1. TEAM 14 John Armitage Douglas DeVoto Brian Polkowski Marykate Wioncek SOUTHCO Vibration Fatigue Tester

2. Southco Global manufacturer of access hardware solutions Fasteners, latches, hinges, handles, etc. Industries served: Computers, electronics, automotive, aerospace, marine, etc.

3. Project Goal Design and build a vibration fatigue tester Simulate off-highway service environment Test compression latches

4. Compression Latches T-HANDLE CUSTOM COLORS CUP LOCK PLUG CUP VERSIONS PAWL HOUSING LOCK PLUG

5. Business Benefit Quality assurance Provide quality test data to customer Aids in proper latch selection Product improvement Accurate data on failure conditions

6. Customers/Wants Top 3 Wants: - Accurate Data - Adaptable to Different Kinds of Latches - Adjustable Forces and Hz

7. Metrics

8. Current State/Future State Outsourced to testing company Used linear actuators (not designed for high speed testing)

9. Benchmarking Existing vibration testers Shaker tables Instron machines Other benchmarking Actuators Hammer drills

10. Concept Selection Cam and Follower Shaker Table Actuator Instron

11. Final Concept

12. How It Works

13. Subsystem: Fixed Parts Pillow Blocks Linear bearings Bearing Mounting Plate

14. Subsystem: Motor system Baldor Motor Drive Belt Sprockets Cam Cam Shaft

15. 2 secondary springs Roller follower Alignment rods Cam Follower Bracket Subsystem: Secondary Spring System

16. Subsystem: Primary Spring System Primary Spring Spanner Nut Threaded Rod Main Shaft Pawl

17. Subsystem: Latch Latch Latch Plate Latch Plate Mount Base Plate

18. Subsystem: Frame Safety Shield Polycarbonate 80/20 Machine Base Base Plate Frame Motor Mount Alumilite Covers

19. Measurement and Control System

20. Prototype

21. Functioning Prototype

22. Prototype Testing Procedure Used dummy latch with built in force sensor Adjusted to 100lb preload Ran machine with calibrated sensors at several speeds up to 3600 rpm to verify that the prototype achieved 3000N of force

23. Latch Testing Procedure Bolt latch plate to base Adjust spanner nut to apply the appropriate initial load Confirm correct load using labview software Turn on motor and change to correct speed Record number of cycles to failure

24. Validation of Metrics GoalResults Adjustable to 60Hz√ Adjustable initial load up to 100lb√ Adjustable Dynamic load up to 3000N√ ± 5% of desired load√

25. Metric: Adjustability

26. Additional Test Results Measurement of Decibels OSHA standards state that a worker can be exposed to 90 dB for an 8 hour work day. Hearing Equipment is required in Southco testing facility rpmdB 60074.8 120079.8 180082.8 240084.3 300084.8 360088.1

27. Project Management Schedule

28. Project Costs Mechanical ComponentsCost Motor$4,000 Springs$170 Machine Table$1,300 Drive Belt$250 Linear Bearings$400 Roller Follower$200 Pillow Blocks$300 Cam Bushing$200 Raw Material$1,700 $8,520 Software ComponentsCost Force Sensor$400 Accelerometer$365 Controllers$4000 $4,765 Total CostsCost Mechanical Components$8,520 Software Components$4,765 Machinist Time$6,500 Engineering Time$50,000 $69,785

29. Cost Analysis Final cost of testing mechanism to Southco $15000 Cost of latch testing Previous testing - $625 per latch Current testing – Cost of Latch Save on shipping costs Faster data acquisition

30. Implementation Plan Hand off of Prototype to Southco Representatives: 12/4 Plans: Move Prototype to Southco facility Begin testing of latches as soon as possible Produce machines for other Southco facilities

31. Acknowledgements Thank you to our Southco Sponsors: Ratnesh Dwivedi Ron Magidson Mark DiAntonio Jesus Albillos Al Frattarola Thank you to our Advisor: Mr. Nate Cloud Special Thanks to: Ed Cicutti

