Upload
ngohanh
View
214
Download
0
Embed Size (px)
Citation preview
P14471 Vibration Testing
Application
Team Introductions Name Role Major
Brett Billings Team Leader Industrial Engineer
Nick Greco Lead Engineer Mechanical Engineer
Ashley Waldron Scribe Mechanical Engineer
Claire Kobal EDGE Master Mechanical Engineer
Jacob Gardner Mechanical Engineer
Ron Jimbo Electrical Engineer
Ryan Selig Electrical Engineer
Agenda
Background
System Analysis
Alternatives considered
Selected system
Test Plan
Engineering Analysis
Next Phase
Problem Statement
Update company’s vibration test apparatus Meet UL 844 Standard
Vibration RPM
Displacement
Duration
Continue progress started by Team 13471
Done: the eccentric drive mechanism
Still needs:
Frame
Motor
Control system
Project Deliverables
Completed frame
Appropriate motor selection and implementation
Motor speed control alternatives
Visual display
Frequency of oscillation
Displacement
Documentation
User Manual
Maintenance Manual
Test data verifying the operation of the apparatus
Customers Needs Requirements Importance
Adherence to UL 844 standard 5
Apparatus is safe 5
Motor must be compatible with available voltage 5
Ability to test a range of luminaire weights 4
Long service life 4
Ability to test multiple configurations 3
Easy to use 3
Visually display test information/feedback to operator 3
Cost under $4,000 3
Easy to maintain 2
Similar dimensions to existing machine 1
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
9 Completely stop machine with Emergency Stop 25 seconds < 10
10 Maximum voltage of Motor 25 V AC 240
11 Minimize number of operators 21 people 2
12 Max weight of mounted luminaire 20 lbs > 150
13 Visually display settings and status of test 18 Binary Yes
14 Steps to set up 16 steps < 10
15 Setup Time 16 seconds < 120
16 Low Sound 15 dBA < 85
17 Minimize pinch points 15 Count < 3
18 Total materials cost 15 $ < 4,000
19 Mount stanchion configuration 7 Binary Yes
20 Mount yoke configuration 7 Binary Yes
21 Mount trunnion configuration 7 Binary Yes
22 Machine footprint 5 in2 < 34X48
Engineering Requirements:
The Design Drivers
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
0
10
20
30
40
50
60
70
80
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
Cu
mu
lati
ve %
Weig
ht
of
Imp
ort
an
ce
Engineering Requirement
1 Displacement of luminaire
2 Vibration of luminaire
3 Duration of vibration test
4 Isolate motor from oil spills
5 Maintenance documentation
Top 5
Benchmarking Current Model Our Design
Displacement Mechanism Open Encased
Motor Mounting Below shaft Offset
Brake None Between shaft and motor
Display None Digital
Displacement measurement None +/- .5µm
Functional Decomposition
Risk Assessment ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due
14Project deadline is not
met
Customer is dissatisfied,
Students receive poor course Correction of mistakes 3 2 6
Participate in milestone design
reviewsALL Ongoing
2Vibration is not 2000
cycles per min
Apparatus doesn't meet
UL844Crankshaft slipping 3 2 6 Evaluate previous teams design Ashley 10/7/2013
1Displacement is not
equal to 1/32in
Apparatus doesn't meet
UL844Mechanical Failure 3 2 6 Make it adjustable Jake 10/30/2013
7 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6Design guarding, enclosure,
and/or warning labelsBrett 10/30/2013
12 Over budgetCustomer is dissatisfied,
engineering requirements Unforeseeable expenses 2 2 4
Proper budgeting/compare
prices/buy standard sizesNick Ongoing
14Can't mount all
configurations types
Customer is not able to test
some configurationsProject scope 2 2 4 Use current fixtures Claire 10/7/2013
2Vibration is not 2000
cycles per min
Apparatus doesn't meet
UL844Speed reducer slipping 2 2 4 Splash guard/maintenance Jake 10/30/2013
8Apparatus is not
ergonomically safe to Operator injury could occur
Setup requires awkward
positioning2 2 4
Evaluate setup with ergonomic
lifting equationsBrett 10/30/2013
14Project deadline is not
met
Customer is dissatisfied,
Students receive poor course
Materials are delivered
late2 2 4 Order before Christmas Nick 12/20/2013
14Project deadline is not
met
Customer is dissatisfied,
Students receive poor course Delay in Tool Shop 2 2 4
Schedule machine time 1 week
