P14471 Vibration Testing Apparatus...
Transcript of P14471 Vibration Testing Apparatus...
P14471 Vibration Testing Apparatus II Subsystems Design Review
10/29/2013
Brett Billings
Jacob Gardner
Nick Greco
Ron Jimbo
Claire Kobal
Ryan Selig
Ashley Waldron
Agenda System Design Selection
Subsystem Selection
Frame
Motor
Displacement Measurement
RPM Measurement
Display and Control System
Test Plan
Risk Analysis
BoM / Cost Estimate
Next Phase
System Design Selected
Vertically mounted motor with v-belt offset for maximum
torque and speed control
Dial gauge to confirm displacement and verticality
Encoder and VFD to read and control speed
LCD Display of RPM and time elapsed
Safety: belt guard, polycarbonate guards, E-stop
Multiple diameter conduits with dedicated flanges and collars
for quick change-overs
Spray paint to prevent rust
System Design
Selected
Frame Design
Frequency Analysis Vibration frequency:
33.3 Hz (2000 RPM)
Natural frequency of apparatus:
42.3 Hz
Maximum deflection
.853” (shown in red)
Structural Analysis of Cantilever
Maximum stress:
= 6897 PSI
Maximum deflection
= .046 inches
Overall System Analysis
Motor Selection
Maximum Load= 150 lbs
Torque Necessary= 1.68 ft-lbs
We will be running the motor at full load torque to allow for a longer life.
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =𝑖𝑛𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑
𝑜𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑=
3500
2000= 1.75
Motor Continued
Total Cost: $472.00
Motor Performance Data:
Baldor M3545
V-Drive Selection All information was gathered from the Dodge catalog
For the given gear ratio of 1.72, Type A, 1-Groove
Driver Datum Diameter: 3.4”
Outer Diameter= 3.4”+.37”= Approx. 3.75” P/N 118190
Driven Datum Diameter: 6.2”
Outer Diameter= 6.2”+.37”= Approx. 6.55” P/N 118204
Driver Taper Lock Bushing (1210), .5” Shaft Diameter: Keyway P/N 119191
Driven Taper Lock Bushing (1610), 1” Shaft Diameter: Keyway P/N 117159
Distance from center shaft to center shaft using donated belt guard: 9.5”
P/N A33
Belt Life: 25,000 hours (714 testing cycles)
Cost of V-Drive
Driver:
Sheave: $10-20
Bushing: $10-20
Driven:
Sheave: $30-35
Bushing: $10-25
Belt: $10
Total: $70-110
Dial Gauge Selection
Digital Dial Gauge can
connect to final display
More reliable and less
expensive than a laser
$150
½” range
0.0005” resolution
Maintaining Displacement Clamping force:
Provided by 2 screws - ½’’-13
M = torque on screws
Screw vs. T-Block (u=.2)
210 M ft-1 (see Appendix)
Frictional force (prevents slipping): 2 possible locations:
Adjustment Base vs. Adjustment Slider (u=.8)
Adjustment Base vs. T-Block (u=.2 to .8)
Assume worst case, u=.2
42 M ft-1
Maximum force applied (causes slipping): 1.68 ft-lbs. (motor) at 1/32’’
645 lbs.
Required screw torque: Safety factor of 2
31 ft-lbs.
Control System
Encoder Selection: TRD-S100-VD
Inexpensive incremental (quadrature)
encoder
Capable of sending (depending on exact
model) 100-1024 pulses per revolution
Speed of motor can be determined based on
number of pulses received and time elapsed
Hardware allows for maximum of 6000 RPM
– well above 2000 RPM expected
Micro-Controller
Firsthand objective: proof of concept
TI Launchpad
Comes pre-equipped with on-board emulation and simple
outputs for ease of testing & debugging
Control procedure can be implemented using pseudo-inputs
and pseudo-outputs to prove feasibility of concept
In final design encoder sends signal to controller, which is
interpreted and fed in through VFD for feedback
After concept is proven a permanent microcontroller can be
selected to optimize system integration
Test Plan
Test Displacement
Tighten adjustment screws to proper torque
Measure displacement with dial gauge during setup
Validate 1/32” total displacement
Test Vibration Cycles
Measure RPM with encoder and display for feedback
Validate 2000 cycles/min
Test fittings
Do they fit the frame?
