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

▶
design review
SMART_READER_LITE
LIVE PREVIEW

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

Mar 19, 2024 165 likes •780 views

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

slide-1
SLIDE 1

Design Review

UL Vibration Test Apparatus

February 21, 2013 11:30AM Est.

slide-2
SLIDE 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, 2013 UL Vibration Test Apparatus 2

slide-3
SLIDE 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, 2013 UL Vibration Test Apparatus 3

slide-4
SLIDE 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, 2013 UL Vibration Test Apparatus 4

slide-5
SLIDE 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, 2013 UL Vibration Test Apparatus 5

slide-6
SLIDE 6

Free Body Diagram (eccentric w/crank)

February 21, 2013 UL Vibration Test Apparatus 6 800 lbf

slide-7
SLIDE 7

Crankshaft Analysis

February 21, 2013 UL Vibration Test Apparatus 7

A solution to an engine crankshaft force analysis was applied to

  • ur 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

slide-8
SLIDE 8

Force Equations

February 21, 2013 UL Vibration Test Apparatus 8 Courtesy of Dr. Boedo

Fc

X1

Fc

Y1

N 1140 lbf 12 lbf 2.5 lbf Maximum Forces on Crankpin:

slide-9
SLIDE 9

Final Design

February 21, 2013 UL Vibration Test Apparatus 9

slide-10
SLIDE 10

February 21, 2013 UL Vibration Test Apparatus 10

slide-11
SLIDE 11

February 21, 2013 UL Vibration Test Apparatus 11

slide-12
SLIDE 12

February 21, 2013 UL Vibration Test Apparatus 12

slide-13
SLIDE 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, 2013 UL Vibration Test Apparatus 13

slide-14
SLIDE 14

Adjustment Mechanism

February 21, 2013 UL Vibration Test Apparatus 14

slide-15
SLIDE 15

February 21, 2013 UL Vibration Test Apparatus 15

slide-16
SLIDE 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, 2013 UL Vibration Test Apparatus 16

pelicanparts.com

slide-17
SLIDE 17

February 21, 2013 UL Vibration Test Apparatus 17

slide-18
SLIDE 18

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: μs=0.8 (via engineeringtoolbox.com)

February 21, 2013 UL Vibration Test Apparatus 18

slide-19
SLIDE 19

Adjustment Mechanism Calculations

  • Required clamping force (each bolt)

– 𝐺𝑐𝑝𝑚𝑢 =

𝑂 𝜈𝑡(2 2−2) ≅ 1840 lb

  • Required torque (each bolt)

– 𝑈

𝑠𝑓𝑟 = 𝑂𝐸 𝜈𝑡( 2−1) ≅ 150 lb ∙ ft

  • Where N=1200lbf, μs=0.8, D=0.5”
  • Assuming simplified estimate: 𝑈

𝑠𝑓𝑟 ≈ 2𝐸𝐺 𝑐𝑝𝑚𝑢

February 21, 2013 UL Vibration Test Apparatus 19

slide-20
SLIDE 20

GFEM of Adjustment Mechanism

  • \
  • Elements: 41159
  • Nodes: 72467
  • 1200 lbf bearing load on pin
  • 1800 lbf bolt pretension on

locking bolts

February 21, 2013 UL Vibration Test Apparatus 20

slide-21
SLIDE 21

Von-Mises Stress

February 21, 2013 UL Vibration Test Apparatus 21

slide-22
SLIDE 22

Von-Mises Stress

February 21, 2013 UL Vibration Test Apparatus 22

slide-23
SLIDE 23

Adjustment Mechanism Displacement

February 21, 2013 UL Vibration Test Apparatus 23

slide-24
SLIDE 24

Linear Motion Mechanism

February 21, 2013 UL Vibration Test Apparatus 24

slide-25
SLIDE 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, 2013 UL Vibration Test Apparatus 25

