1. Detailed Design Presentation
Loading, Measurement, Control, and Test of a Journal Bearing Test Platform
Kris Kidder | John Dolan | Shay Stanistreet | Anthony Miuccio

2. Agenda Team Vision Preliminary MSD II Timeline
Load Cell Parameters (as discussed prior)
Detailed Design Components
Bill of Materials
Feasibility Analysis
Oil Flow Characteristics
Test Plans
Updated Risk Assessment
Plans to round out MSD I

3. Team Vision
A concept for the pre-loaded spring assembly and loading subsystem will be modelled and simulated under operating conditions. Necessary parts will be identified and a preliminary bill of materials will display expected cost of the systems to be built. If time allows, parts will be purchased and the subsystems will be implemented, with the expectation that preliminary tests will be run to get a feel for real-world results and feasibility.

4. Timeline

5. Current Load Cell Parameters
Potential problems can arise from load cell not taking data quickly enough to be used for analysis (slower than 25 Hz)
Load cell measurement rate is not available in any website/manual
Leads us to believe that the actual trouble is in the DPM-3 Signal Monitors, not the load cell.
Signal Monitors refresh at 3 times per second according to the documentation
60 Hz is a possibility, will take more time to fully understand signal monitors
Other Relevant Parameters
Max Load: 2000 lbs.
Calibration: Leveled out to exactly 0.00 when weight was added and then removed, shows little to no signs of fluctuation. Further tests will be completed to show higher levels of accuracy in calibration.

6. Detailed Design - EMA Arm Redesign

7. Detailed Design - EMA Arm

8. Detailed Design - Load Cell Plate

9. Detailed Design - Anti-backlash System

10. Detailed Design - Sliding Plate

11. Detailed Design - Sliding Plate

12. Detailed Design - Cont.

13. Detailed Design - Backing Plate

14. Current Bill of Materials

15. Lead Screw Feasibility
Calculations done in MATLAB to remove human error and allow for iterative solution making
Equations used to determine torque required to turn a preloaded spring system like this one.
Found very reasonable torques, on the order of under 10 ft-lbs.
About 5.5 ft-lbs to raise lead screw (analytical)
Constructed quick experiment to verify findings, findings correlated to expectations

16. Spring Fatigue Capability
Calculations done in MATLAB to remove human error and allow for iterative solution making
Answers provided match online calculator website for reinforcement
Used soderberg because it outputs the most conservative estimate
With 5 Factors of Safety, our spring will show very minimal fatigue signs.

17. Oil Flow 2 new journals ¼” Step reduction ~0.6 - 1.3 gallons/minute
How much is too much clearance?
Bending of a thinner shaft due to heavy load
Excessive eccentricity leads to instability

18. Test Plans - Fabrication
Fabrication of Related Parts for Testing
Journal Bearings
Already have journal bearings with similar characteristics
Will be making modifications to flow hole and groove width to observe oil flow changes
Journals
Will be designing and procuring two additional shafts to be used in oil flow testing
Due to necessary tolerancing, will likely need to be outsourced
3 total shafts will allow us to check linearity
Clearance measurement is most critical to oil flow, so that’ll be the prime concern

19. Test Plans - Procedure
Run current setup with full sensing capability to collect pertinent data
Collected data will include vibrations, oil flow, housing displacement, and oil temperature.
Remove current journal, replace with first fabricated journal, run same profile and obtain similar data.
Journal Shaft Change SOP currently in progress and on EDGE
Remove second journal, replace with third, collect similar data.
Remove bearing, replace with modified bearing.
(Repeat steps 3, 4, and 5 until all data has been collected & logged.
Utilize data overlays to see the effects of changing the clearance, maximizing displacements, etc. Provide an analytical comparison to see how well our data matches our current expectations.

20. Risk Assessment

21. Risk Assessment Cont.

22. Plans for Next Phase Finalize Detailed Design Plan
Begin purchasing of components
Finalize Journal Shaft Change SOP
Finalize MSD II Timeline

23. Any Questions?