Design Review UL Vibration Test Apparatus May 13, :30PM Est.

Project & Team Information Project: UL Vibration Test Apparatus Project Number: Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries) Customer Contacts: Joe Manahan Ed Leubner RIT Faculty Guide: Dr. Benjamin Varela Project Team:Walter Bergstrom Sean Coots Spencer Crandell Mark Ellison February 21, 2013UL Vibration Test Apparatus2

Presentation Overview 1)Detailed Design Overview 2)Final Design 3)Testing 4)Improvements & Future Work 5)Budget Appendix: UL Test Stand and Project Background February 21, 2013UL Vibration Test Apparatus3

Design Review Discussion Discussed Design: – Adjustment Mechanism – Crank Arm Key Action Items: – Adjustment Mechanism Strength – Crank Arm Actions Taken: – Crank Arm to be a single piece February 21, 2013UL Vibration Test Apparatus4

Final Design February 21, 2013UL Vibration Test Apparatus5

Final Design (video) February 21, 2013UL Vibration Test Apparatus6

Adjustment Mechanism February 21, 2013UL Vibration Test Apparatus7 Allows for adjustment in eccentricity in order to account for tolerance stack-ups and wear Set screw used for fine adjustment Two socket head cap screws for locking the system in place Nord Lock washers to prevent loosening of adjustment mechanism

5/8-11 Nord Lock Washers Rated for maximum locking at 197 ft-lbs with 20900lb clamping force Allows for reusable hardware February 21, 2013UL Vibration Test Apparatus8 pelicanparts.com

Pushrod Connection February 21, 2013UL Vibration Test Apparatus9 Extension rod is threaded into both the pushrod and pipe collar to allow for adjustment Pushrod position can vary in shaft supports to allow for additional adjustment Pushrod is robust and will not deflect during operation Nuts used to lock threaded portion at the end of the pushrod in place

Testing Displacement testing completed on the system As motor implementation is not within the scope of this project, frequency was not validated Test frame rigidly fastened to testing table – Angle steel welded into frame shape – Aluminum cantilever with flange connection Dial indicators used in two locations to verify the displacement across the system – Contacting linear slider box – Contacting collar at connection to vertical conduit February 21, 2013UL Vibration Test Apparatus10

Testing February 21, 2013UL Vibration Test Apparatus11 Dial Indicator Contacting Slider Box Dial Indicator Contacting Conduit Collar

Test 1: Verify zero-displacement – Centering dowels mated between adjustment mechanism and rotating disk to signify zero-displacement – Dial indicators showed zero displacement for the system Test 2: Verify 3 displacement values – 0.016”: found that dial indicators give very low value for displacement ( ”) – 0.100”: again found that measured values were lower than expected ( ”) – 0.250”: met expected displacement value within ± 0.010” Test 3: Verify torque – Torque wrench used not ideal; not precise enough to measure low torque range – Did verify that the required torque to drive the steady-state system is below ~2 lbf-ft February 21, 2013UL Vibration Test Apparatus12 Cantilever Flange Connection Vertical Conduit Conduit Collar Testing Table Test Frame

Testing Conclusions Zero-displacement point is validated Displacement measurements do not agree at low eccentric values, but they do at higher distances – Postulated that the dial indicators are not precise enough to accurately measure low eccentric distances Torque measurement has a high degree of uncertainty due to the low level of precision associated with the torque wrench used during testing Recommended: – Purchase more precise dial indicator (re-test) – Purchase more precise torque wrench (re-test) February 21, 2013UL Vibration Test Apparatus13

Frame Design February 21, 2013UL Vibration Test Apparatus14 44” 34”

Frame Design February 21, 2013UL Vibration Test Apparatus15 Advantages: Allows for a single technician to mount the luminaire Extra support of U-channel decrease vibration of system Rubber pads in-between supporting beams help in dampening the system More space efficient than current design *Approximately 44” X 34” footprint Footprint may become larger due to resonate frequency of design (to be tackled by next senior design group)

Motor Selection February 21, 2013UL Vibration Test Apparatus16

February 21, 2013UL Vibration Test Apparatus17

Recommended Motor February 21, 2013UL Vibration Test Apparatus18

February 21, 2013UL Vibration Test Apparatus19 ParameterGoverning EquationValue Max Bearing Load Upper bearing force2450lbf3150lbf Lower bearing force1225lbf3150lbf SeSe 1.10e4psi- F.O.S. Shaft10- F.O.S. Key39- Where k a, k b and k c are Marin factors for surface condition, size, and loading conditions, respectively. l 1 =2, l 2 =4, σ min, σ max, Sy, Sut can be found in Appendix

Identified Improvements Install a brake Plate or coat steel parts (zinc plating) Development of 2 section maintenance compartment Removable tapered dowels for gauging Possible addition of counter weight Fixed dial gauge for reading smaller deflections Isolate motor from drive shaft

2 Section Maintenance hatch

Needed Before Running Final Testing Reassemble using Loctite Use lock nuts or lock washers with hardware holding linear bearings in place Ensure all bearings are properly lubricated Bolt system to floor

Next Steps of Project Manufacture frame Install motor with motor base Choose shaft coupling and install Choose and install brake Choose motor control and install Develop other features designated by customer input (LabView integration)

Things We Learned Consult machinist before diving into manufacturing part/system Many parts may need to be machined as an assembly Dowels are useful for location and assembly but have limitations in their use Check hardness of steel from scrap bin before machining them!!!