slide-26
SLIDE 26

February 21, 2013 UL Vibration Test Apparatus 26

Linear Motion Mechanism Calculations

Parameter Governing Equation Value Factor of Safety PV value each bearing

𝐺

𝑂𝑇 = 1

4 𝐺

𝐷 𝑍1 2 + 𝑛𝑡𝑚𝑗𝑒𝑓𝑠𝑕 2

29lbf 850lbf MAX Shear force each bolt

𝐺

𝑊 = 1

16 𝑂 2 + 𝑛𝑡𝑚𝑗𝑒𝑓𝑠𝑕 2

80lbf 1477 Rail deflection

𝑧𝑛𝑏𝑦 = 𝑛𝑡𝑚𝑗𝑒𝑓𝑠𝑕𝑚3 48𝐹𝐽

0.0088in

  • Critical load for

extension rod buckling

𝑄

𝑑𝑠 = 𝐵 𝑇𝑧 −

𝑇𝑧 2𝜌 ∙ 𝑚 𝑙 1 𝐷𝐹

1.2e5lbf 100 Axial deflection of extension rod

𝜀𝑛𝑏𝑦 = 𝑂𝑚 𝐵𝐹

6.06e-4in

  • Phi due to rail

deflection

𝜒𝑛𝑏𝑦 = 𝑢𝑏𝑜−1 𝑧𝑛𝑏𝑦 𝑚/2

0.05° 1° MAX

slide-27
SLIDE 27

Linear Motion Mechanism Calculations

February 21, 2013 UL Vibration Test Apparatus 27

  • 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, msliderg=115lbf, l=22.25in
  • Equations via Shigley’s Mechanical Engineering

Design

slide-28
SLIDE 28

Connecting Rod

  • Peel-Away Brass Shaft Shims
  • Shaft collars for holding bearings in place

February 21, 2013 UL Vibration Test Apparatus 28

slide-29
SLIDE 29

Connecting Rod Analysis

February 21, 2013 UL Vibration Test Apparatus 29

Parameter Governing Equation Value Max Bearing Load Bearing Forces

𝑆𝐶

𝑌 = 𝑂𝑑𝑝𝑡(𝜄)

2

600lbf 1300lbf Bolt F.O.S. (Shear)

𝑜𝑊 = 𝑇𝑄𝐵𝑐𝑝𝑚𝑢 𝐺

𝑊

1800

  • Bolt F.O.S. (Tension)

𝑜𝑈 = 𝑇𝑄𝐵𝑐𝑝𝑚𝑢 𝐺𝑈

72

  • Axial Force F.O.S.

𝑜 = 𝑇𝑧𝑥𝑢 𝑂

62

slide-30
SLIDE 30

GFEM Analysis of Connecting Rod

  • Elements: 65557
  • Nodes: 108327

February 21, 2013 UL Vibration Test Apparatus 30

Loading Case 1 Loading Case 2

slide-31
SLIDE 31

Von-Mises Stress

February 21, 2013 UL Vibration Test Apparatus 31

  • Load Case 1
  • Load Case 2
slide-32
SLIDE 32

Frame Design

February 21, 2013 UL Vibration Test Apparatus 32

44” 34”

slide-33
SLIDE 33

Frame Design

February 21, 2013 UL Vibration Test Apparatus 33

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)

slide-34
SLIDE 34

Motor Selection

  • 3-Phase, 240V AC Motor
  • Steady-state period

– No acceleration of system – 𝑈

𝑠𝑓𝑟 = 𝑈𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 = 𝑠 𝐺 𝑑 𝑌1 sin 𝜄 + 𝐺 𝑑 𝑍1 𝜄

  • 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 = 𝑈𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 + 𝐾𝑡𝑧𝑡𝛽

  • Where: 𝐾𝑡𝑧𝑡 = 𝐾𝑠𝑓𝑔𝑚𝑓𝑑𝑢𝑓𝑒 + 𝐾𝑡ℎ𝑏𝑔𝑢 + 𝐾𝑒𝑗𝑡𝑑/𝑛𝑓𝑑ℎ𝑏𝑜𝑗𝑡𝑛 + 𝐾𝑛𝑝𝑢𝑝𝑠
  • Assuming 50-60 seconds to reach 2000RPM, Treq ≈ 3 lbf∙ft

February 21, 2013 UL Vibration Test Apparatus 34

slide-35
SLIDE 35

February 21, 2013 UL Vibration Test Apparatus 35

  • 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
slide-36
SLIDE 36

Recommended Motor

February 21, 2013 UL Vibration Test Apparatus 36

slide-37
SLIDE 37

February 21, 2013 UL Vibration Test Apparatus 37

Parameter Governing Equation Value Max Bearing Load Upper bearing force

𝑆𝐶1

𝑌 =

𝑚2 𝑚1 𝐺

𝐷 𝑌1

𝑚2 𝑚1 − 1

2450lbf 3150lbf Lower bearing force

𝑆𝐶2

𝑌 =

𝐺

𝐷 𝑌1

𝑚2 𝑚1 − 1

1225lbf 3150lbf Se

𝑇𝑓 = 0.5𝑙𝑏𝑙𝑐𝑙𝑑𝑇𝑣𝑢

1.10e4psi

  • F.O.S. Shaft

𝑜 = 𝑇𝑓𝑇𝑧 𝑇𝑧𝜏𝑏 + 𝑇𝑓𝜏𝑛

10

  • F.O.S. Key

𝑜𝐿𝐹𝑍 = 𝑇𝑧𝑥𝑚𝑠 𝑈𝑁𝑃𝑈𝑃𝑆

39

  • Where ka, kb and kc are Marin factors for surface condition, size, and loading

conditions, respectively.

