P14471 Vibration Testing Apparatus II Detailed Design Review 12/10/2013 Brett Billings Jacob Gardner Nick Greco Ron Jimbo Claire Kobal Ryan Selig Ashley Waldron 1

Agenda Project Summary Selected Design Preliminary Analysis Frame Motor Electrical / Control System Safety Improvements from P13471 Test Plan BOM Project Plan Concerns/Issues Appendix 2

Project Summary 3

Problem Statement Update company’s vibration test apparatus Meet UL 844 Standard Continue progress started by Team Done: the eccentric drive mechanism Still needs: Frame Motor Control system 4

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House of Quality Engineering Metrics Customer Requirements Customer Weights Displacement of luminaire Vibration of luminaire Duration of vibration test Low sound Machine won't operate if moving parts are exposed Completely stop machine with Emergency Stop Minimize pinch points Minimize number of operators Voltage of motor Mount pendant configuration Mount stanchion configuration Mount yoke configuration Mount trunnion configuration Visually display settings and status of test Operation documentation Steps required for Set-up Isolate motor from oil spills Maintenance documentation Max weight of mounted luminaire Total materials cost Time to Set up Machine footprint Adherence to UL844 testing standard5555 Apparatus is safe Motor must be compatible with available voltage Ability to test multiple configurations Easy to use Easy to maintain Visually display test information/feedback to operator Ability to test a range of luminaire weights Cost under $ Long service life Similar dimensions to existing machine1 5 Technical Targets (Specifications) 1/32 in cycles/min 35 hours < 85 dBA yes < 10 seconds < 3 ≤ 2 < 240 V AC Yes 80% via survey (easy to follow) < 10 steps Yes 80% via survey (easy to follow) > 150 lbs < $4000 < 120 seconds < 34X48 in 2 Raw score Relative Weight 11% 2%4% 2%3%4%6%1% 3%5%3%7% 3%2%3%1% 6

Engineering Requirements NumberRequirement Raw Score Units Ideal Measure 1 Displacement of luminaire69in1/32 2 Vibration of luminaire69cycles/min Duration of vibration test69hours35 4 Isolate motor from oil spills45BinaryYes 5 Maintenance Documentation44Survey (easy to follow)80% 6 Mount pendant configuration35BinaryYes 7 Operation Documentation33Survey (easy to follow)80% 8 Machine won't operate if crankshaft enclosure is open25BinaryYes 9 Completely stop machine with Emergency Stop25seconds< Maximum voltage of Motor25V AC Minimize number of operators21people2 12 Max weight of mounted luminaire20lbs> Visually display settings and status of test18BinaryYes 14 Steps to set up16steps< Setup Time16seconds< Low Sound15dBA< Minimize pinch points15Count< 3 18 Total materials cost15$< 4, Mount stanchion configuration7BinaryYes 20 Mount yoke configuration7BinaryYes 21 Mount trunnion configuration7BinaryYes 22 Machine footprint5in 2 < 34X48 7

Selected Design 8

Interchangeable Conduits Motor with V-belt VFD Digital Dial Gauge Encoder LCD, Microcontroller Polycarbonate Guards E-stop Paint for Rust Protection 9

Preliminary Analysis 10

Maintaining Displacement ER #1: Displacement must be 1/32’’ Clamping force: Provided by 2 x A574 screws - 5/8’’-11 M = torque on screws = M ft -1 Frictional force: 2 possible locations: = 33.8 M ft -1 (worst case) Maximum force applied: 1.68 ft-lbs. (motor) at 1/32’’ = 645 lbs. Required screw torque: = 38 ft-lbs. (Safety factor of 2) Max recommended A574 torque = 220 ft-lbs *Detailed calculations in Appendix

Engineering Analysis: Forces ER # 12 – Maximum Luminaire Weight Force on collar/conduit = N ( lbf) Force from connecting rod = N ( lbf) Calculated friction forces Worst case = N ( lbf) Torque on connecting rod = Nm (1.575 lbft) Torque on block = 2.399Nm (1.769 lb ft) Torque on crankshaft = 2.399Nm(1.769 lb ft) *Refer to Appendix 12

Engineering Analysis: Fatigue Conduit σ a = psi so σ m =0psi σ a < 0.5* σ 0 Therefore Infinite Life Factor of Safety σ ar =15,5229psi < 0.5* σ 0 Infinite life C-Channel Max stress = psi = σ a σ a < 0.5* σ 0 Infinite Life Refer to appendix σ 0 =35,000psi; σ u =58,000psi 13

Engineering Analysis: Fatigue/Buckling Extension Rod: Buckling: P cr = lbf lbf < lbf No buckling Fatigue: σ a = psi σ a < 0.5* σ 0 Infinite Life Threaded Connector Buckling: P cr = lbf lbf < lbf No buckling Fatigue: σ a = psi σ a < 0.5* σ 0 Infinite Life Refer to appendix σ 0 =35,000psi; σ u =58,000psi 14

