Design Review UL Vibration Test Apparatus February 21, 2013 - PowerPoint PPT Presentation

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

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, 2013 UL Vibration Test Apparatus 2

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, 2013 UL Vibration Test Apparatus 3

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, 2013 UL Vibration Test Apparatus 4

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, 2013 UL Vibration Test Apparatus 5

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

Crankshaft Analysis 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 February 21, 2013 UL Vibration Test Apparatus 7

Force Equations Maximum Forces on Crankpin: F c X1 F c Y1 N 1140 lbf 12 lbf 2.5 lbf Courtesy of Dr. Boedo February 21, 2013 UL Vibration Test Apparatus 8

Final Design February 21, 2013 UL Vibration Test Apparatus 9

February 21, 2013 UL Vibration Test Apparatus 10

February 21, 2013 UL Vibration Test Apparatus 11

February 21, 2013 UL Vibration Test Apparatus 12

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, 2013 UL Vibration Test Apparatus 13

Adjustment Mechanism February 21, 2013 UL Vibration Test Apparatus 14

February 21, 2013 UL Vibration Test Apparatus 15

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

February 21, 2013 UL Vibration Test Apparatus 17

Adjustment Mechanism Calculations • Assumptions: – Rigid connection between bed and disc surface – θ = 45°; sin( θ ) = cos( θ ) = 2 2 – Worst-case loading along the plane of motion for slider at maximum N value (N ≈ 1200lbf) – Dry steel: μ s =0.8 ( via engineeringtoolbox.com ) February 21, 2013 UL Vibration Test Apparatus 18

Adjustment Mechanism Calculations • Required clamping force (each bolt) 𝑂 – 𝐺 𝑐𝑝𝑚𝑢 = 𝜈 𝑡 (2 2−2) ≅ 1840 lb • Required torque (each bolt) 𝑂𝐸 – 𝑈 𝑠𝑓𝑟 = 𝜈 𝑡 ( 2−1) ≅ 150 lb ∙ ft • Where N=1200lbf, μ s =0.8, D=0.5” • Assuming simplified estimate: 𝑈 𝑠𝑓𝑟 ≈ 2𝐸𝐺 𝑐𝑝𝑚𝑢 February 21, 2013 UL Vibration Test Apparatus 19

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

Von-Mises Stress February 21, 2013 UL Vibration Test Apparatus 21

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

Adjustment Mechanism Displacement February 21, 2013 UL Vibration Test Apparatus 23

Linear Motion Mechanism February 21, 2013 UL Vibration Test Apparatus 24

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, 2013 UL Vibration Test Apparatus 25

Linear Motion Mechanism Calculations Factor of Parameter Governing Equation Value Safety 𝑂𝑇 = 1 𝑍1 2 + 𝑛 𝑡𝑚𝑗𝑒𝑓𝑠 𝑕 2 PV value each bearing 29lbf 850lbf MAX 𝐺 𝐺 𝐷 4 𝑊 = 1 𝑂 2 + 𝑛 𝑡𝑚𝑗𝑒𝑓𝑠 𝑕 2 Shear force each bolt 80lbf 1477 𝐺 16 𝑧 𝑛𝑏𝑦 = 𝑛 𝑡𝑚𝑗𝑒𝑓𝑠 𝑕𝑚 3 Rail deflection 0.0088in - 48𝐹𝐽 Critical load for 2𝜌 ∙ 𝑚 𝑇 𝑧 1 𝑄 𝑑𝑠 = 𝐵 𝑇 𝑧 − 1.2e5lbf 100 𝐷𝐹 𝑙 extension rod buckling Axial deflection of 𝜀 𝑛𝑏𝑦 = 𝑂𝑚 6.06e-4in - 𝐵𝐹 extension rod Phi due to rail 𝜒 𝑛𝑏𝑦 = 𝑢𝑏𝑜 −1 𝑧 𝑛𝑏𝑦 0.05° 1° MAX 𝑚/2 deflection February 21, 2013 UL Vibration Test Apparatus 26

Linear Motion Mechanism Calculations • 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 February 21, 2013 UL Vibration Test Apparatus 27

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

Connecting Rod Analysis Max Bearing Parameter Governing Equation Value Load 𝑌 = 𝑂𝑑𝑝𝑡(𝜄) Bearing Forces 600lbf 1300lbf 𝑆 𝐶 2 𝑜 𝑊 = 𝑇 𝑄 𝐵 𝑐𝑝𝑚𝑢 Bolt F.O.S. (Shear) 1800 - 𝐺 𝑊 𝑜 𝑈 = 𝑇 𝑄 𝐵 𝑐𝑝𝑚𝑢 Bolt F.O.S. (Tension) 72 - 𝐺 𝑈 𝑜 = 𝑇 𝑧 𝑥𝑢 Axial Force F.O.S. 62 - 𝑂 February 21, 2013 UL Vibration Test Apparatus 29

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

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

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

Frame Design 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) February 21, 2013 UL Vibration Test Apparatus 33

Motor Selection • 3-Phase, 240V AC Motor • Steady-state period – No acceleration of system 𝑌1 sin 𝜄 + 𝐺 𝑍1 𝜄 – 𝑈 𝑠𝑓𝑟 = 𝑈 𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 = 𝑠 𝐺 𝑑 𝑑 𝑈 𝑠𝑓𝑟 = 1.07 lbf ∙ ft • • This corresponds to a motor horsepower of 0.41,therefore a 1hp motor is desired – Where r= 1 64 in (stroke of crank), θ is angle of rotation of the motor ( 0 ≤ 𝜄 ≤ 2𝜌) • Start-up period – 𝑈 𝑠𝑓𝑟 = 𝑈 𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 + 𝐾 𝑡𝑧𝑡 𝛽 • Where: 𝐾 𝑡𝑧𝑡 = 𝐾 𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 + 𝐾 𝑡ℎ𝑏𝑔𝑢 + 𝐾 𝑒𝑗𝑡𝑑/𝑛𝑓𝑑ℎ𝑏𝑜𝑗𝑡𝑛 + 𝐾 𝑛𝑝𝑢𝑝𝑠 Assuming 50-60 seconds to reach 2000RPM, T req ≈ 3 lbf ∙ ft • February 21, 2013 UL Vibration Test Apparatus 34

At 2000RPM, a general purpose 1HP AC Baldor motor will produce 90oz ∙ ft ≈ 5.7lb ∙ ft torque • • Our estimated range for required start-up torque is highlighted in yellow At ~5.7lb ∙ ft torque, it is estimated that 2000RPM will be reached in approximately 30 • seconds • A variable-frequency drive will be used to obtain the required 2000RPM speed February 21, 2013 UL Vibration Test Apparatus 35

Recommended Motor February 21, 2013 UL Vibration Test Apparatus 36