  • l1=2 , l2=4 , σmin, σmax, Sy, Sut can be found in Appendix

𝜏 𝑏 = 𝜏𝑛𝑏𝑦 − 𝜏𝑛𝑗𝑜 2 𝜏 𝑛 = 𝜏𝑛𝑏𝑦 + 𝜏𝑛𝑗𝑜 2

slide-38
SLIDE 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, 2013 UL Vibration Test Apparatus 38

slide-39
SLIDE 39

Test Plan

  • Test the deflection of the pipe
  • Dial gauge
  • Measure required torque using torque wrench
  • Flanged collar mechanism

February 21, 2013 UL Vibration Test Apparatus 39

slide-40
SLIDE 40

Part Part Description Supplier Purchase # Qty.

  • Pkg. Qty. Unit Price

Price Dowel 1/2"D X2" Alloy Steel MSC MSC#73079030 2 1 4.34 8.68 Dowel 1/4"D X 3/4" Alloy Steel MSC MSC#06024079 2 100 17.76 17.76 Dowel 1/4"D X 1" Alloy Steel MSC MSC#06024103 13 100 20.56 20.56 Dowel 1/4"D X 1.5" Alloy Steel MSC MSC#06024152 36 100 24.83 24.83 Dowel 3/4"D X 2" Alloy Steel MSC MSC#00328922 2 1 8.09 16.18 Nut Grade 8 Steel Nylon-Insert Hex Locknut Znc-Yellow Pltd, 1/2"-13 Thrd Sz, 3/4" W, 19/32" H McMaster-Carr MMC#97135A250 4 10 4.44 4.44 Nut Grade 8 Steel Nylon-Insert Hex Locknut Znc-Yellow Pltd, 3/8"-16 Thrd Sz, 9/16" W, 29/64" H McMaster-Carr MMC#97135A230 8 100 4.14 4.14 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/2"-13 Thread, 2-3/4" Length McMaster-Carr MMC#91251A723 2 5 5.86 5.86 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/2"-13 Thread, 3" Length McMaster-Carr MMC#91251A724 2 5 5.94 5.94 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 2" Length McMaster-Carr MMC#91251A550 4 25 5.51 5.51 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 3/8"-16 Thread, 2-1/4" Length McMaster-Carr MMC#91251A633 8 25 9.21 9.21 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 3/4" Length McMaster-Carr MMC#91251A540 18 50 6.96 6.96 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 1" Length McMaster-Carr MMC#91251A542 19 50 7.58 7.58 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 3/8"-16 Thread, 7/8" Length McMaster-Carr MMC#91251A623 4 25 6.09 6.09 Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 1-1/4" Length McMaster-Carr MMC#91251A544 16 50 11.03 11.03 Set Screw Alloy Steel Flat Point Socket Set Screw 1/2"-13 Thread, 1-1/4" Length McMaster-Carr MMC#94105A715 1 5 9.87 9.87 Die Spring Screw Die-Spring Screw Cap 9/16"-18 Thread, 1/4" Hex, 5/16" Thickness McMaster-Carr MMC#96235K700 2 1 2.54 5.08 Nylon Bushing Nylon Bearing Flanged, for 1/2" Shaft Dia, 5/8" OD, 3/8" Length McMaster-Carr MMC#6389K419 2 1 5.54 11.08 Drive Shaft Fully Keyed Precision Drive Shaft W/Cert 1" OD, 1/4" Keyway Width, 12" Length McMaster-Carr MMC#8488T84 1 1 34.06 34.06 Shim Wide-Rim Zinc-Plated Steel Shim .075" Thick, 1" ID, 1-1/2" OD McMaster-Carr MMC#97669A330 2 25 5.82 5.82 Key Steel Machine Key Oversized w/ Square Ends, 1/4" Square, 1" Length McMaster-Carr MMC#98870A395 1 10 5.1 5.1 Flanged Shaft Collar Mounting Flange One-Piece Steel Shaft Collar 1" Bore, 2" Collar OD, 1" Overall Width McMaster-Carr MMC#9684T4 1 1 38.13 38.13 T Block Black-Oxide Steel Full-Thread T-Slot Nut 1/2"-13 Thread Size, for 5/8" Slot Width McMaster-Carr MMC#94750A584 2 1 3.17 6.34 Lock Washer Zinc-Coated Steel Wedge Lock Washer 1/2" Screw Size, .77" OD, .10" Thick McMaster-Carr MMC#91074A133 2 10 9.32 9.32 spring Type 302 Stainless Steel Compression Spring .750" Length, .500" OD, .062" Wire Diameter McMaster-Carr MMC#1986K118 2 6 4.76 4.76 Shaft Collar Two-Piece Shaft Collar with Wrench Flats 1" Bore, 1-3/4" Outside Diameter, 1/2" Width McMaster-Carr MMC#9746T4 1 1 7.17 7.17 Extension Rod Steel Drive Shaft 1" OD, 24" Length McMaster-Carr MMC#1346K38 1 1 40.82 40.82 Linear Rail Hardened Precision Steel Shaft 1" Diameter, 18" Length McMaster-Carr MMC#6061K45 2 1 21.18 42.36 Linear Bearing High-Speed Pillow-Block Linear Sleeve Bearing Closed, for 1" Shaft Diameter McMaster-Carr MMC#6674K16 4 1 93.37 373.48 Pin Collar Two-Piece Clamp-on Shaft Collar Steel, 3/4" Bore, 1-1/2" OD, 1/2" Width McMaster-Carr MMC#6436K16 2 1 4.46 8.92 Shaft Support Quick-Access Base Mount Shaft Support for 1" Shaft OD McMaster-Carr MMC#1865K6 6 1 24.57 147.42 Peel Away Shim 1 Peel-Away Brass Shim .032" Thick, 3/4" ID, 1-1/8" OD McMaster-Carr MMC#90805A164 3 1 6.8 20.4 Peel Away Shim 2 Peel-Away Brass Shim .062" Thick, 3/4" ID, 1-1/8" OD McMaster-Carr MMC#90805A184 1 1 9.17 9.17 Ball bearing High-Load Steel Ball Bearing Dbl Sealed, for Shaft Dia 3/4" X 1-3/4" OD X 1/2" W McMaster-Carr MMC#2780T3 2 1 17.85 35.7 Flange Mount Bearing Cast Iron Flange-Mounted Steel Ball Bearing 4-Bolt SQ-Flange, for 1" Shaft Diameter McMaster-Carr MMC#5967K84 2 1 41.97 83.94 1053.71 Hardware & Standard Parts Hardware and Standard Parts Total:

