Drop Testing Apparatus
Team Members: Deatly ButlerMark ClouseChris DuxKris HonasShaun ScottDrew Stephens
Client: Itron, Inc. Brian Priest
Technical Advisors: Steve Beyerlein
Mike Severance
Presentation OverviewCustomer NeedsMechanical Components Table Drop Design Orientation Devices Height Adjustment
Electrical Components Data Acquisition CPU Interface Software Camera
CostsRecommended DesignWork RemainingQuestions?
Needs
Repeatable Impacts ( 45 +/- 5 deg)
Adjustable Drop Height (18-60 inches)
Portable (Wheels)
Short Setup time (<1 min)
Video Data Acquisition (automatically named and stored)
Mechanical Components
Table Drop Design
Orientation Devices
Height Adjustment
Table Drop Design Using Pneumatics
Fast Acceleration
Simple
Inexpensive
Non Electrical
Long Life
Table Drop Design #1Frontside Pneumatic
PROSOne Pneumatic
Four Linear Bearings
CONSTable Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects
No Initial Vertical Motion
Table Drop Design #1Frontside Pneumatic
Table Drop Design #2Backside Pneumatic
PROSOne Pneumatic DeviceFour Linear BearingsPneumatic Does Not Interfere With Table Space
CONSTable Only Rotates – Could Potentially Cause Slight Rotation On Dropped ObjectsNo Initial Vertical Motion
Table Drop Design #2Backside Pneumatic
Table Drop Design #3Double Pneumatic
PROSVertical Pneumatic Prevents Rotation on Test Device
CONSMore Linear BearingsMore Pneumatic CylindersIncreased Chance of System Malfunction
Table Drop Design #3Double Pneumatic
Orientation DevicesCradle Block Design
PROSSimple Block Design
Inexpensive
Simple Operation
Minimal Setup Time
Easily Removable
CONSWorks Best for Smaller Devices
Additional Testing Required to Confirm Functionality
Orientation Device Design #1Edge Testing
Orientation Device Design #2Corner Testing
Orientation Device Design #2Corner Testing
Height Adjustment Design #1
Manual Hand Crank
ProsSmooth Adjustment For Any HeightAble To Raise And Lower Heavier Loads.
ConsSlow AdjustmentInvolved Manufacturing ProcessIncreased Cost
Height Adjustment Design #1Manual Hand Crank
Height Adjustment Design #2
Pin and Collar ProsQuick Adjustment
Predetermined Standard Heights
Secure Locking Mechanism
ConsOperator Must Be Able To Support Weight Of Table And Mechanism
Height Adjustment Design #2Pin and Collar
Electrical Components
Data Acquisition
CPU
Interface
Software
Camera
Importing to a PC
Video for each test will be imported to a PC by using GPIB interface.
Instrument controlled by Labview.
Automatically will name and store video clips for each test.
CPUZero Footprint PC - $500 (w/o monitor)
LCD PC - $1000
GPIB Interface
General Purpose Interface Bus
Standard interface between instruments and controllers from various vendors.
8-bit parallel communication.
5 bus management lines (ATN, EOI, IFC, REN, & SRQ)
3 handshaking lines.
8 ground lines.
LabVIEW Software
Uses VI’s
(Virtual Instrumentation)
Imitates physical instruments.
Cheaper than Hardware.
Modular Program design.
Will be used with GPIB to control the video.
Video Camera
Handheld will fall in about 0.5 seconds
Video below 200 fps may be able to capture enough images
Acquisition (fps)
Distance between images
192 ½ inch
96 1 inch
48 2 inches
Camera Option #1Machine Vision System
• Pros High Speed Acquisition
(>10000 fps)
• Cons Small Picture Area
(1.5” x 1.25”) Designed as an Automatic
Inspection Sensor Doesn’t capture video
Camera Option #2High Speed Video Camera
• Pros Easily interfaced and controlled
with LabVIEW software Could be tested with lower
quality cameras• Cons
High Cost Low Acquisition Speeds
(< 500 fps)
Mechanical Costs
Pneumatic Cylinder (1-3) $50eaShafts (1-2) $40eaRaw Materials Sheet Metal $70 Metal Tubing $20 Misc. Hardware $60
Linear Bearings (2-6) $60eaSpur Gear and Rack $200Valves and Fittings $100Compressor (Optional) $300Total ~$1400
Electrical Costs
Computer ~$1500
GPIB $300
Misc. $200
Camera ~$800
Recommended Design
Single Pneumatic Operation (Back Side)
Track Mounted Block Orientation Device
Pin and Collar Height Adjustment
LCD PC or Laptop
GPIB Interface
LabVIEW Software
Work RemainingSpring 2006
Detail Design: (Jan. 9th 2006 – Feb. 1st 2006) - Order parts. - Assess Drawing package. - Complete drawing package.
Fabrication: (Feb 2nd 2006 – March 20th 2006) - Build product.
Validation: (March 21st 2006 – April 20th 2006) - Debug and fix product. - Validate performance of product. - Draft final project report.
Delivery: (April 21st 2006 – May 9th 2006) - Archive project documentation. - Deliver product. - Write final report.
Our Questions for ItronWill ~200 fps be enough for the video?
Computer?
Camera?
GPIB?
Labview license?
Questions?
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