Detailed Design Presentation Loading, Measurement, Control, and Test of a Journal Bearing Test Platform Kris Kidder | John Dolan | Shay Stanistreet | Anthony Miuccio

Agenda Team Vision Preliminary MSD II Timeline Load Cell Parameters (as discussed prior) Detailed Design Components Bill of Materials Feasibility Analysis Oil Flow Characteristics Test Plans Updated Risk Assessment Plans to round out MSD I

Team Vision A concept for the pre-loaded spring assembly and loading subsystem will be modelled and simulated under operating conditions. Necessary parts will be identified and a preliminary bill of materials will display expected cost of the systems to be built. If time allows, parts will be purchased and the subsystems will be implemented, with the expectation that preliminary tests will be run to get a feel for real-world results and feasibility.

Timeline

Current Load Cell Parameters Potential problems can arise from load cell not taking data quickly enough to be used for analysis (slower than 25 Hz) Load cell measurement rate is not available in any website/manual Leads us to believe that the actual trouble is in the DPM-3 Signal Monitors, not the load cell. Signal Monitors refresh at 3 times per second according to the documentation 60 Hz is a possibility, will take more time to fully understand signal monitors Other Relevant Parameters Max Load: 2000 lbs. Calibration: Leveled out to exactly 0.00 when weight was added and then removed, shows little to no signs of fluctuation. Further tests will be completed to show higher levels of accuracy in calibration.

Detailed Design - EMA Arm Redesign

Detailed Design - EMA Arm

Detailed Design - Load Cell Plate

Detailed Design - Anti-backlash System

Detailed Design - Sliding Plate

Detailed Design - Sliding Plate

Detailed Design - Cont.

Detailed Design - Backing Plate

Current Bill of Materials

Lead Screw Feasibility Calculations done in MATLAB to remove human error and allow for iterative solution making Equations used to determine torque required to turn a preloaded spring system like this one. Found very reasonable torques, on the order of under 10 ft-lbs. About 5.5 ft-lbs to raise lead screw (analytical) Constructed quick experiment to verify findings, findings correlated to expectations

Spring Fatigue Capability Calculations done in MATLAB to remove human error and allow for iterative solution making Answers provided match online calculator website for reinforcement Used soderberg because it outputs the most conservative estimate With 5 Factors of Safety, our spring will show very minimal fatigue signs.

Oil Flow 2 new journals ¼” Step reduction ~0.6 - 1.3 gallons/minute How much is too much clearance? Bending of a thinner shaft due to heavy load Excessive eccentricity leads to instability

Test Plans - Fabrication Fabrication of Related Parts for Testing Journal Bearings Already have journal bearings with similar characteristics Will be making modifications to flow hole and groove width to observe oil flow changes Journals Will be designing and procuring two additional shafts to be used in oil flow testing Due to necessary tolerancing, will likely need to be outsourced 3 total shafts will allow us to check linearity Clearance measurement is most critical to oil flow, so that’ll be the prime concern

Test Plans - Procedure Run current setup with full sensing capability to collect pertinent data Collected data will include vibrations, oil flow, housing displacement, and oil temperature. Remove current journal, replace with first fabricated journal, run same profile and obtain similar data. Journal Shaft Change SOP currently in progress and on EDGE Remove second journal, replace with third, collect similar data. Remove bearing, replace with modified bearing. (Repeat steps 3, 4, and 5 until all data has been collected & logged. Utilize data overlays to see the effects of changing the clearance, maximizing displacements, etc. Provide an analytical comparison to see how well our data matches our current expectations.

Risk Assessment

Risk Assessment Cont.

Plans for Next Phase Finalize Detailed Design Plan Begin purchasing of components Finalize Journal Shaft Change SOP Finalize MSD II Timeline

Any Questions?