February 21, 2013 UL Vibration Test Apparatus 40

slide-41
SLIDE 41

Part Part Qty. Part Description Supplier Purchase #

  • Qty. Unit Price

Price Alignment Block 1 Adjustment Screw Plate 1 Spring Plate 1 Adjustment Base 1 12"X4"X1" 1018 Steel MSC MSC #03913977 1 55.32 55.32 Adjustment Slider 1 12X4X1.5 1018 Steel MSC MSC #03915626 1 83.64 83.64 Circular Plate 1 8"D X 3/4" 304 Stainless Steel MSC MSC #75335299 1 154.7 154.7 Side Plates 2 Multipurpose O1 Tool Steel Tight-Tolerance Flat Stock, 1/2" X 8", 1-1/2'L McMaster-Carr MMC#9516K718 2 163.23 326.46 Front Plate 1 Low-Carbon Steel Sheet 1/2" Thick, 8" X 12", Ground Finish McMaster-Carr MMC#1388K371 1 88.1 88.1 Support Rib 2 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 2-1/2" Width McMaster-Carr MMC#9517K526 2 29.96 59.92 Platform Plate 1 Multipurpose 4140/4142 Alloy Steel Oversized Sheet, 1/2" Thick, 10" X 12" McMaster-Carr MMC#4473T13 1 84.78 84.78 Back Support Rib 2 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 2" Width McMaster-Carr MMC#9517K524 2 27.01 54.02 Riser Block 4 Low-Carbon Steel Tight-Tolerance Rect Bar 1" Thick, 1" Width McMaster-Carr MMC#9517K595 1 52.76 52.76 Polycarbonate Sheet 1 1 Polycarbonate Sheet 2 1 Crank Arm 1 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 3" Width McMaster-Carr MMC#9517K528 1 35.74 35.74 Base Plate 1 Low-Carbon Steel Sheet 1" Thick, 24" X 24", Ground Finish McMaster-Carr MMC#1388K581 1 416.39 416.39 Extension Rod 1 Steel Drive Shaft 1" OD, 24" Length McMaster-Carr MMC#1346K38 1 40.82 40.82 Pin Block 1 Low-Carbon Steel Sheet 1-1/2" Thick, 4" X 4", Ground Finish McMaster-Carr MMC#1388K704 1 44.76 44.76 1657 Raw Materials Raw Material: 66.56 12"X4"X.5" 6061 Aluminum MSC MSC #86466356 1 93.03 93.03 Impact-Resistant Polycarbonate Sheet 1/4" Thick, 24" X 36", Clear McMaster-Carr MMC#8574K285 1 66.56

