Drop Testing Apparatus Team Members: Deatly Butler Mark Clouse Chris Dux Kris Honas Shaun Scott Drew Stephens Client: Itron, Inc. Brian Priest Technical Advisors: Steve Beyerlein Mike Severance

Presentation Overview Customer Needs Mechanical Components Table Drop Design Orientation Devices Height Adjustment Electrical Components Data Acquisition CPU Interface Software Camera Costs Recommended Design Work Remaining Questions?

Needs Repeatable Impacts ( 45 +/- 5 deg) Adjustable Drop Height (18-60 inches) Portable (Wheels) Short Setup time (<1 min) Video Data Acquisition (automatically named and stored)

Mechanical Components Table Drop Design Orientation Devices Height Adjustment

Table Drop Design Using Pneumatics Fast Acceleration Simple Inexpensive Non Electrical Long Life

Table Drop Design #1 Frontside Pneumatic PROS One Pneumatic Four Linear Bearings CONS Table Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects No Initial Vertical Motion

Table Drop Design #1 Frontside Pneumatic

Table Drop Design #2 Backside Pneumatic PROS One Pneumatic Device Four Linear Bearings Pneumatic Does Not Interfere With Table Space CONS Table Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects No Initial Vertical Motion

Table Drop Design #2 Backside Pneumatic

Table Drop Design #3 Double Pneumatic PROS Vertical Pneumatic Prevents Rotation on Test Device CONS More Linear Bearings More Pneumatic Cylinders Increased Chance of System Malfunction

Table Drop Design #3 Double Pneumatic

Orientation Devices Cradle Block Design PROS Simple Block Design Inexpensive Simple Operation Minimal Setup Time Easily Removable CONS Works Best for Smaller Devices Additional Testing Required to Confirm Functionality

Orientation Device Design #1 Edge Testing

Orientation Device Design #2 Corner Testing

Height Adjustment Design #1 Manual Hand Crank Pros Smooth Adjustment For Any Height Able To Raise And Lower Heavier Loads. Cons Slow Adjustment Involved Manufacturing Process Increased Cost

Height Adjustment Design #1 Manual Hand Crank

Height Adjustment Design #2 Pin and Collar Pros Quick Adjustment Predetermined Standard Heights Secure Locking Mechanism Cons Operator Must Be Able To Support Weight Of Table And Mechanism

Height Adjustment Design #2 Pin and Collar

Electrical Components Data Acquisition CPU Interface Software Camera

Importing to a PC Video for each test will be imported to a PC by using GPIB interface. Instrument controlled by Labview. Automatically will name and store video clips for each test.

CPU Zero Footprint PC - $500 (w/o monitor) LCD PC - $1000

GPIB Interface General Purpose Interface Bus Standard interface between instruments and controllers from various vendors. 8-bit parallel communication. 5 bus management lines (ATN, EOI, IFC, REN, & SRQ) 3 handshaking lines. 8 ground lines.

LabVIEW Software Uses VI’s (Virtual Instrumentation) Imitates physical instruments. Cheaper than Hardware. Modular Program design. Will be used with GPIB to control the video.

Video Camera Handheld will fall in about 0.5 seconds Video below 200 fps may be able to capture enough images Acquisition (fps) Distance between images 192½ inch 961 inch 482 inches

Camera Option #1 Machine Vision System Pros High Speed Acquisition (>10000 fps) Cons Small Picture Area (1.5” x 1.25”) Designed as an Automatic Inspection Sensor Doesn’t capture video

Camera Option #2 High Speed Video Camera Pros Easily interfaced and controlled with LabVIEW software Could be tested with lower quality cameras Cons High Cost Low Acquisition Speeds (< 500 fps)

Mechanical Costs Pneumatic Cylinder (1-3) $50ea Shafts (1-2)$40ea Raw Materials Sheet Metal$70 Metal Tubing$20 Misc. Hardware$60 Linear Bearings (2-6)$60ea Spur Gear and Rack$200 Valves and Fittings $100 Compressor (Optional)$300 Total~$1400

Electrical Costs Computer~$1500 GPIB$300 Misc.$200 Camera~$800

Recommended Design Single Pneumatic Operation (Back Side) Track Mounted Block Orientation Device Pin and Collar Height Adjustment LCD PC or Laptop GPIB Interface LabVIEW Software

Work Remaining Spring 2006 Detail Design: (Jan. 9 th 2006 – Feb. 1 st 2006) - Order parts. - Assess Drawing package. - Complete drawing package. Fabrication: (Feb 2 nd 2006 – March 20 th 2006) - Build product. Validation: (March 21 st 2006 – April 20 th 2006) - Debug and fix product. - Validate performance of product. - Draft final project report. Delivery: (April 21 st 2006 – May 9 th 2006) - Archive project documentation. - Deliver product. - Write final report.

Our Questions for Itron Will ~200 fps be enough for the video? Computer? Camera? GPIB? Labview license?

Questions?