TEAM 14 John Armitage Douglas DeVoto Brian Polkowski Marykate Wioncek SOUTHCO Vibration Fatigue Tester

Southco Global manufacturer of access hardware solutions Fasteners, latches, hinges, handles, etc. Industries served: Computers, electronics, automotive, aerospace, marine, etc.

Project Goal Design and build a vibration fatigue tester Simulate off-highway service environment Test compression latches

Compression Latches T-HANDLE CUSTOM COLORS CUP LOCK PLUG CUP VERSIONS PAWL HOUSING LOCK PLUG

Business Benefit Quality assurance Provide quality test data to customer Aids in proper latch selection Product improvement Accurate data on failure conditions

Customers/Wants Top 3 Wants: - Accurate Data - Adaptable to Different Kinds of Latches - Adjustable Forces and Hz

Metrics

Current State/Future State Outsourced to testing company Used linear actuators (not designed for high speed testing)

Benchmarking Existing vibration testers Shaker tables Instron machines Other benchmarking Actuators Hammer drills

Concept Selection Cam and Follower Shaker Table Actuator Instron

Final Concept

How It Works

Subsystem: Fixed Parts Pillow Blocks Linear bearings Bearing Mounting Plate

Subsystem: Motor system Baldor Motor Drive Belt Sprockets Cam Cam Shaft

2 secondary springs Roller follower Alignment rods Cam Follower Bracket Subsystem: Secondary Spring System

Subsystem: Primary Spring System Primary Spring Spanner Nut Threaded Rod Main Shaft Pawl

Subsystem: Latch Latch Latch Plate Latch Plate Mount Base Plate

Subsystem: Frame Safety Shield Polycarbonate 80/20 Machine Base Base Plate Frame Motor Mount Alumilite Covers

Measurement and Control System

Prototype

Functioning Prototype

Prototype Testing Procedure Used dummy latch with built in force sensor Adjusted to 100lb preload Ran machine with calibrated sensors at several speeds up to 3600 rpm to verify that the prototype achieved 3000N of force

Latch Testing Procedure Bolt latch plate to base Adjust spanner nut to apply the appropriate initial load Confirm correct load using labview software Turn on motor and change to correct speed Record number of cycles to failure

Validation of Metrics GoalResults Adjustable to 60Hz√ Adjustable initial load up to 100lb√ Adjustable Dynamic load up to 3000N√ ± 5% of desired load√

Metric: Adjustability

Additional Test Results Measurement of Decibels OSHA standards state that a worker can be exposed to 90 dB for an 8 hour work day. Hearing Equipment is required in Southco testing facility rpmdB

Project Management Schedule

Project Costs Mechanical ComponentsCost Motor$4,000 Springs$170 Machine Table$1,300 Drive Belt$250 Linear Bearings$400 Roller Follower$200 Pillow Blocks$300 Cam Bushing$200 Raw Material$1,700 $8,520 Software ComponentsCost Force Sensor$400 Accelerometer$365 Controllers$4000 $4,765 Total CostsCost Mechanical Components$8,520 Software Components$4,765 Machinist Time$6,500 Engineering Time$50,000 $69,785

Cost Analysis Final cost of testing mechanism to Southco $15000 Cost of latch testing Previous testing - $625 per latch Current testing – Cost of Latch Save on shipping costs Faster data acquisition

Implementation Plan Hand off of Prototype to Southco Representatives: 12/4 Plans: Move Prototype to Southco facility Begin testing of latches as soon as possible Produce machines for other Southco facilities

Acknowledgements Thank you to our Southco Sponsors: Ratnesh Dwivedi Ron Magidson Mark DiAntonio Jesus Albillos Al Frattarola Thank you to our Advisor: Mr. Nate Cloud Special Thanks to: Ed Cicutti

Questions?

Resonance

Cam Torque spring force no preloadfollower displacment mmcam offset mmsecondary kinitial secondary force thetav m/sa m/s^2x mmk N/mmmFwT N*mT lbsf*ftThpF of fTf N*mTf lbsf*ftTf hpT total hp E E E E E

Cam Shaft Calculations

Cam Shaft Calculations Continued