32. Questions?

33. Resonance

34. Cam Torque spring force no preloadfollower displacment mmcam offset mmsecondary kinitial secondary force 2555.17782.7761601481.38808007410381380 thetav m/sa m/s^2x mmk N/mmmFwT N*mT lbsf*ftThpF of fTf N*mTf lbsf*ftTf hpT total hp 00197.2660920.463008.418376.9800030.084182.2924151.6907981.158963 50.045582453196.51534330.1210944053241.0660.3918930.2890450.19812732.410662.4696921.8215511.2485881.446715 100.090817997194.26908620.24195833464.2880.8345790.6155540.42193334.642882.6397871.9470071.3345821.756516 150.135362361190.5443240.3623616133677.7371.3205670.9740.66763136.777372.8024362.066971.4168112.084443 200.178876535185.36940450.4820751513881.1351.8415931.358290.93104438.811352.9574252.1812841.4951682.426212 250.221029351178.78371190.6008710314074.272.3888091.7618951.20769740.74273.1045942.2898311.5695722.777268 300.2615170.83736730.7185231184257.0022.9529582.177991.4929142.570023.2438362.392531.6399673.132877 350.299980476161.59084720.8348074574429.2543.5245632.5995841.78189344.292543.3750922.489341.7063263.488219 400.33617792151.11452310.9495026924591.0154.0941113.0196612.06983645.910153.4983542.5802531.7686433.838479 450.369816847139.48812631.0623904944742.3374.6522253.4313052.35199947.423373.613662.6652991.8269384.178936 500.400641244126.80014061.1732559764883.3285.1898313.8278222.62379348.833283.7210962.7445391.8812534.505046 550.428416519113.14712931.2818880985014.1555.6983044.2028532.88085950.141553.8207862.8180671.9316534.812512 600.45293128698.6331.3880800745135.0366.1696074.5504683.11913351.350363.9128982.8860051.9782215.097354 650.47399897383.368214021.491629765246.2396.5964034.8652573.33490652.462393.9976342.9485032.0210615.355967 700.49145924167.468945591.5923400445348.0756.9721495.1423933.52486953.480754.0752333.0057372.0602925.585161 750.50517920751.056197751.6900192195440.8937.2911725.3776923.68615654.408934.145963.0579032.0960495.782205 800.51505445534.254881421.7844813455525.087.5487215.5676513.81636455.25084.2101113.1052182.1284825.944845 850.52100982717.192864751.8755466115601.057.7415.7094683.91357356.01054.2683.1479152.1577486.071321 900.5231.2084E-141.9630416665669.2437.8651765.8010563.97635256.692434.3199633.1862412.1840196.160371 950.521009827-17.192864752.046799965730.1187.919385.8410344.00375557.301184.366353.2204542.2074716.211226 1000.515054455-34.254881422.1266620545784.1487.9026775.8287153.99531157.841484.4075213.250822.2282856.223596 1050.505179207-51.056197752.2024759265831.8147.8150335.7640723.95100158.318144.4438423.277612.2466486.197649 1100.491459241-67.468945592.274097265873.6017.6572645.6477073.87123958.736014.4756843.3010952.2627466.133985 1150.473998973-83.368214022.3413897215909.9917.4309765.4808063.75683659.099914.5034133.3215472.2767656.033601 1200.452931286-98.6332.4042252135941.4597.1385025.2650893.60897259.414594.5273923.3392322.2888875.897859 1250.428416519-113.14712932.4624841265968.4686.7828285.0027573.42915559.684684.5479733.3544122.2992935.728448 1300.400641244-126.80014062.516055565991.4656.367524.6964423.21919159.914654.5654963.3673372.3081525.527342 1350.369816847-139.48812632.5648375396010.8715.8966564.349152.98113960.108714.5802843.3782442.3156285.296767 1400.33617792-151.11452312.6087372056027.0865.374753.9642122.71728160.270864.592643.3873572.3218745.039156 1450.299980476-161.59084722.6476709916040.4764.8066873.545232.43008960.404764.6028433.3948822.3270334.757122 1500.2615-170.83736732.6815647856051.3744.1976613.0960362.12218860.513744.6111473.4010072.3312314.453419 1550.221029351-178.78371192.7103540676060.0773.5531192.6206461.7963360.600774.6177793.4058992.3345844.130914 1600.178876535-185.36940452.7339840376066.842.8787082.1232261.45537260.66844.6229323.4096992.3371893.792561 1650.135362361-190.5443242.7524097136071.8752.1802311.6080561.10224760.718754.6267693.4125292.3391293.441376 1650.135362361-190.5443242.7524097136071.8752.1802311.6080561.10224760.718754.6267693.4125292.3391293.441376 1700.090817997-194.26908622.765596026075.3511.4636091.0795020.73994860.753514.6294173.4144832.3404683.080416 1750.045582453-196.51534332.7735178586077.3880.7348460.5419950.37151260.773884.6309693.4156272.3412532.712764 1806.40753E-17-197.2662.7761601486078.0581.03E-157.62E-165.22E-1660.780584.631483.4160042.341511

35. Cam Shaft Calculations

36. Cam Shaft Calculations Continued