Test User Interface
Check connections
Ease of use
Safety Evaluation
Risk Analysis ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due
1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844 Poor design 3 2 6 Make it adjustable Brett DONE
1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844 Disp. changes during test 3 2 6Calculate torque required on bolts so
displacement won't slip.Brett DONE
2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844 Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE
2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844 RPM changes during test 3 2 6Design closed loop feedback and VFD
to adjust RPMRyan DONE
12 Frame falls apart Test fails, costly to fixVibration is same as natural
frequency3 2 6
Perform ANSYS Analysis, add supports
to change natural frequencyNick DONE
12 Frame falls apart Test fails, costly to fix Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE
12 Frame falls apart Test fails, costly to fix Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE
10 Can't mount all configurations typesCustomer is not able to test some
configurationsProject scope 2 2 4 Use current fixtures Claire DONE
15 Project deadline is not met
Customer is dissatisfied, Students
receive poor course grade, RIT's
reputation is negatively impacted
Materials are delivered late 2 2 4 Order before Christmas Nick 12/20/2013
18Unable to integrate measurement devices
with display
Machine is just as difficult to setup
and monitor as beforeLack of knowledge 2 2 4
Research integration requirements
and prepare LabView backupRyan 11/20/2013
19Can't get items (Motor, VFD, etc.) from
Eaton in available time
Need to purchase items instead,
increased cost of projectLead time is too long 2 2 4
Request items by specified date from
CCH and ask for delivery date. Have
backup supplier prepared.
Ron 11/20/2013
3 Motor burns out Costly to replace, test fails Motor burns out 3 1 3Calculate required torque and RPM,
select appropriate motorRon DONE
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
BoM & Costs
Item Cost Item Cost
Materials for Frame $700 Rust Protection $200
Materials for Conduits / Flange / Collar $250 Welder Fees $200 (est.)
Digital Dial Gauge $150 Electrician Fees $0
Motor $470 Shipping Costs (for testing) $200 (est.)
VFD $480 Upgraded displacement adjustment $50
Encoder $100 Polycarbonate Sheet ¼’’x36’’x24’’ $70
LCD Display $100 Belt Guard $0
Micro-controller & components $100 Electrical Lockout $40
Electrical Box $200 (est.) V-Drive $90
Total $3400
Next Phase
Questions for Cooper-Crouse Hinds
Electrical wiring done by students and checked by CCH?
Questions?
Appendix
More Motor Information
V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-pt.com/products/pt_components/belts/belts.html
Safety Checklist
Item Safety Item Yes No N/A Owner Due Date
1 Is lockout/tagout procedure posted?
2 Can all energy sources be locked out? (electrical, air, hydraulic, water, etc.)
3 Are all electrical devices labeled with voltage and power source?
4 Are all machine controls labeled?
5 Are all machine hazards adequate guarded to prevent bodily contact? (motion, heat, light, ejection, etc.)
6 Do machine interlocks/light curtains inhibit motion?
7 Are E-Stops located at all operator stations?
8 Are utilities routed to avoid trip hazards?
9 Have any potential waste materials been identified? Do they have a disposal procedure?
10 Is there adequate egress from area?
11 Is a fire extinguisher located within 75 ft?
12 Is there adequate access for all operations? (maintenance, setups, operation, etc.)
13 Is machine designed to minimize overhead and extended reaching, pulling, bending, and twisting?
14 Is all required training complete and documented? (LOTO, maintenance, setup, operation, etc.)
Functional Decomposition
Full Risk Analysis ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due
Poor design 3 2 6 Make it adjustable Brett DONE
Disp. changes during test 3 2 6 Calculate torque required on bolts so displacement won't slip. Brett DONE
Poor calibration 2 1 2 Define calibration procedure and schedule Jake MSDII
Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE
RPM changes during test 3 2 6 Design closed loop feedback and VFD to adjust RPM Ryan DONE
Belt slips 2 2 4 Use v-belt and belt guard (for oil drip) Ashley DONE
Motor inefficiencies 3 1 3 Accept Risk --- DONE
Belt is too loose 1 2 2 Design motor mount to be adjustable Ashley 11/20/2013
Frame misalignment 2 1 2 Write procedure to verify conduit is 100% vertical Claire 11/20/2013
3 Motor burns out Costly to replace, test fails Motor burns out 3 1 3 Calculate required torque and RPM, select appropriate motor Ron DONE
Crankshaft improperly lubricated 3 1 3 Define maintenance procedure and schedule Ron MSDII
Motor is too loud 2 1 2 Add motor enclosure, sound damping, hearing protection Brett MSDII
Vibration of frame 2 1 2 Add sound damping, add hearing protection Brett MSDII
Luminaire breaks and rattles 2 1 2 Accept Risk - test will be ended early --- DONE
Operators don't wear earplugs 1 2 2 Accept Risk - exposure duration is still low --- DONE
