1. Design Review UL Vibration Test Apparatus February 21, 2013 11:30AM Est.

2. Project & Team Information Project: UL Vibration Test Apparatus Project Number: 13471 Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries) Customer Contacts: Joe Manahan Ed Leubner RIT Faculty Guide: Dr. Benjamin Varela Project Team:Walter Bergstrom Sean Coots Spencer Crandell Mark Ellison February 21, 2013UL Vibration Test Apparatus2

3. Presentation Overview 1)Systems Level Design Review Overview 2)Calculation of Deflection Force 3)Final Design 4)Adjustment Mechanism 5)Linear Motion Mechanism 6)Crank Arm 7)Frame Design 8)Drive System and Motor Selection 9)Lubrication 10)Test Plan 11)Cost Breakdown 12)MSD II Schedule 13)Questions for Customer 14)Open Discussion Appendix: UL Test Stand and Project Background February 21, 2013UL Vibration Test Apparatus3

4. Systems Level Design Review Discussed Designs: – Eccentric Shaft – Scotch Yoke* – Crank Arm* – *Adjustment Mechanism Key Action Items: – Develop adjustment mechanism for fine adjustment of eccentricity – Go ahead with the development of Scotch Yoke Actions Taken: – Adjustment Mechanism refined after multiple design iterations – Development of Crank Arm with Adjustment after feasibility issues arose over lubrication of Scotch Yoke February 21, 2013UL Vibration Test Apparatus4

5. Force Applied to Deflect Luminaire Equations of relative motion were applied to derive the acceleration of the desired deflection assuming a constant angular velocity of the primary shaft. The moment of inertia was than approximated for the conduit with a 100lb cylinder at its end. Assuming the system acted as a pendulum and using the moment of inertia and acceleration we acquired a force. This was then superimposed with the force needed to bend the conduit (cantilever pipe) to the proper deflection. The calculated force was approximately 400lbf. Assuming a factor of safety of 2, the force acting axially on the slider mechanism was approximated at 800lbf. February 21, 2013UL Vibration Test Apparatus5

6. Free Body Diagram (eccentric w/crank) February 21, 2013UL Vibration Test Apparatus6 800 lbf

7. Crankshaft Analysis February 21, 2013UL Vibration Test Apparatus7 A solution to an engine crankshaft force analysis was applied to our problem. The piston side-wall force is the lateral force on the slider mechanism, and the pressure force is replaced with the 800lbf axial force due to the vertical conduit. Courtesy of Dr. Boedo

8. Force Equations February 21, 2013UL Vibration Test Apparatus8 Courtesy of Dr. Boedo F c X1 F c Y1 N 1140 lbf12 lbf2.5 lbf Maximum Forces on Crankpin:

9. Final Design February 21, 2013UL Vibration Test Apparatus9

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13. Adjustment Mechanism Allows for adjustment in eccentricity in order to account for tolerance stack-ups and wear Allows for verification and adjustment of deflection Set screw used for fine adjustment Alignment blocks allow for the measurement of adjustment using calipers Two socket head cap screws for locking the system in place Nord Lock washers to prevent loosening of adjustment mechanism February 21, 2013UL Vibration Test Apparatus13

14. Adjustment Mechanism February 21, 2013UL Vibration Test Apparatus14

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16. 5/8-11 Nord Lock Washers Rated for maximum locking at 197 ft-lbs with 20900lb clamping force Allows for reusable hardware February 21, 2013UL Vibration Test Apparatus16 pelicanparts.com

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18. Adjustment Mechanism Calculations February 21, 2013UL Vibration Test Apparatus18

19. Adjustment Mechanism Calculations February 21, 2013UL Vibration Test Apparatus19

20. GFEM of Adjustment Mechanism \ Elements: 41159 Nodes: 72467 1200 lbf bearing load on pin 1800 lbf bolt pretension on locking bolts February 21, 2013UL Vibration Test Apparatus20