Frame 15

Final Frame Design 16

Frame Halve Views Front and Back Views of Full Assembly Front and Back Views of Crankshaft 17

Analysis Overview 18

Frame Analysis at in. Displacement 19

Frame Analysis at in. Displacement 20

Motor 21

Motor Selection ER #2 – Vibration of Luminaire ER #10 – Max Motor Voltage ER #12 – Maximum Luminaire Weight 22

Motor Performance Data: Baldor M3545 Updated cost from Volland Electric Equipment Corp: $ *This is a saving of almost $ from the original estimate We chose a 1 HP motor with a full-load torque of 1.5 LB-FT 23

V-Drive Selection All information was gathered from the Dodge catalog For the given gear ratio of 1.75, Type A, 1-Groove Driver Datum Diameter: 3.4” Outer Diameter= 3.4”+.37”= Approx. 3.75” Driven Datum Diameter: 6.2” Outer Diameter= 6.2”+.37”= Approx. 6.55” Driver Taper Lock Bushing (1210),.5” Shaft Diameter Driven Taper Lock Bushing (1610), 1” Shaft Diameter Distance from center shaft to center shaft using donated belt guard: 9.5” *Unable to locate actual Dodge belt. A very similar belt will be purchased through AutoZone. ER #2 – Vibration of Luminaire ER #4 – Isolate Motor from Oil Spills 24

Motor Mount to Frame 25

Encoder Placement The current shaft has to be machined down to a smaller size at the very end to add a coupling for the encoder. *Encoder to be discussed further in electrical systems 26

Electrical / Control System 27

Component Placement at CCH 28

Flow Diagram 29

Power Connection Schematic 30

Power Supply VGS Watt 5V AC-DC converter 5A max delivered current 3.1 x 1.11 x 2.03 inches *Refer to appendix for power calculations 31

Encoder TRD-N1024-RZWD ER #2 – Vibration of Luminaire ER #13 – Display System Status Resolution: 1024 Pulses Per Revolution (PPR) Max frequency: 100 kHz Max RPM detection: 100 kHz / 1024 PPR * 60 = 5859 RPM 32

33 ER # 10 – Max voltage of Motor

Enclosure AMP1426CCLF Polycarbonate enclosure with metal snap latch 14 x 12 x 6 inches 34

Control System Pseudo Code Initial delay to allow sufficient startup time for motor Repeat (loop) the following until Timer_A value reads 35 hrs Wait for appropriate delay time to avoid overworking MCU CPU Use Timer_A capture from pin 11 of MCU to retrieve digital encoder signal Read and store timer value upon rising edge of signal into var "A" Read and store timer value upon next rising edge into var "B" Period = B - A Frequency = 1 / Period Resolution = 1024 Speed of vibration in RPM = Frequency / Resolution * 60 ; Dimensions = (rev / min) = (pulses/sec) / (pulses/rev) * (60 sec/min) Send RPM and elapsed time (also from Timer_A) to LCD display via pinouts if RPM exists above safety threshold (2000 RPM + threshold) exit loop with error code set high Update VFD with new RPM information to step up or down accordingly Send signal to alert VFD to bring motor to a complete stop if error code set high Write "Test Ended Abruptly: High RPM" to LCD display else Write "Test Completed Successfully" to LCD display 35

Launchpad and Display Encasing ER # 3 – Duration of Vibration Test ER #13 – Display System Status 36

Safety 37

Polycarbonate Guards ER # 8 – Crankshaft Enclosure is Guarded ER # 17 – Minimize Pinch Points Top and rear guard Clear, Polycarbonate ½’’ Excellent impact resistance Warning labels Replace existing top guard Move mounting holes away from edge Increases strength, but slight overhang Modify rear guard Add access hole to decrease setup time 38

Belt Guard ER # 17 – Minimize Pinch Points Protects operator from 2000 RPM belt Donated Modifications required: Convert to “split” type Weld existing halves together Cut guard in half in other direction Change existing mounting brackets 39

Lock Out, E-stop ER # 8 – Crankshaft Enclosure is Guarded Lock out during maintenance On electrical box, after power is isolated Lock out procedure to be written in MSDII ER # 9 – Completely Stop Machine with E-Stop E-stop Located on machine Manually cuts power immediately 40

Engineering Analysis: Sound ER # 16 – Low Sound Hearing Protection / Engineering Intervention To be determined in MSD II with Test Plan Based on sound “dosage” Dosage Calculation: L = dBA Sound Level T = 8 hour exposure limit C = actual exposure hours  D = 100 * (C1/T1 + C2/T2 + C3/T3 +…)  D > 50% requires hearing protection  D > 80% requires engineering intervention

Safety Checklist ER # 8 – Machine Guarding ER # 9 – Emergency Stop ER # 16 – Low Sound 42

