Integration Demo 4152014 Brett Billings Jacob Gardner Nick Greco Ron Jimbo Claire Kobal Ryan Selig Ashley Waldron 1 Agenda Demo Items BoM amp Budget Issues Project Plan Appendix ID: 508661
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P14471 Vibration Testing Apparatus IIIntegration Demo4/15/2014
Brett BillingsJacob Gardner Nick Greco Ron JimboClaire KobalRyan SeligAshley Waldron
1Slide2
AgendaDemo Items
BoM & BudgetIssuesProject PlanAppendix2Slide3
Demo Items3
Mount 18 lb luminaire to 3/4'' conduitAdjust displacementTurn on VFD & motor, 500 RPMDisplay RPM & elapsed time on LCDEnd with E-StopSlide4
BoM / Budget4
Current costs:Remaining costs:VFD enclosure - $80Shipping to Syracuse - $600Travel Expenses - $240Expected final cost: $3,400https://edge.rit.edu/edge/P14471/public/WorkingDocuments/Detailed%20Design/BOM_rev6_tracking.pdfSlide5
Issues5
Reinforce motor mountVibration noise at certain frequencies
Decide on Control Panel layout
Shipping apparatus to Syracuse
RyanSlide6
Project Plan6Slide7
Questions?7Slide8
Appendix
8Slide9
Room Layout9Slide10
Selected Design
Interchangeable ConduitsMotor with V-beltVFDDigital Dial GaugeEncoderLCD, MicrocontrollerPolycarbonate GuardsE-stopPaint for Rust Protection10Slide11
11Slide12
Engineering Requirements
Number
Requirement
Raw Score
Units
Ideal Measure
1
Displacement of luminaire
69
in
1/32
2
Vibration of luminaire
69
cycles/min
2000
3
Duration of vibration test
69
hours
35
4
Isolate motor from oil spills
45
Binary
Yes
5
Maintenance Documentation
44
Survey (easy
to follow)
80%
6
Mount pendant configuration
35
Binary
Yes
7
Operation Documentation
33
Survey (easy
to follow)
80%
8
Machine won't operate if crankshaft enclosure is open
25
Binary
Yes
9Completely stop machine with Emergency Stop25seconds< 1010Maximum voltage of Motor25V AC24011Minimize number of operators21people212Max weight of mounted luminaire20lbs> 15013Visually display settings and status of test18BinaryYes14Steps to set up16steps< 1015Setup Time16seconds< 12016Low Sound15dBA< 85 17Minimize pinch points15Count< 318Total materials cost15$< 4,00019Mount stanchion configuration7BinaryYes20Mount yoke configuration7BinaryYes21Mount trunnion configuration7BinaryYes22Machine footprint5in2< 34X48
12Slide13
House of Quality
Engineering
Metrics
Customer Requirements
Customer Weights
Displacement of luminaire
Vibration of luminaire
Duration of vibration test
Low sound
Machine won't operate if moving parts are exposed
Completely stop machine with Emergency Stop
Minimize pinch points
Minimize number of operators
Voltage of motor
Mount pendant configuration
Mount stanchion configuration
Mount yoke configuration
Mount trunnion configuration
Visually display settings and status of test
Operation documentation
Steps required for Set-up
Isolate motor from oil spills
Maintenance documentation
Max weight of mounted luminaire
Total materials cost
Time to Set up
Machine footprint
Adherence
to UL844 testing standard
5
5
5
5
Apparatus is safe5 3553 3 1 Motor must be compatible with available voltage5 5 33 Ability to test multiple configurations3555 5111 Easy to use3 5 133 1 3 Easy to maintain2 3 1 53 Visually display test information/feedback to operator3333 511 1 1 Ability to test a range of luminaire weights4555 5111 5 Cost under $40003 5 Long service life4 1153 1 Similar dimensions to existing machine1 5Technical Targets (Specifications) 1/32 in.2000 cycles/min35 hours< 85 dBAyes< 10 seconds< 3≤ 2< 240 V ACYesYesYesYesYes80% via survey (easy to follow)< 10 stepsYes80% via survey (easy to follow)> 150 lbs< $4000< 120 seconds< 34X48 in2Raw score6969691525251521253577718331645442015165Relative Weight11%11%11%2%4%4%2%3%4%6%1%1%1%
3%
5%
3%7%7%3%2%3%1%
13Slide14
Safety ChecklistER # 8 – Machine Guarding
ER # 9 – Emergency StopER # 16 – Low Sound
14Slide15
Test Plans15
Refer to Excel documenthttps://edge.rit.edu/edge/P14471/public/WorkingDocuments/MSDII_Build%20Test%20Documentation/P14471 Test Plans_Rev2.xlsxor EDGEhttps://edge.rit.edu/edge/P14471/public/Build%2C%20Test%2C%20DocumentSlide16
Maintaining Displacement
ER #1: Displacement must be 1/32’’Clamping force:Provided by 2 x A574 screws - 5/8’’-11 M = torque on screws= 168.9 M ft-1
Frictional force:2 possible locations:= 33.8 M ft-1
(worst case)Maximum force applied:1.68 ft-lbs. (motor) at 1/32’’= 645 lbs.Required screw torque:= 38 ft-lbs. (Safety factor of 2)Max recommended A574 torque = 220 ft-lbs*Detailed calculations in Appendix
1
2
16Slide17
Bolt TorqueGuide
17Slide18
Setup ImprovementsER # 11 – Minimize number of operators
ER # 14 – Steps to set upER # 15 – Setup time18Slide19
Setup Improvements
Finer set screwBefore:11 threads per inch1 turn = 290% of displacement!After:100 threads per inch1 turn = 33% of displacementChanges required:Machine new set screw plateRequires threaded bushing for set screw
19Slide20
Set Up Improvements
Set screwAccount for excess space between conduit and collarFlange Dimensioned to be placed in same location every timeBlocks on the C
channel
Flange
Collar – crankshaft connection
Collar – set screws
ER # 11 – Minimize number of operators
ER # 6, 19-21 – Mount 4 configuration types
ER # 13, 14 – Setup time, number of steps
20Slide21
Full Risk Analysis21
See EDGEhttps://edge.rit.edu/edge/P14471/public/ProjectManagement/Risk%20Analysis.pdfSlide22
VFD Damage Incident22
See EDGEhttps://edge.rit.edu/edge/P14471/public/WorkingDocuments/VFD%20Damage%20Incident/VFD%20Damage%20Incident.pdf