Fatigue Life Testing PlatformFatigue Life Testing Platformfor Electroformed Bellowsfor Electroformed Bellows

EEEEEEEEJadon WeinelJadon WeinelHector VargasHector Vargas

Customer: NiCoForm, Inc. Advisor: Dr. E. Debartolo

EMEMRichard Kraynik

Zachary EastmanJames Haschmann

© 2003-2004, Team 04035February, 2004

OutlineOutline

IntroductionIntroductionGoalsGoalsPreliminary DesignPreliminary DesignRedesignRedesignFabricationFabrication– MechanicalMechanical– ElectricalElectricalSoftware FlowSoftware FlowConclusionConclusion

GoalsGoals

Design, fabricate and debug a fatigue life Design, fabricate and debug a fatigue life testing platform for electroformed bellowstesting platform for electroformed bellows

Deliver a technical data package that Deliver a technical data package that allows the sponsor to reproduce the allows the sponsor to reproduce the platformplatform

What Is a Bellows?What Is a Bellows?

Bellows are dynamic components requiring a Bellows are dynamic components requiring a combination of strength, elasticity and long cycle combination of strength, elasticity and long cycle life.life.

Consisting of stacked circular convolutions, Consisting of stacked circular convolutions, bellows can facilitate axial, angular, and/or bellows can facilitate axial, angular, and/or defected motion.defected motion.

Common uses:Common uses:

Hermetically sealed vibration dampenersHermetically sealed vibration dampeners

Aligned and Offset axis torque couplingsAligned and Offset axis torque couplings

Pressure sensors activatorsPressure sensors activators

SpringsSprings

Test Procedure ConceptTest Procedure Concept

Place bellows into test platformPlace bellows into test platformInput desired dataInput desired data– FrequencyFrequency– DisplacementDisplacementStart testStart test– Pressurize bellowsPressurize bellowsRun testRun testTest ends when the PLC detects a loss of Test ends when the PLC detects a loss of pressure in the system which indicates a failure pressure in the system which indicates a failure in the bellows integrity. in the bellows integrity.

Preliminary DesignPreliminary Design

BaseBase

Tester TopTester Top

Support RodsSupport Rods

SolenoidSolenoid

Pressure SwitchPressure Switch

Isolator FeetIsolator Feet

Bellows AdaptersBellows Adapters

Actuator FlangeActuator Flange

Bellows Adapter FlangeBellows Adapter Flange

RedesignRedesign

Minor cosmetic changes to the baseMinor cosmetic changes to the baseActuator flangeActuator flangeDevelopment of optical feedback systemDevelopment of optical feedback systemAddition of centering spider diaphragmAddition of centering spider diaphragmRelocated the solenoid and pressure switchRelocated the solenoid and pressure switchTop bellows adapter Top bellows adapter Tester topTester top

Final Test Platform DesignFinal Test Platform Design

Exploded ViewExploded ViewFeet

Base

Actuator and actuator collar

Hose fitting

Supportrod

Slide

Upper bellows adapter

Lower bellows adapter

Spider diaphragm

Spidercollar

Spacer

Test Platform Design DetailsTest Platform Design DetailsO-rings seat in the recesses. One prevents the upper bellows adapter from falling. The other provides a seal between the bellows adapter and the slide.

Here, the spider diaphragm and major components attached to the base can be seen.

FabricationFabrication

Conventional MethodsConventional Methods– GrindingGrinding

– MillingMilling

– TurningTurning

– Wire Electrical Discharge MachiningWire Electrical Discharge Machining

MaterialsMaterials– 304 Stainless Steel304 Stainless Steel

Base, Slide, Support Rods, Coil CollarBase, Slide, Support Rods, Coil Collar

– BrassBrass

Bellows Adapters, Spider CollarBellows Adapters, Spider Collar

Optical Feedback SystemOptical Feedback System

OPTEK 830L Series

Circuit to drive the LED in the OPTEK 830L Series optical chopper and also condition the return signal brought back by the optical detector to provide feedback to the BEI Inc. motion controller.

OPTEK Inc. 831L55 transmissive photo transistor package. Works with above circuit to provide position feedback of the motion of the actuator.

Electronics CabinetElectronics Cabinet

Closed – Position for normal operation and storage when not in use.

Open – For maintenance purposes and reprogramming of the PLC and Motion Controller.

Software FlowSoftware FlowOperator inputs

frequency via Ez-TextControl Panel

Operator selectsF1 on Ez-Text

Control Panel tostart fatigue test

Control systembegins

pressurizingbellow

Is Bellow atPressure

Bellowpressurization

Timed-out

No

No

Signal Ez-Text contolPanel bellow failed to

pressurize

YesDisplace voicecoil to home

position

Move voice coil in anoscillatory motion

Start PressureMonitor

Is Bellow atPressre

Move Bellow tohome position and

turn off motioncontroller

Report number ofcycles completed

to the Ez-Textcontrol Panel

Yes

No

Conclusion/OutcomesConclusion/Outcomes

Completed ItemsCompleted ItemsMechanical ComponentsMechanical ComponentsElectronics CabinetElectronics CabinetWiring of Electronics CabinetWiring of Electronics CabinetLow Frequency Actuator MotionLow Frequency Actuator MotionCritical Design Review PackageCritical Design Review Package

To Be Completed Before DemonstrationTo Be Completed Before DemonstrationReceive Spider From VendorReceive Spider From VendorTest Motion of Voice Coil at Higher FrequenciesTest Motion of Voice Coil at Higher FrequenciesInstall Optical SensorInstall Optical Sensor

QuestionsQuestionsoror

Comments!Comments!

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