Improvements from P

Setup Improvements ER # 11 – Minimize number of operators ER # 14 – Steps to set up ER # 15 – Setup time 44

Setup Improvements Current setup procedure: 1. Measure displacement with dial gauge 2. Lockout machine 3. Remove top guard (8 screws) 4. Remove rear guard (4 screws) 5. Remove collars (2) 6. Remove connecting plate 7. Loosen locking bolts (2) 8. Adjust set screw 9. Perform 2-7 in reverse 10. Repeat 1-9 until 1/32’’ reached ~ 5x Approximately 60 minutes to setup 10 minutes 2x 45

Setup Improvements Displacement adjustment without removing rear guard, collars, or connecting plate Also, U-bolt prevents block from rotating Changes required: Add 2 access holes to connecting plate Add 4 holes total for u-bolt Add 1 access hole to rear guard Doesn’t impact safety,.2’’ 46

Setup Improvements Finer set screw Before: 11 threads per inch 1 turn = 290% of displacement! After: 100 threads per inch 1 turn = 33% of displacement Changes required: Machine new set screw plate Requires threaded bushing for set screw 47

Set Up Improvements Set screw Account for excess space between conduit and collar Flange Dimensioned to be placed in same location every time Blocks on the C channel Flange Collar – crankshaft connection Collar – set screws ER # 11 – Minimize number of operators ER # 6, – Mount 4 configuration types ER # 13, 14 – Setup time, number of steps 48

Test Plan 49

Test Plan Displacement Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. # Specification (description) Unit of Measure Marginal Value ToleranceComments/Status 1 The total displacement of the Luminaire must be 1/32" inches 1/32+/- 2% 1,2 The adjustment screws must be tightened to the proper torque ft-lbs>=38- 50

Test Plan Vibration Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. # Specification (description) Unit of Measure Marginal Value ToleranceComments/Status 2 Vibration of Luminaire must be 2000 rpm rpm2000+/- 2% 13 Vibration measurement is sent back to the display binaryYes- 12 Apparatus will sufficiently vibrate a large weight luminaire lb>=150- 3Vibrates for 35 hourshours>= Motor power is sufficient to fully run the test hp>=1- 51

Test Plan Dimensional Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. #Specification (description)Unit of Measure Marginal Value Comments/Status 11Conduits fit the framebinaryYes 22 Footprint difference compared to old apparatus ft^2<=2 52

Test Plan Configuration Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. #Specification (description)Unit of Measure Marginal Value Comments/Status 6Apparatus works while pendant mountedbinaryYes 19 Apparatus works while stanchion mounted binaryYes 20Apparatus works while yoke mountedbinaryYes 21 Apparatus works while trunnion mounted binaryYes 53

Test Plan Ease of Use Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. # Specification (description) Unit of Measure Marginal Value Tolerance Comments/Status 13 Display shows rpms and running time binaryYes 14,15 Closed loop feedback keeps rpms in check rpm2000 +/- 2% 11,14,15 Survey given says apparatus is easy to operate %>=80 4Motor is isolated from oil spillsbinaryYes 5 Survey given says apparatus is easy to maintain %>80 54

Test Plan Safety Test Date Completed: ______________________ Performed By: _______________________________ Engr. Spec. # Specification (description) Unit of Measure Marginal Value Comments/Status 8 Machine will not run during LOTO binaryYes 17Pinch points are covered# exposed0 16Noise is below 85 decibelsdB<=85 9 Emergency Stop cuts all power to the apparatus binaryYes 7Complete Safety Checklist# fail0 55

Bill of Materials 56

Bill of Materials ER # 18 – Total cost <= $4,000 Total Overall Price: $2,

Project Planning 58

Engineering Requirements to be addressed in MSDII 59 ER # 5 – Maintenance Documentation ER # 7 – Operation Documentation

Completed Action Items from DDRs Update CAD drawings for machine shop Perform additional vibration simulations Perform additional torque analysis Check VFD effect on motor poles Check voltage, current, and load requirements 60

Risk Assessment *Highest risk items only, refer to Appendix for full list 61

MSD II Schedule 62

MSD II Schedule 63

Concerns/Issues Where to place display? Modifying apparatus once shipped to CCH for testing? 64

Questions? 65

Appendix 66

Full Risk Analysis 67

Engineering Analysis: Displacement 68

Engineering Analysis: Displacement 69

Engineering Analysis: Forces 70

Engineering Analysis: Fatigue 71

Engineering Analysis: Machine Guarding General Industry (29 CFR 1910)29 CFR (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 (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 72

Power Calculations 73

Bolt Torque Guide 74

Morph Table 75

Architecture Central System Power supplyMotor system Sensors Display/user interface Luminaire connection Crankshaft connection Safety features 76

Alternatives Considered: Consider Systems Level 77

Alternatives Considered: 78

Alternatives Considered: 79

Alternatives Considered: Consider Systems Level 80