Design Review UL Vibration Test Apparatus May 13, 2013 1:30PM
Est.
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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, 2013UL Vibration Test Apparatus2
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Presentation Overview 1)Detailed Design Overview 2)Final Design
3)Testing 4)Improvements & Future Work 5)Budget Appendix: UL
Test Stand and Project Background February 21, 2013UL Vibration
Test Apparatus3
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Design Review Discussion Discussed Design: Adjustment Mechanism
Crank Arm Key Action Items: Adjustment Mechanism Strength Crank Arm
Actions Taken: Crank Arm to be a single piece February 21, 2013UL
Vibration Test Apparatus4
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Final Design February 21, 2013UL Vibration Test Apparatus5
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Final Design (video) February 21, 2013UL Vibration Test
Apparatus6
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Adjustment Mechanism February 21, 2013UL Vibration Test
Apparatus7 Allows for adjustment in eccentricity in order to
account for tolerance stack-ups and wear Set screw used for fine
adjustment Two socket head cap screws for locking the system in
place Nord Lock washers to prevent loosening of adjustment
mechanism
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5/8-11 Nord Lock Washers Rated for maximum locking at 197
ft-lbs with 20900lb clamping force Allows for reusable hardware
February 21, 2013UL Vibration Test Apparatus8 pelicanparts.com
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Pushrod Connection February 21, 2013UL Vibration Test
Apparatus9 Extension rod is threaded into both the pushrod and pipe
collar to allow for adjustment Pushrod position can vary in shaft
supports to allow for additional adjustment Pushrod is robust and
will not deflect during operation Nuts used to lock threaded
portion at the end of the pushrod in place
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Testing Displacement testing completed on the system As motor
implementation is not within the scope of this project, frequency
was not validated Test frame rigidly fastened to testing table
Angle steel welded into frame shape Aluminum cantilever with flange
connection Dial indicators used in two locations to verify the
displacement across the system Contacting linear slider box
Contacting collar at connection to vertical conduit February 21,
2013UL Vibration Test Apparatus10
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Testing February 21, 2013UL Vibration Test Apparatus11 Dial
Indicator Contacting Slider Box Dial Indicator Contacting Conduit
Collar
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Test 1: Verify zero-displacement Centering dowels mated between
adjustment mechanism and rotating disk to signify zero-displacement
Dial indicators showed zero displacement for the system Test 2:
Verify 3 displacement values 0.016: found that dial indicators give
very low value for displacement (.004-0.008) 0.100: again found
that measured values were lower than expected (0.045-0.055) 0.250:
met expected displacement value within 0.010 Test 3: Verify torque
Torque wrench used not ideal; not precise enough to measure low
torque range Did verify that the required torque to drive the
steady-state system is below ~2 lbf-ft February 21, 2013UL
Vibration Test Apparatus12 Cantilever Flange Connection Vertical
Conduit Conduit Collar Testing Table Test Frame
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Testing Conclusions Zero-displacement point is validated
Displacement measurements do not agree at low eccentric values, but
they do at higher distances Postulated that the dial indicators are
not precise enough to accurately measure low eccentric distances
Torque measurement has a high degree of uncertainty due to the low
level of precision associated with the torque wrench used during
testing Recommended: Purchase more precise dial indicator (re-test)
Purchase more precise torque wrench (re-test) February 21, 2013UL
Vibration Test Apparatus13
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Frame Design February 21, 2013UL Vibration Test Apparatus14 44
34
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Frame Design February 21, 2013UL Vibration Test Apparatus15
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)
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Motor Selection February 21, 2013UL Vibration Test
Apparatus16
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February 21, 2013UL Vibration Test Apparatus17
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Recommended Motor February 21, 2013UL Vibration Test
Apparatus18
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February 21, 2013UL Vibration Test Apparatus19
ParameterGoverning EquationValue Max Bearing Load Upper bearing
force2450lbf3150lbf Lower bearing force1225lbf3150lbf SeSe
1.10e4psi- F.O.S. Shaft10- F.O.S. Key39- Where k a, k b and k c are
Marin factors for surface condition, size, and loading conditions,
respectively. l 1 =2, l 2 =4, min, max, Sy, Sut can be found in
Appendix
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Identified Improvements Install a brake Plate or coat steel
parts (zinc plating) Development of 2 section maintenance
compartment Removable tapered dowels for gauging Possible addition
of counter weight Fixed dial gauge for reading smaller deflections
Isolate motor from drive shaft
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2 Section Maintenance hatch
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Needed Before Running Final Testing Reassemble using Loctite
Use lock nuts or lock washers with hardware holding linear bearings
in place Ensure all bearings are properly lubricated Bolt system to
floor
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Next Steps of Project Manufacture frame Install motor with
motor base Choose shaft coupling and install Choose and install
brake Choose motor control and install Develop other features
designated by customer input (LabView integration)
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Things We Learned Consult machinist before diving into
manufacturing part/system Many parts may need to be machined as an
assembly Dowels are useful for location and assembly but have
limitations in their use Check hardness of steel from scrap bin
before machining them!!!
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Project Cost Cooper has paid as of now: $3,000.00 Cost of
project to date: $3,076.26 Estimated total cost: ~$8,000.00
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Open Discussion Any questions? Design concerns not discussed?
Implementation of LabView? February 21, 2013UL Vibration Test
Apparatus26
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Appendix UL Test Standard and Project Background
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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, 2013UL Vibration Test
Apparatus28
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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,
2013UL Vibration Test Apparatus29
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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, 2013UL
Vibration Test Apparatus30
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UL844 Vibration Test Standard February 21, 2013UL Vibration
Test Apparatus31
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Design Flaws Associated with Original Design February 21,
2013UL Vibration Test Apparatus32 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
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Customer Design Needs Need #Importance High 3 2 1 Low Design
CriteriaMeasure of Effectiveness CN13Obtain vibration frequency of
2000 cycles/minStroboscope CN23Create displacement of 1/32 at 22.5
bellow pipe flangeDial Gauge CN32Adjustment of attachment collar
position for perpendicularity___ CN42240 V electrical input___
CN52System envelope size is maintained or decreased from original
system___ CN61Mounts to current anchor points in floor___
CN73Capability to adjust for different pipe sizes___ CN81Use
current flange mounting for pipes___ CN92Design in an easily
removable collar___ CN103Will support multiple types of
Luminaires___ CN112Easy to mount the Luminaires1 Technician can run
entire test CN121Ease of lubrication___ CN132Containment of
LubricantLook for leaking of Lubricant CN143System to not run near
resonate frequencyDoes not shake itself apart CN151Minimize noise
of systemUnder 85 decibels (OCIA standard for requiring ear
protection) February 21, 2013UL Vibration Test Apparatus33
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PUGH Matrix: Rotational to Linear Motion Mechanism February 21,
2013UL Vibration Test Apparatus34
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PUGH Matrix: Slider Mechanism February 21, 2013UL Vibration
Test Apparatus35
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PUGH Matrix: Displacement Adjustment Mechanism February 21,
2013UL Vibration Test Apparatus36
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February 21, 2013UL Vibration Test Apparatus37 Risk
Assessment
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February 21, 2013UL Vibration Test Apparatus38
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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, 2013UL Vibration Test
Apparatus39