February 21, 2013 UL Vibration Test Apparatus 41

slide-42
SLIDE 42

Part Description Supplier Purchase # Qty.

  • Pkg. Qty. Unit Price

Price 1/2" x 2.5" 13 Bolt McMaster-Carr MMC#92327A308 36 1 4.11 147.96 1/2" 13 Nut McMaster-Carr MMC#90499A033 52 50 7.83 15.66 3/4" 10 Bolt McMaster-Carr MMC#92327A362 8 1 8.03 64.24 3/4" 10 Lock Nut McMaster-Carr MMC#90630A135 8 5 4.45 8.90 1/2" x 4" 13 Bolt McMaster-Carr MMC#92327A314 16 1 6.00 96.00 Pipe Flange McMaster-Carr MMC#6806K125 1 1 30.00 30.00 5/8" 11 Bolt McMaster-Carr MMC#92327A332 5 1 5.08 25.40 5/8" 11 Nut McMaster-Carr MMC#90499A832 5 50 12.04 12.04 U Channel Metals Depot C21025 1 1 157.48 157.48 H Beam Metals Depot B2413 6 1 107.50 645.00 3' Crossbeam McMaster-Carr MMC#8910K58 5 1 102.87 514.35 Rubber Damper McMaster-Carr MMC#9023K26 2 1 20.47 40.94 H Beam Feet McMaster-Carr MMC#8910K58 1 1 102.87 102.87 L Bracket McMaster-Carr MMC#8910K302 1 1 256.91 256.91 2117.75 Frame Components Frame Components Total:

February 21, 2013 UL Vibration Test Apparatus 42

slide-43
SLIDE 43

Part Part Description Supplier Purchase # Qty. Price Flanged Shaft Collar Mounting Flange One-Piece Steel Shaft Collar 1" Bore, 2" Collar OD, 1" Overall Width McMaster-Carr MMC#9684T4 1 38.13 Socket Drive 3/8" Square Drive Socket 12-Point Std, 3/4" Sz, 1-1/8" L O'all, Black Fnsh McMaster-Carr MMC#5484A49 1 5.28 Dial Indicator Mitutoyo Dial Indicator Continuous, 1-5/8" Dia, 0-0.250" Range, 1410S-10 McMaster-Carr MMC#2246A41 1 95.23 138.64 Test Materials Test Material Total:

Part Part Description Supplier Purchase # Price Motor 1Hp 3450RPM, 3PH, 60Hz, 230/460V Baldor M3545 472 Motor Base Adjustable NEMA Motor-Mount Base for NEMA 56 Frame McMaster-Carr MMC#62035K21 19.02 491.02 Motor Components Motor Components Total:

February 21, 2013 UL Vibration Test Apparatus 43

slide-44
SLIDE 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)

Cost Category Cost Hardware & Standard Components 1053.71 Raw Materials 1657.00 Frame Components 2117.75 Test Materials 138.64 Motor Components 491.02

  • Est. Machining Costs

800.00

  • Est. Unexpected Costs

800.00 Total: 7058.12 Cost Breakdown

February 21, 2013 UL Vibration Test Apparatus 44

slide-45
SLIDE 45

February 21, 2013 UL Vibration Test Apparatus 45

slide-46
SLIDE 46

February 21, 2013 UL Vibration Test Apparatus 46

slide-47
SLIDE 47

Questions For Customer

  • NPT Pipe Length
  • Pipe Collar
  • Testing with Lamp
  • Financing logistics of Project

