1. P15661 Reciprocating Friction Tester Base Subsystem
Systems Level Design Review

2. Team Roles Team Member Major Role Alexandra Woodward
Industrial Engineering
Project Manager, Customer Point of Contact
Sean Cummings
Mechanical Engineering
Lead LabVIEW Engineering, Subsystem Design
Ethan Hanson
Lead Subsystem Design Engineer
Tyler Nigolian
Electrical Engineering
Data Acquisition System Engineer, Facilitator
Matt Lebowitz
Electrical Component Engineer
Project Guide: Gary Werth
Customer: Dr. Iglesias Victoria
P Systems Level Design Review
11/27/2018

3. Agenda Project Background & Deliverables
Engineering Requirements & House of Quality
Test Plan
Functional Decomposition
Systems Architecture
Concept Development & Selection
Engineering Analysis
System Level Proposal
Risk Assessment
Project Plan
Alexandra
P Systems Level Design Review
11/27/2018

4. Project Background & Deliverables
Current State
Reciprocating friction testers are too expensive
Dr. Iglesias only has a rotationally reciprocating friction tester
Desired State
Easy-to-use linearly reciprocating friction tester
Used to test wear and friction characteristics of various materials under dry and lubricated conditions
Project Deliverables
Linearly reciprocating friction tester
LabVIEW program
Operation and maintenance manuals
Constraints
Budget
Time
Adheres to ASTM Standards
Ethan
P Systems Level Design Review
11/27/2018

5. Engineering Metrics P15661 - Systems Level Design Review 11/27/2018
Sean
P Systems Level Design Review
11/27/2018

6. House of Quality
Sean
P Systems Level Design Review
11/27/2018

7. Test Plan Examples
Ensure the base does not deform with 20N normal force and associated frictional forces.
Customer provided 0.8 coefficient of friction. Use 10% overload margin and apply forces normal to and laterally to the sides of base.
Verifying calculations for motor speed for given frequency and stroke
Use of optical light sensor with markings on reciprocating base to verify frequency across several test conditions.
Measuring cleanability of the specimen holder
Time cleaning of holder using different viscosities of lubricant across several different users and compare data. Identify superior cleaning solutions and methods.
Matt
P Systems Level Design Review
11/27/2018

8. Functional Decomposition
Ethan
P Systems Level Design Review
11/27/2018

9. Functional Decomposition: Base Subsystem
Secure specimen
Place specimen
Tighten clamping mechanism
Clamp testbed
Reciprocate base
Start motor
Actuate base
Convert rotational to linear motion
Set stroke
Acquire data
Run LabVIEW
Input parameters
Set frequency
Input stroke
Input weight
Convert to normal force
Set test duration
Set temperature
Start button
Collect data
Measure temperature
Measure strain
Convert to friction force
Interface with armature subsystem
Ethan
P Systems Level Design Review
11/27/2018

10. System Architecture *All lengths are in mm
Tyler
*All lengths are in mm
P Systems Level Design Review
11/27/2018

11. Interface with Armature Team
Armature team will provide bolt hole pattern
Base subsystem will be mounted and fixed to a predefined location on the foundation plate
Distance from center of bolt hole pattern to center of specimen will be provided by Armature team
Voltage output signal required from Armature team that represents friction force
Sean
P Systems Level Design Review
11/27/2018

12. Morph Chart
Matt
P Systems Level Design Review
11/27/2018

13. Engineering Analysis 𝑥 𝑡 = 𝑠 0 2 ∗sin⁡(𝜔𝑡) 𝑣 𝑡 = 𝑠 0 2 ∗𝜔∗cos⁡(𝜔𝑡)
Ethan/Sean
𝑎 𝑡 = 𝑠 0 2 ∗ 𝜔 2 ∗−sin⁡(𝜔𝑡)
P Systems Level Design Review
11/27/2018

14. Benchmarking: Rotary Motor
Matt
P Systems Level Design Review
11/27/2018

15. Benchmarking: Voice Coil
Tyler
P Systems Level Design Review
11/27/2018

16. Benchmarking: Rotary Encoder
Tyler
P Systems Level Design Review
11/27/2018

17. Benchmarking: 3-Jaw Chuck
Tyler
P Systems Level Design Review
11/27/2018

18. Concept Selection: Risk Assessment
P Systems Level Design Review
11/27/2018

19. Pugh Chart – iteration 1
Sean

20. Pugh Chart – iteration 2 P15661 - Systems Level Design Review
Tyler
P Systems Level Design Review
11/27/2018

21. Morph Chart
Ethan
P Systems Level Design Review
11/27/2018

22. Proposed Design Voice coil 3-jaw chuck Bolt hole pattern
Creates motion
Translates motion
Varies stroke
3-jaw chuck
Holds specimen
Bolt hole pattern
Attach armature subsystem with base subsystem
Removable platform
In order to clean system
Ethan

23. Alternative Design Rotary motor Scotch yoke 3-jaw chuck
Creates motion
Scotch yoke
Translates motion
3-jaw chuck
Holds specimen
Bolt hole pattern
Attach armature subsystem with base subsystem
Removable platform
In order to clean system
Ethan
P Systems Level Design Review
11/27/2018

24. Risk Assessment P15661 - Systems Level Design Review 11/27/2018
Alexandra
P Systems Level Design Review
11/27/2018

25. Project Plan P15661 - Systems Level Design Review 11/27/2018 Alexandra
Will also talk about lessons learned (plan for exam-heavy weeks) because we address it here
P Systems Level Design Review
11/27/2018

26. Questions?
P Systems Level Design Review
11/27/2018