21. Von-Mises Stress February 21, 2013UL Vibration Test Apparatus21

22. Von-Mises Stress February 21, 2013UL Vibration Test Apparatus22

23. Adjustment Mechanism Displacement February 21, 2013UL Vibration Test Apparatus23

24. Linear Motion Mechanism February 21, 2013UL Vibration Test Apparatus24

25. Linear Motion Mechanism Keeps mechanisms enclosed for safety Prevents contaminates from getting into mechanisms Polycarbonate maintenance hatches on top and side of mechanism 1” diameter extension rod allows for more robust design without concern of buckling February 21, 2013UL Vibration Test Apparatus25

26. February 21, 2013UL Vibration Test Apparatus26 Linear Motion Mechanism Calculations ParameterGoverning EquationValue Factor of Safety PV value each bearing29lbf850lbf MAX Shear force each bolt80lbf1477 Rail deflection0.0088in- Critical load for extension rod buckling 1.2e5lbf100 Axial deflection of extension rod 6.06e-4in- Phi due to rail deflection 0.05°1° MAX

27. Linear Motion Mechanism Calculations February 21, 2013UL Vibration Test Apparatus27 Refer to Appendix A of handout for E, I, Sy, A Assumptions Rail deflection assumes a single load at the center of the rail (worst-case scenario) For buckling: C=4 (rigid end and free slider connection) N=1200lbf, m slider g=115lbf, l=22.25in Equations via Shigley’s Mechanical Engineering Design

28. Connecting Rod Peel-Away Brass Shaft Shims Shaft collars for holding bearings in place February 21, 2013UL Vibration Test Apparatus28

29. Connecting Rod Analysis February 21, 2013UL Vibration Test Apparatus29 ParameterGoverning EquationValue Max Bearing Load Bearing Forces600lbf1300lbf Bolt F.O.S. (Shear)1800- Bolt F.O.S. (Tension)72- Axial Force F.O.S.62-

30. GFEM Analysis of Connecting Rod Elements: 65557 Nodes: 108327 February 21, 2013UL Vibration Test Apparatus30 Loading Case 1 Loading Case 2

31. Von-Mises Stress February 21, 2013UL Vibration Test Apparatus31  Load Case 1  Load Case 2

32. Frame Design February 21, 2013UL Vibration Test Apparatus32 44” 34”

33. Frame Design February 21, 2013UL Vibration Test Apparatus33 Advantages: Allows for a single technician to mount the luminaire Extra support of U-channel decrease vibration of system Rubber pads in-between supporting beams help in dampening the system More space efficient than current design *Approximately 44” X 34” footprint Footprint may become larger due to resonate frequency of design (to be tackled by next senior design group)

34. Motor Selection February 21, 2013UL Vibration Test Apparatus34

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36. Recommended Motor February 21, 2013UL Vibration Test Apparatus36

37. February 21, 2013UL Vibration Test Apparatus37 ParameterGoverning EquationValue Max Bearing Load Upper bearing force2450lbf3150lbf Lower bearing force1225lbf3150lbf SeSe 1.10e4psi- F.O.S. Shaft10- F.O.S. Key39- Where k a, k b and k c are Marin factors for surface condition, size, and loading conditions, respectively. l 1 =2, l 2 =4, σ min, σ max, Sy, Sut can be found in Appendix

38. Lubrication Drive Shaft Bearings: Double sealed flange mount bearings with easy access grease zerk fittings. Linear Bearings: Double sealed closed bearings with easy access grease zerk fittings. Crank Arm Bearings: Double Sealed roller bearings pre-packed with grease. Easy access for lubrication by taking off Polycarbonate cover. February 21, 2013UL Vibration Test Apparatus38

39. Test Plan Test the deflection of the pipe Dial gauge Measure required torque using torque wrench Flanged collar mechanism February 21, 2013UL Vibration Test Apparatus39

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44. -Brinkman Lab Machining: $90 per hour -Only part of the frame may be developed for test purposes -Unexpected tooling costs that may arise -Need for remaking parts (we are not expert machinists) February 21, 2013UL Vibration Test Apparatus44

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47. Questions For Customer NPT Pipe Length Pipe Collar Testing with Lamp Financing logistics of Project February 21, 2013UL Vibration Test Apparatus47

48. Open Discussion Any questions? Design concerns not discussed? Feed back on work done to this point? Validity of our Design? Do we have approval to purchase materials and begin developing the product? February 21, 2013UL Vibration Test Apparatus48

