1. P14471 Vibration Testing Apparatus II Subsystems Design Review 10/29/2013 Brett Billings Jacob Gardner Nick Greco Ron Jimbo Claire Kobal Ryan Selig Ashley Waldron

2. Agenda System Design Selection Subsystem Selection Frame Motor Displacement Measurement RPM Measurement Display and Control System Test Plan Risk Analysis BoM / Cost Estimate Next Phase

3. System Design Selected Vertically mounted motor with v-belt offset for maximum torque and speed control Dial gauge to confirm displacement and verticality Encoder and VFD to read and control speed LCD Display of RPM and time elapsed Safety: belt guard, polycarbonate guards, E-stop Multiple diameter conduits with dedicated flanges and collars for quick change-overs Spray paint to prevent rust

4. System Design Selected

5. Frame Design

6. Frequency Analysis Vibration Frequency: 33.3 Hz (2000 RPM) Natural Frequency of Apparatus: 42.3 Hz Maximum deflection.853” (shown in red)

7. Structural Analysis of Cantilever Maximum Stress: = 6897 PSI Maximum Deflection =.046 inches

8. Overall System Analysis

12. Motor Selection

13. Motor Continued

14. Total Cost: $472.00 Motor Performance Data: Baldor M3545

15. V-Drive Selection All information was gathered from the Dodge catalog For the given gear ratio of 1.72, Type A, 1-Groove Driver Datum Diameter: 3.4” Outer Diameter= 3.4”+.37”= Approx. 3.75” P/N 118190 Driven Datum Diameter: 6.2” Outer Diameter= 6.2”+.37”= Approx. 6.55” P/N 118204 Driver Taper Lock Bushing (1210),.5” Shaft Diameter: Keyway P/N 119191 Driven Taper Lock Bushing (1610), 1” Shaft Diameter: Keyway P/N 117159 Distance from center shaft to center shaft using donated belt guard: 9.5” P/N A33 Belt Life: 25,000 hours (714 testing cycles)

16. Cost of V-Drive Driver: Sheave: $10-20 Bushing: $10-20 Driven: Sheave: $30-35 Bushing: $10-25 Belt: $10 Total: $70-110

17. Dial Gauge Selection Digital Dial Gauge can connect to final display More reliable and less expensive than a laser $150 ½” range 0.0005” resolution

18. Maintaining Displacement Clamping force: Provided by 2 screws - ½’’-13 M = torque on screws Screw vs. T-Block (u=.2) 210 M ft -1 (see Appendix) Frictional force (prevents slipping): 2 possible locations: Adjustment Base vs. Adjustment Slider (u=.8) Adjustment Base vs. T-Block (u=.2 to.8) Assume worst case, u=.2 42 M ft -1 Maximum force applied (causes slipping): 1.68 ft-lbs. (motor) at 1/32’’ 645 lbs. Required screw torque: Safety factor of 2 31 ft-lbs.

19. Control System

26. Encoder Selection: TRD-S100-VD Inexpensive incremental (quadrature) encoder Capable of sending (depending on exact model) 100-1024 pulses per revolution Speed of motor can be determined based on number of pulses received and time elapsed Hardware allows for maximum of 6000 RPM – well above 2000 RPM expected

27. Micro-Controller Firsthand objective: proof of concept TI Launchpad Comes pre-equipped with on-board emulation and simple outputs for ease of testing & debugging Control procedure can be implemented using pseudo-inputs and pseudo-outputs to prove feasibility of concept In final design encoder sends signal to controller, which is interpreted and fed in through VFD for feedback After concept is proven a permanent microcontroller can be selected to optimize system integration

28. Test Plan Test Displacement Tighten adjustment screws to proper torque Measure displacement with dial gauge during setup Validate 1/32” total displacement Test Vibration Cycles Measure RPM with encoder and display for feedback Validate 2000 cycles/min Test fittings Do they fit the frame? Test User Interface Check connections Ease of use Safety Evaluation

29. Risk Analysis

30. BoM & Costs ItemCostItemCost Materials for Frame$700Rust Protection$200 Materials for Conduits / Flange / Collar$250Welder Fees$200 (est.) Digital Dial Gauge$150Electrician Fees$0 Motor$470Shipping Costs (for testing)$200 (est.) VFD$480Upgraded displacement adjustment$50 Encoder$100Polycarbonate Sheet ¼’’x36’’x24’’$70 LCD Display$100Belt Guard$0 Micro-controller & components$100Electrical Lockout$40 Electrical Box$200 (est.)V-Drive$90 Total$3400

31. Next Phase

32. Questions for Cooper-Crouse Hinds Electrical wiring done by students and checked by CCH?

33. Questions?

34. Appendix

35. More Motor Information V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-pt.com/products/pt_components/belts/belts.html

36. Safety Checklist

37. Functional Decomposition

38. Full Risk Analysis

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

40. Conduit Pipe Size Considerations Concept: each conduit size will have its own: Flange Collar This concept allows for easier usage by operator Plan: Provide the 1 st and possibly the 2 nd most used size conduit Provide the drawings/files necessary for the fabrication of the remaining conduits Flange Collar – crankshaft connection Collar – set screws

41. Conduit Verticality Attempt to keep the conduit as vertical as possible Based on conversations with an operator – verticality is not very critical Very basic method: Place a vertical level in the same place every time and using the adjustable crankshaft to make minor adjustments

42. Safety Features Fixed polycarbonate guards on drive system Clear, light-weight Excellent impact strength, ¼’’ thick “Split” type belt guard Left and right half for easy removal Lock-out on electrical box for maintenance http://www.eriecustomproducts.com/beltguards/

43. Adjustment Mechanism

44. Additional holes in connecting plate Access to adjustment bolts U-bolt to lock system in place during adjustment Finer set screw 3x finer than current 8-32: ¼’’ turn ~ 1/128’’ displacement Setup Improvements

45. New Connecting Plate

46. UL844 Vibration Test Standard

47. Maintaining Displacement Calculations

50. Design characteristics for VFD HP : VFD must be rated for the appropriate HP. Full Load Amps : Motors Full Load Amps must not exceed VFD’s continuous amp load. Voltage : number of phases and voltage must be matched as well with the VFD. Load Type: Constant vs. variable Torque during operation. Programmability: programmable parameters of a VFD