Fixed guard not in place 3 1 3 Place warning labels on apparatus Brett MSDII
Machine not properly guarded 3 1 3 Install polycarbonate guard and belt guard Brett MSDII
Energy source not isolated 3 2 3 Install location to lockout machine Brett MSDII
Lockout not observed 3 1 3 Accept Risk --- DONE
Button is broken 3 1 3 Define maintenance schedule Ryan MSDII
Electrical failure 3 1 3 Use certified electrician Ron MSDII
8 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6 Guard all pinch points Brett DONE
Setup requires awkward positioning 2 2 4 Design conduit to be assembled first, then attached all at once Claire DONE
Luminaire is too heavy 2 1 2 Specify use of lift assist or 2nd operator, Design for use Brett 11/20/2013
10 Can't mount all configurations typesCustomer is not able to test some
configurationsProject scope 2 2 4 Use current fixtures Claire DONE
11 Oil spill on motor connection Motor failure/smoke Leakage 1 2 2 Offset motor so oil can't drip on it Ashley DONE
Vibration is same as natural frequency 3 2 6 Perform ANSYS Analysis, add supports to change natural frequency Nick DONE
Improper construction 3 2 6 Use certified welder Nick MSDII
Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE
Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE
13 Project runs over budget
Customer is dissatisfied,
engineering requirements must be
sacrificed
Unforeseeable expenses 2 2 4 Proper budgeting/compare prices/buy standard sizes Nick Ongoing
14 Apparatus is larger than existing one Customer is dissatisfied New holes must be drilled in concrete floor 1 2 2 Accept Risk --- ---
Correction of mistakes 3 2 6 Participate in milestone design reviews ALL Ongoing
Delay in Tool Shop 2 2 4 Schedule machine time 1 week in advance with Tool Shop Ashley MSDII
Materials are delivered late 2 2 4 Order before Christmas Nick 12/20/2013
16 Electrical shock from apparatus Operator injury could occur Improper wiring 3 2 6 Use certified electrician Ron MSDII
17 RPM can't be measured accurately Apparatus doesn't meet UL844 Tachometer vibrates too much 3 1 3 Add damping Jake MSDII
18 Unable to integrate measurement devices with displayMachine is just as difficult to setup
and monitor as beforeLack of knowledge 2 2 4 Research integration requirements and prepare LabView backup Ryan 11/20/2013
19 Can't get items (Motor, VFD, etc.) from Eaton in available timeNeed to purchase items instead,
increased cost of projectLead time is too long 2 2 4
Request items by specified date from CCH and ask for delivery date. Have
backup supplier prepared.Ron 11/20/2013
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
Customer is dissatisfied, Students
receive poor course grade, RIT's
reputation is negatively impacted
Project deadline is not met15
Operator injury could occurApparatus is not ergonomically safe to setup9
12 Frame falls apart Test fails, costly to fix
Operator injury could occurMachine starts during maintenance6
Operator injury could occurEmergency stop doesn't work7
1
2
Machine is too loud4
Operator injury could occurMachine operates when moving parts exposed5
Hearing conservation or
engineering intervention is
required
Apparatus doesn't meet UL844Vibration is not 2000 cycles per min
Apparatus doesn't meet UL844Displacement is not equal to 1/32in
Architecture
Central System
Power supply Motor system
Sensors
Display/user
interface
Luminaire
connection
Crankshaft
connection
Safety features
Conduit Pipe Size Considerations
• Concept: each conduit size will
have its own:
• Flange
• Collar
• This concept allows for easier
usage by operator
• Plan:
• Provide the 1st and possibly
the 2nd most used size
conduit
• Provide the drawings/files
necessary for the fabrication
of the remaining conduits
Flange
Collar –
crankshaft
connection
Collar – set
screws
Conduit Verticality
Attempt to keep the conduit as vertical as possible
Based on conversations with an operator – verticality is not
very critical
Very basic method:
Place a vertical level in the same place every time and using the
adjustable crankshaft to make minor adjustments
Safety Features Fixed polycarbonate guards on drive system
Clear, light-weight
Excellent impact strength, ¼’’ thick
“Split” type belt guard
Left and right half for easy removal
Lock-out on electrical box for maintenance
http://www.eriecustomproducts.com/beltguards/
Adjustment Mechanism
Additional holes in connecting plate
Access to adjustment bolts
U-bolt to lock system in place during adjustment
Finer set screw
3x finer than current
8-32: ¼’’ turn ~ 1/128’’ displacement
Setup Improvements
New Connecting Plate
UL844 Vibration Test Standard
Maintaining
Displacement
Calculations
Maintaining
Displacement
Calculations
Maintaining
Displacement
Calculations
Design characteristics for VFD
HP : VFD must be rated for the appropriate HP.
Full Load Amps : Motors Full Load Amps must not exceed
VFD’s continuous amp load.
Voltage : number of phases and voltage must be matched as
well with the VFD.
Load Type: Constant vs. variable Torque during operation.
Programmability: programmable parameters of a VFD