49. Appendix UL Test Standard and Project Background

50. Project Background To pass safety requirements for certification the luminaires must meet a series of Underwriters Laboratories Inc. Standards. A Vibration Test Stand is currently being used by Cooper Crouse-Hinds to test pendant mount luminaires according to section 33 of the UL844 Standard. The Current Vibration Test Stand is outdated, has multiple design flaws, and design documentation and drawings are non-existent. Cooper Crouse-Hinds would like a new modernized Vibration Test Stand to be developed that addresses some of the design flaws of the current system while maintaining UL844 Test Standards. This new Design must also have a LabView interface and control capability integrated into the system. February 21, 2013UL Vibration Test Apparatus50

51. Design Goals over Winter/Spring MSD Note: It has been decided that this apparatus will be developed in multiple Senior Design Sequences. Provide customer with two design concepts for vibration mechanism Develop a final design of the vibration mechanism. Design a steel test frame that will support the vibration mechanism and the vertical conduit. Design but do not develop steel frame for entire vibration test machine. Develop a full set of engineering drawings. Calculate and select the required drive train system components. Purchase materials, machine components, and assemble the vibration mechanism and test frame. Test the mechanism to ensure that it meets 1 / 32 ” deflection requirement February 21, 2013UL Vibration Test Apparatus51

52. Summary of UL844 Vibration Test Standard LUMINAIRES FOR USE IN HAZARDOUS (CLASSIFIED) LOCATIONS – UL 844 Section 33 – Vibration Test Standards Luminaire is to be subjected to 35 hours of vibration testing. Luminaire assembly is to be attached to a 26- 1 / 2 ” long conduit via NPT threading. The other end of the NPT threaded pipe is to be secured to the hub of a rigid mounting frame so that the conduit hangs vertically. The conduit should correspond to the smallest size of threaded conduit hub that is designed to attach to the Luminaire being tested. The horizontal force to be applied to the system in order to obtain the deflection must me located 4” above the location of the conduit where the Luminaire attaches. The deflection must be 1 / 32 ” with 1 / 16 ” total deflection per cycle. The system must run at 2000 cycles/min. February 21, 2013UL Vibration Test Apparatus52

53. UL844 Vibration Test Standard February 21, 2013UL Vibration Test Apparatus53

54. Design Flaws Associated with Original Design February 21, 2013UL Vibration Test Apparatus54 Difficult for one technician to set up test Lubricant not contained Machine components exposed to contaminants Belts used (slipping) Uses single speed motor with a speed reducer Frequency adjustment dial held in place with rope No displacement adjustment Attachment collar may experience minor buckling Does not accounted for part wear and tolerance stack up

55. Customer Design Needs Need #Importance High 3 – 2 – 1 Low Design CriteriaMeasure of Effectiveness CN13Obtain vibration frequency of 2000 cycles/minStroboscope CN23Create displacement of 1/32” at 22.5” bellow pipe flangeDial Gauge CN32Adjustment of attachment collar position for perpendicularity___ CN42240 V electrical input___ CN52System envelope size is maintained or decreased from original system___ CN61Mounts to current anchor points in floor___ CN73Capability to adjust for different pipe sizes___ CN81Use current flange mounting for pipes___ CN92Design in an easily removable collar___ CN103Will support multiple types of Luminaires___ CN112Easy to mount the Luminaires1 Technician can run entire test CN121Ease of lubrication___ CN132Containment of LubricantLook for leaking of Lubricant CN143System to not run near resonate frequencyDoes not shake itself apart CN151Minimize noise of systemUnder 85 decibels (OCIA standard for requiring ear protection) February 21, 2013UL Vibration Test Apparatus55

56. PUGH Matrix: Rotational to Linear Motion Mechanism February 21, 2013UL Vibration Test Apparatus56

57. PUGH Matrix: Slider Mechanism February 21, 2013UL Vibration Test Apparatus57

58. PUGH Matrix: Displacement Adjustment Mechanism February 21, 2013UL Vibration Test Apparatus58

59. February 21, 2013UL Vibration Test Apparatus59 Risk Assessment

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