Project Cost Cooper has paid as of now: $3, Cost of project to date: $3, Estimated total cost: ~$8,000.00

Open Discussion Any questions? Design concerns not discussed? Implementation of LabView? February 21, 2013UL Vibration Test Apparatus26

Appendix UL Test Standard and Project Background

Project Background To pass safety requirements for certification the luminaires must meet a series of Underwriters Laboratories Inc. Standards. A Vibration Test Stand is currently being used by Cooper Crouse-Hinds to test pendant mount luminaires according to section 33 of the UL844 Standard. The Current Vibration Test Stand is outdated, has multiple design flaws, and design documentation and drawings are non-existent. Cooper Crouse-Hinds would like a new modernized Vibration Test Stand to be developed that addresses some of the design flaws of the current system while maintaining UL844 Test Standards. This new Design must also have a LabView interface and control capability integrated into the system. February 21, 2013UL Vibration Test Apparatus28

Design Goals over Winter/Spring MSD Note: It has been decided that this apparatus will be developed in multiple Senior Design Sequences. Provide customer with two design concepts for vibration mechanism Develop a final design of the vibration mechanism. Design a steel test frame that will support the vibration mechanism and the vertical conduit. Design but do not develop steel frame for entire vibration test machine. Develop a full set of engineering drawings. Calculate and select the required drive train system components. Purchase materials, machine components, and assemble the vibration mechanism and test frame. Test the mechanism to ensure that it meets 1 / 32 ” deflection requirement February 21, 2013UL Vibration Test Apparatus29

Summary of UL844 Vibration Test Standard LUMINAIRES FOR USE IN HAZARDOUS (CLASSIFIED) LOCATIONS – UL 844 Section 33 – Vibration Test Standards Luminaire is to be subjected to 35 hours of vibration testing. Luminaire assembly is to be attached to a / 2 ” long conduit via NPT threading. The other end of the NPT threaded pipe is to be secured to the hub of a rigid mounting frame so that the conduit hangs vertically. The conduit should correspond to the smallest size of threaded conduit hub that is designed to attach to the Luminaire being tested. The horizontal force to be applied to the system in order to obtain the deflection must me located 4” above the location of the conduit where the Luminaire attaches. The deflection must be 1 / 32 ” with 1 / 16 ” total deflection per cycle. The system must run at 2000 cycles/min. February 21, 2013UL Vibration Test Apparatus30

UL844 Vibration Test Standard February 21, 2013UL Vibration Test Apparatus31

Design Flaws Associated with Original Design February 21, 2013UL Vibration Test Apparatus32 Difficult for one technician to set up test Lubricant not contained Machine components exposed to contaminants Belts used (slipping) Uses single speed motor with a speed reducer Frequency adjustment dial held in place with rope No displacement adjustment Attachment collar may experience minor buckling Does not accounted for part wear and tolerance stack up

Customer Design Needs Need #Importance High 3 – 2 – 1 Low Design CriteriaMeasure of Effectiveness CN13Obtain vibration frequency of 2000 cycles/minStroboscope CN23Create displacement of 1/32” at 22.5” bellow pipe flangeDial Gauge CN32Adjustment of attachment collar position for perpendicularity___ CN42240 V electrical input___ CN52System envelope size is maintained or decreased from original system___ CN61Mounts to current anchor points in floor___ CN73Capability to adjust for different pipe sizes___ CN81Use current flange mounting for pipes___ CN92Design in an easily removable collar___ CN103Will support multiple types of Luminaires___ CN112Easy to mount the Luminaires1 Technician can run entire test CN121Ease of lubrication___ CN132Containment of LubricantLook for leaking of Lubricant CN143System to not run near resonate frequencyDoes not shake itself apart CN151Minimize noise of systemUnder 85 decibels (OCIA standard for requiring ear protection) February 21, 2013UL Vibration Test Apparatus33

PUGH Matrix: Rotational to Linear Motion Mechanism February 21, 2013UL Vibration Test Apparatus34

PUGH Matrix: Slider Mechanism February 21, 2013UL Vibration Test Apparatus35

PUGH Matrix: Displacement Adjustment Mechanism February 21, 2013UL Vibration Test Apparatus36

February 21, 2013UL Vibration Test Apparatus37 Risk Assessment

February 21, 2013UL Vibration Test Apparatus38

Lubrication Drive Shaft Bearings: Double sealed flange mount bearings with easy access grease zerk fittings. Linear Bearings: Double sealed closed bearings with easy access grease zerk fittings. Crank Arm Bearings: Double Sealed roller bearings pre-packed with grease. Easy access for lubrication by taking off Polycarbonate cover. February 21, 2013UL Vibration Test Apparatus39