February 21, 2013 UL Vibration Test Apparatus 47

slide-48
SLIDE 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, 2013 UL Vibration Test Apparatus 48

slide-49
SLIDE 49

Appendix

UL Test Standard and Project Background

slide-50
SLIDE 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, 2013 UL Vibration Test Apparatus 50

slide-51
SLIDE 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, 2013 UL Vibration Test Apparatus 51

slide-52
SLIDE 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, 2013 UL Vibration Test Apparatus 52

slide-53
SLIDE 53

UL844 Vibration Test Standard

February 21, 2013 UL Vibration Test Apparatus 53

slide-54
SLIDE 54

Design Flaws Associated with Original Design

February 21, 2013 UL Vibration Test Apparatus 54

  • 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
slide-55
SLIDE 55

Customer Design Needs Need # Importance High 3 – 2 – 1 Low Design Criteria Measure of Effectiveness CN1 3 Obtain vibration frequency of 2000 cycles/min Stroboscope CN2 3 Create displacement of 1/32” at 22.5” bellow pipe flange Dial Gauge CN3 2 Adjustment of attachment collar position for perpendicularity ___ CN4 2 240 V electrical input ___ CN5 2 System envelope size is maintained or decreased from original system ___ CN6 1 Mounts to current anchor points in floor ___ CN7 3 Capability to adjust for different pipe sizes ___ CN8 1 Use current flange mounting for pipes ___ CN9 2 Design in an easily removable collar ___ CN10 3 Will support multiple types of Luminaires ___ CN11 2 Easy to mount the Luminaires 1 Technician can run entire test CN12 1 Ease of lubrication ___ CN13 2 Containment of Lubricant Look for leaking of Lubricant CN14 3 System to not run near resonate frequency Does not shake itself apart CN15 1 Minimize noise of system Under 85 decibels (OCIA standard for requiring ear protection) February 21, 2013 UL Vibration Test Apparatus 55

slide-56
SLIDE 56

PUGH Matrix: Rotational to Linear Motion Mechanism

February 21, 2013 UL Vibration Test Apparatus 56

# Evaluation Criteria Crankshaft Eccentric Shaft Scotch Yoke Cam & Follower 1 Robustness s + +

  • 2

Cost +

  • +

s 3 Design Simplicity s + s s 4 Adjustability s

  • +

s 5 Component Wear s s

  • 6

Ease of Lubrication

  • +
  • 7

Part Replacement s

  • +

+ 8 Accuracy/Tolerance Stack-up + + +

  • 9

Ease of Maintenance s s + s 10 Ease of Manufacture +

  • +

s 11 In-house Manufacture +

  • +

s 12 Ease of Assembly s s s s 13 Noise/Vibration + +

  • s

14 Safety s + s s 4 1 5

  • 3

Rotational to Linear Conversion Sum

slide-57
SLIDE 57

PUGH Matrix: Slider Mechanism

February 21, 2013 UL Vibration Test Apparatus 57

# Evaluation Criteria Pillow Block Bearings Viscous Fluid Layer Roller Bearings w/wheels Linear Bearings on rails 1 Robustness + + S + 2 Cost S + S S 3 Design Simplicity S S

  • S

4 Component Wear +

  • S

+ 5 Ease of Lubrication + + S + 6 Containment of Lubricant S

  • S

+ 7 Part Replacement +

  • +

+ 8 Ease of Maintenance + S + + 9 Ease of Manufacture + + S + 10 In-house Manufacture S S S S 11 Ease of Assembly S S S S 12 Noise/Vibration S

  • S

S 6 1 7 Slider Mechanism Sum

slide-58
SLIDE 58

PUGH Matrix: Displacement Adjustment Mechanism

February 21, 2013 UL Vibration Test Apparatus 58

# Evaluation Criteria Screw Linear Actuator Pivot Cam slider w/ tightening bolt 1 Robustness

  • +
  • 2 Cost
  • +

+ 3 Design Simplicity

  • +

+ 4 Part Replacement

  • +

S 5 Accuracy of Adjustment +

  • 6 Ease of Manufacture
  • S

+ 7 In-house Manufacture

  • +

+ 8 Ease of Assembly

  • +

+ 9 User Friendly + S S

  • 5

5 3 Displacement Adjustment Mechanism Sum

slide-59
SLIDE 59

February 21, 2013 UL Vibration Test Apparatus 59

Risk Assessment

slide-60
SLIDE 60

February 21, 2013 UL Vibration Test Apparatus 60