 Blender

100 2 Motorcycle

110 0.5 Live Rock Music = Pain Threshold

120 0.125 Thunderclap

130 0.03125

140 0.0078125

150 0.001953125 Jet Take-Off (25m) = Eardrum Rupture

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736






http://www.coopersafety.com/noisereduction.aspx

Engineering Analysis: Machine Guarding General Industry (29 CFR 1910)

1910.211(d)(44)

"Pinch point" means any point other than the

point of operation at which it is possible for a

part of the body to be caught between the

moving parts of a press or auxiliary

equipment, or between moving and stationary

parts of a press or auxiliary equipment or

between the material and moving part or

parts of the press or auxiliary equipment.

1910.212(a)(1)

Types of guarding. One or more methods of machine guarding shall be

provided to protect the operator and other employees in the machine area

from hazards such as those created by point of operation, ingoing nip points,

rotating parts, flying chips and sparks. Examples of guarding methods are-

barrier guards, two-hand tripping devices, electronic safety devices, etc.

Plus specifics for Electrical Markings, Lubrication Access, Belts, and more

https://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=1910

https://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1910_0212&src_anchor_name=1910.212(a)(1)



Engineering Analysis: Costs

Category Cost

Raw Materials $850

Motor $900

Belt-Drive System $100

Control system $1,000

Display $250

System to calibrate

displacement $300

Rust Prevention $300

Total $3,700

Schedule for Next Phase

Questions?

Appendix /Reference Information

Laser Sensor Long Range/High Accuracy

Sensor LK-G152/G157 Series

Range: 150 +/- 40mm Accuracy: +/-0.05%

Sensor Speed: 50kHz Repeatability: 0.5µm

Sources http://www.keyence.com/products/me

asure/laser-1d/lk-g3000/applications/application-04.jsp

http://www.ia.omron.com/products/category/sensors/displacement-sensors_measurement-sensors/index.html

http://www.keyence.com/products/measure/laser-1d/lk-g3000/applications/application-04.jsp
















More Motor Information

V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-

pt.com/products/pt_components/belts/belts.html

http://www.dodge-pt.com/products/pt_components/belts/belts.html




Design Element:

Evaluation Criteria Brake Pads AC Clutch Dynamic Spring

Time to stop 0 0 0

Durability + + +

Cost - - -

Technical difficulty + + -

Maintenance + + 0

Total + +3 +3 +1

Total - -1 -1 -2

Net 0 +2 +2 -1

Braking System

DATUM

DATUM

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

Mechanical Failure 3 2 6 Make it adjustable Jake 10/30/2013

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

Speed reducer slipping 2 2 4 Splash guard/maintenance Jake 10/30/2013

Frame misalignment 2 1 2 Verify conduit is 100% vertical Claire 10/30/2013

Motor inefficiencies 3 1 3 Accept Risk --- ---

Crankshaft slipping 3 2 6 Evaluate previous teams design Ashley 10/7/2013

Frame fall apart 3 1 3 Use certified welder, test and adjust natural frequency Ashley MSDII

Motor burns out 3 1 3 Run at full speed/cool it Ryan MSDII

Motor is too loud 2 1 2 Add motor enclosure, add sound dampening Brett MSDII

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

Luminaire breaks 2 1 2 Accept Risk --- ---

Crankshaft improperly

lubricated3 1 3 Define maintenance procedure and schedule Ryan MSDII

Operator injury could occur Interlocks fail 3 1 3 Use multiple interlocks as backup Ron 11/20/2013

Operator injury could occur Machine not properly guarded 3 1 3 Perform safety inspection prior to customer delivery Brett MSDII

Operator injury could occur Safety features bypassed 3 1 3 Place warning labels on apparatus Brett MSDII

Button is broken 3 1 3 Define maintenance schedule Ron MSDII

Electrical failure 3 1 3 Define maintenance schedule Ron MSDII

7 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6 Design guarding, enclosure, and/or warning labels Brett 10/30/2013

Luminaire is too heavy 2 1 2 Specify use of lift assist or 2nd operator, Design for use Brett 10/30/2013

Setup requires awkward

positioning2 2 4 Evaluate setup with ergonomic lifting equations Brett 10/30/2013

Fixture doesn't work with frame 1 1 1 Change frame and/or fixture design Claire MSDII

Project scope 2 2 4 Use current fixtures Claire 10/7/2013

10 Oil spill on motor connection Motor failure/smoke Leakage 1 2 2 Offset motor/isolate connection Ryan 10/7/2013

11 Apparatus can not support luminaire weight Fixture falls, Test fails Poor material selection 3 1 3 Analysis and testing Ashley 10/30/2013

12 Over budgetCustomer is dissatisfied, engineering

requirements must be sacrificedUnforeseeable expenses 2 2 4 Proper budgeting/compare prices/buy standard sizes Nick Ongoing

13 Apparatus is larger than existing one Customer is dissatisfiedNew holes must be drilled in

concrete floor1 2 2 Accept Risk --- ---

Poor planning 2 1 2 Maintain accurate project plan and adjust as needed Brett Ongoing

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

Member doesn't finish assigned

work2 1 2 Refer to Norms and Values - seek help or adjust workload ALL Ongoing

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 Nick MSDII

15 Laser vibratesUnable to get accurate displacement

and frequencyNot properly damped 3 1 3 Attach laser to wall to avoid vibration of machine Jake MSDII

16 Laser isn't compatible with displayCan't get feedback for displacement

and frequency

Software and Feedback

problems2 2 4 Look at software requirements and compatibility Ron 10/30/2013

Transportation damage 2 1 2 Look at other options or possible solutions Nick 10/30/2013

Scratches 2 1 2 Look at other options or possible solutions Nick 10/30/2013

18 Belt is too lose Vibration frequency too low Motor positioning 1 2 2 Make motor mount adjustable Ashley 10/30/2013

19 Operators don't wear earplugs Hearing loss Absence of hearing protection 1 2 2 Accept Risk - exposure duration is still low --- ---

20 Motor is too loud Hearing loss Earplugs aren't enough alone 2 2 4 Buy motor enclosure if necessary Brett MSDII



Electroplating is damaged Machine rusts17

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

configurations

14 Project deadline is not met

Customer is dissatisfied, Students

receive poor course grade, RIT's

reputation is negatively impacted

8 Apparatus is not ergonomically safe to setup Operator injury could occur

3 Test duration does not reach 35 hours Apparatus doesn't meet UL844

4 Machine is too loudHearing conservation or engineering

intervention is required

5 Machine operates when moving parts exposed

6 Emergency stop doesn't work Operator injury could occur

1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844

2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844

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.)

p14471 vibration testing application - rochester...

Documents