Systems Level Design Review UL Vibration Test Apparatus January 11, 2013 KGCOE Room # :00AM-12:00PM Est.

Project & Team Information Project: UL Vibration Test Apparatus Project Number: Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries) Customer Contact: Joe Manahan RIT Faculty Guide: Dr. Benjamin Varela Project Team:Walter Bergstrom Sean Coots Spencer Crandell Mark Ellison January 11, 2013UL Vibration Test Apparatus2

Project Background Cooper Crouse-Hinds develops luminaires that are used in hazardous environments where ignition or explosion can have catastrophic consequences. 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 The Current Vibration Test Stand is outdated, has multiple design flaws, and design documentation and drawings are non-existent.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. January 11, 2013UL Vibration Test Apparatus3

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 – One of the two designs must be an eccentric shaft mechanism while the customer is open to considering other design alternatives. – After discussing benefits and costs of the designs in this Systems Level Design Review, the Customer will decide on the vibration mechanism to be developed further. 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 January 11, 2013UL Vibration Test Apparatus4

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. January 11, 2013UL Vibration Test Apparatus5

Force Applied to Deflect Luminaire Equations of relative motion were applied to derive the acceleration of the desired deflection assuming a constant angular velocity of the primary shaft. The moment of inertia was than approximated for the conduit with 100lbf cylinder at its end. Assuming the system acted as a pendulum and using the moment of inertia and acceleration we acquired a force. This was then superimposed with the force needed to bend the conduit (cantilever pipe) to the proper deflection. The calculated force was approximately 400lbf. January 11, 2013UL Vibration Test Apparatus6

UL844 Vibration Test Standard January 11, 2013UL Vibration Test Apparatus7

Design Flaws Associated with Current Design January 11, 2013UL Vibration Test Apparatus8 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)

Rotational Input at 2000 rpm Rotational to Linear Motion Mechanism Options: Eccentric Shaft Crankshaft Variation for Adjustment Capabilities Scotch Yoke Variation for Adjustment Capabilities? Cam Follower Output Linear Motion to Slider Mechanism Allows for design of a single motor input and slider output mechanism for either the eccentric shaft or scotch yoke design Slight adjustments to frame required for each case due to the orientation of the motor (either horizontal or vertical) January 11, 2013UL Vibration Test Apparatus10

January 11, 2013 UL Vibration Test Apparatus 11 Continued (next slide) Functional Decomposition (Page 1 of 2)

January 11, 2013UL Vibration Test Apparatus12 Functional Decomposition (Page 2 of 2)

Slider Mechanism Linear bearing with rails Roller bearings w/ wheels Full fluid boundary w/ lubricant Magnetic Pillow block bearings Notes: Ranked from top to bottom, best to worst Need to ask exactly what mechanism the current design employs Issue is lubrication and lubrication containment if bearings are not used January 11, 2013UL Vibration Test Apparatus13

Rotational to Linear Mechanism Scotch Yoke Crankshaft Cam Follower Screw Actuator Eccentric Shaft Notes: Ranked from top to bottom, best to worst Also a linear motor option that does not fall under this category but still converts electrical energy to mechanical January 11, 2013UL Vibration Test Apparatus14

PUGH Matrix: Rotational to Linear Motion Mechanism January 11, 2013UL Vibration Test Apparatus15

Eccentric Shaft Eccentric Shaft (Custom Purchase) Shaft Bearing(s) (Purchase) Connecting Rod (Custom) Connecting Rod Bearing (Purchase) Shims (Purchase) **Note: Green boxes denote optional design components Notes: Current design in use at Cooper Simple design No adjustment capability Eccentric shafts expensive to purchase Relatively few moving parts Lubrication of connecting rod must be further studied Option 1 January 11, 2013UL Vibration Test Apparatus16

January 11, 2013 Scotch Yoke Rotary Disc (Custom) Shaft (Purchase) Yoke Plate (Custom) Pin (Purchase) Connection to Slider Mechanism (Custom) **Note: Green boxes denote optional design components Notes: Alternate design Fairly simple Adjustment capability Lubrication of system must be further studied Gear (Purchase) Key (Purchase) Option 2 May be directly built into design

Scotch Yoke CAD Concept January 11, 2013UL Vibration Test Apparatus18

PUGH Matrix: Slider Mechanism January 11, 2013UL Vibration Test Apparatus19

PUGH Matrix: Displacement Adjustment Mechanism January 11, 2013UL Vibration Test Apparatus20

Cost Analysis January 11, 2013UL Vibration Test Apparatus21 ComponentCountApproximate Cost Per Item Scotch Yoke Yoke1 $20 Drive Shaft1$120 Rotating Plate1 $100 Pin1 $20 Bushing1 $40 Stroke Adjustment Mechanism1 $40 Eccentric Shaft 1 $500 Pivot Arm 1 $100 Shaft Bearings 2 $40 Pivot Arm Bearing1$20 Guide Rail System Bearing1$20 Frame Base plate 12" wide x 3/4" thickness x 48" long1$230 Channel Plate 12" wide x.380 thickness x 72" long1$250 Steel Angle6$200 Fasteners and Associated $200 Guide Rail System Linear Pillow Block Bearings4$320 Hardened Ground Shaft2$120 Shaft Base Mounts4$100 Assorted 2" NPT Pipe 26.5" length1$30 Dial Indicator1$30 Pipe Flange1$40 Approximate Cost w/ Scotch Yoke $2,100 Approximate Cost w/ Eccentric Shaft $2,600

January 11, 2013UL Vibration Test Apparatus22 Risk Assessment

January 11, 2013UL Vibration Test Apparatus23

January 11, 2013UL Vibration Test Apparatus24 Continued (next slide) Project Schedule (Page 1 of 2)

January 11, 2013UL Vibration Test Apparatus25 Project Schedule (Page 2 of 2)

Suggested Design Implementation Scotch Yoke Design Linear Bearings on Rails Pivot Cam for Eccentric Adjustment Mechanism AC Motor with Adjustment Redesigned Flange Platform January 11, 2013UL Vibration Test Apparatus26

Open Discussion Any questions? Design concerns not discussed? Feed back on work done to this point? Feed back on method for calculating deflection force? Follow-up meeting needed? Customer decision on Vibration Mechanism January 11, 2013UL Vibration Test Apparatus27