P15661 Reciprocating Friction Tester Base Subsystem Systems Level Design Review

Team Roles Team Member Major Role Alexandra Woodward Industrial Engineering Project Manager, Customer Point of Contact Sean Cummings Mechanical Engineering Lead LabVIEW Engineering, Subsystem Design Ethan Hanson Lead Subsystem Design Engineer Tyler Nigolian Electrical Engineering Data Acquisition System Engineer, Facilitator Matt Lebowitz Electrical Component Engineer Project Guide: Gary Werth Customer: Dr. Iglesias Victoria P15661 - Systems Level Design Review 11/27/2018

Agenda Project Background & Deliverables Engineering Requirements & House of Quality Test Plan Functional Decomposition Systems Architecture Concept Development & Selection Engineering Analysis System Level Proposal Risk Assessment Project Plan Alexandra P15661 - Systems Level Design Review 11/27/2018

Project Background & Deliverables Current State Reciprocating friction testers are too expensive Dr. Iglesias only has a rotationally reciprocating friction tester Desired State Easy-to-use linearly reciprocating friction tester Used to test wear and friction characteristics of various materials under dry and lubricated conditions Project Deliverables Linearly reciprocating friction tester LabVIEW program Operation and maintenance manuals Constraints Budget Time Adheres to ASTM Standards Ethan P15661 - Systems Level Design Review 11/27/2018

Engineering Metrics P15661 - Systems Level Design Review 11/27/2018 Sean P15661 - Systems Level Design Review 11/27/2018

House of Quality Sean P15661 - Systems Level Design Review 11/27/2018

Test Plan Examples Ensure the base does not deform with 20N normal force and associated frictional forces. Customer provided 0.8 coefficient of friction. Use 10% overload margin and apply forces normal to and laterally to the sides of base. Verifying calculations for motor speed for given frequency and stroke Use of optical light sensor with markings on reciprocating base to verify frequency across several test conditions. Measuring cleanability of the specimen holder Time cleaning of holder using different viscosities of lubricant across several different users and compare data. Identify superior cleaning solutions and methods. Matt P15661 - Systems Level Design Review 11/27/2018

Functional Decomposition Ethan P15661 - Systems Level Design Review 11/27/2018

Functional Decomposition: Base Subsystem Secure specimen Place specimen Tighten clamping mechanism Clamp testbed Reciprocate base Start motor Actuate base Convert rotational to linear motion Set stroke Acquire data Run LabVIEW Input parameters Set frequency Input stroke Input weight Convert to normal force Set test duration Set temperature Start button Collect data Measure temperature Measure strain Convert to friction force Interface with armature subsystem Ethan P15661 - Systems Level Design Review 11/27/2018

System Architecture *All lengths are in mm Tyler *All lengths are in mm P15661 - Systems Level Design Review 11/27/2018

Interface with Armature Team Armature team will provide bolt hole pattern Base subsystem will be mounted and fixed to a predefined location on the foundation plate Distance from center of bolt hole pattern to center of specimen will be provided by Armature team Voltage output signal required from Armature team that represents friction force Sean P15661 - Systems Level Design Review 11/27/2018

Morph Chart Matt P15661 - Systems Level Design Review 11/27/2018

Engineering Analysis 𝑥 𝑡 = 𝑠 0 2 ∗sin⁡(𝜔𝑡) 𝑣 𝑡 = 𝑠 0 2 ∗𝜔∗cos⁡(𝜔𝑡) Ethan/Sean 𝑎 𝑡 = 𝑠 0 2 ∗ 𝜔 2 ∗−sin⁡(𝜔𝑡) P15661 - Systems Level Design Review 11/27/2018

Benchmarking: Rotary Motor Matt P15661 - Systems Level Design Review 11/27/2018

Benchmarking: Voice Coil Tyler P15661 - Systems Level Design Review 11/27/2018

Benchmarking: Rotary Encoder Tyler P15661 - Systems Level Design Review 11/27/2018

Benchmarking: 3-Jaw Chuck Tyler P15661 - Systems Level Design Review 11/27/2018

Concept Selection: Risk Assessment P15661 - Systems Level Design Review 11/27/2018

Pugh Chart – iteration 1 Sean

Pugh Chart – iteration 2 P15661 - Systems Level Design Review Tyler P15661 - Systems Level Design Review 11/27/2018

Morph Chart Ethan P15661 - Systems Level Design Review 11/27/2018

Proposed Design Voice coil 3-jaw chuck Bolt hole pattern Creates motion Translates motion Varies stroke 3-jaw chuck Holds specimen Bolt hole pattern Attach armature subsystem with base subsystem Removable platform In order to clean system Ethan

Alternative Design Rotary motor Scotch yoke 3-jaw chuck Creates motion Scotch yoke Translates motion 3-jaw chuck Holds specimen Bolt hole pattern Attach armature subsystem with base subsystem Removable platform In order to clean system Ethan P15661 - Systems Level Design Review 11/27/2018

Risk Assessment P15661 - Systems Level Design Review 11/27/2018 Alexandra P15661 - Systems Level Design Review 11/27/2018

Project Plan P15661 - Systems Level Design Review 11/27/2018 Alexandra Will also talk about lessons learned (plan for exam-heavy weeks) because we address it here P15661 - Systems Level Design Review 11/27/2018

Questions? P15661 - Systems Level Design Review 11/27/2018