in advance with Tool ShopNick MSDII
11Apparatus can not
support luminaire Fixture falls, Test fails Poor material selection 3 1 3 Analysis and testing Ashley 10/30/2013
5Machine operates
when moving parts Operator injury could occur Interlocks fail 3 1 3 Use multiple interlocks as backup Ron 11/20/2013
2Vibration is not 2000
cycles per min
Apparatus doesn't meet
UL844Motor inefficiencies 3 1 3 Accept Risk --- ---
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
Morph Chart Overview Attach Luminaire
Measure Vibration Displacement
Measure Vibration Frequency
Measure Elapsed Time
Display Feedback
Protect Operator - Hearing
Protect Operator - Moving Parts
Rust Protection
Move Crankshaft
Alternatives Considered: Design Element:
Evaluation Criteria Paint Electroplate Anode Stainless
Technical difficulty - - +
Cost - 0 -
Durability + 0 +
Maintenance + - +
Time required - + -
Total + +2 +1 +3
Total - -3 -2 -2
Net 0 -1 -1 +1
Rust Protection
DATUM
DATUM
Design Element:
Evaluation Criteria Screws Pins Socket Magnet
Setup time required + - +
Durability - 0 -
Cost - + -
Compatibility with luminaires 0 - -
Total + +1 +1 +1
Total - -2 -2 -3
Net 0 -1 -1 -2
Attach Luminaire
DATUM
DATUM
Design Element:
Evaluation Criteria Vertical Direct Speed Reducer Vertical w/ Belt Horiz. w/ 90°
Rotational capabilities - + -
Motor life + + +
Technical difficulty - - -
Safe to operate 0 - 0
Cost - + -
Maintenance - - -
Lubrication isolation + + +
Total + +2 +4 +2
Total - -4 -3 -4
Net 0 -2 +1 -2
DATUM
DATUM
Move Crankshaft
Consider Systems Level
Consider Systems Level
Design Element:
Evaluation Criteria Dial Gauge Laser Electrical Contact Magnify Ruler
Connection difficulty + - -
Cost - - 0
Technical difficulty - - +
Accuracy + + -
Durability + 0 -
Dual purpose + + -
Total + +4 +2 +1
Total - -2 -3 -4
Net 0 +2 -1 -3
Measure Vibration
Displacement
DATUM
DATUM
Alternatives Considered:
Design Element:
Evaluation Criteria Stopwatch Software Egg Timer Hourglass
Technical difficulty - + +
Cost - 0 0
Durability + 0 -
Accuracy + - -
Expandability + - -
Total + +3 +1 +1
Total - -2 -2 -3
Net 0 +1 -1 -2
Measure Elapsed
Time
DATUM
DATUM
Design Element:
Evaluation Criteria Tachometer Laser Electrical Contact Pedometer
Cost - - +
Technical difficulty - - +
Accuracy + 0 -
Connection difficulty + 0 -
Dual purpose + + 0
Durability + 0 0
Total + +4 +1 +2
Total - -2 -2 -2
Net 0 +2 -1 0
DATUM
DATUM
Measure Vibration
Frequency
Design Element:
Evaluation Criteria Seven Segment LED iPhone Dial
Expandability + + -
Cost - - +
Technical difficulty 0 - +
Ease of data relay 0 - -
Lifespan 0 - +
Display accuracy 0 0 -
Total + +1 +1 +3
Total - -1 -4 -3
Net 0 0 -3 0
Display Feedback
DATUM
DATUM
Alternatives Considered:
Design Element:
Evaluation Criteria Guard Plate Robot Enclosure Light Curtain
Safety + 0 -
Cost - - -
Interference with apparatus - - +
Technical difficulty - + -
Durability - 0 -
Dual purpose 0 + 0
Total + +1 +2 +1
Total - -4 -2 -4
Net 0 -3 0 -3
Protect Operator -
Moving Parts
DATUM
DATUM
Design Element:
Evaluation Criteria Damping Pads Earplugs Damp. Enclosure
Area of effect - 0
Cost + -
Safety 0 0
Interference with apparatus + -
Durability 0 0
Technical difficulty + -
Dual purpose 0 +
Total + +3 +1
Total - -1 -3
Net 0 +2 -2
DATUM
DATUM
Protect Operator -
Sound
Alternatives Considered:
Consider Systems Level Consider Systems Level
Attach Luminaire
Measure Vibration Displacement
Measure Vibration Frequency
Measure Elapsed Time
Display Feedback
Protect Operator - Hearing
Protect Operator - Moving Parts
Rust Protection
Move Crankshaft
Morph Chart (Option 1) Screws
Vertical Motor
with Belt
Laser
Laser
Software
LED Screen
Ear Plugs
Belt Guard
+ Guard Plate
Electroplating
Attach Luminaire
Measure Vibration Displacement
Measure Vibration Frequency
Measure Elapsed Time
Display Feedback
Protect Operator - Hearing
Protect Operator - Moving Parts
Rust Protection
Move Crankshaft
Morph Chart (Option 2)
Screws
Vertical Motor
with Speed Reducer
Laser
Laser
Software
LED Screen
Ear Plugs
Guard Plate
Spray Paint
Attach Luminaire
Measure Vibration Displacement
Measure Vibration Frequency
Measure Elapsed Time
Display Feedback
Protect Operator - Hearing
Protect Operator - Moving Parts
Rust Protection
Move Crankshaft
Morph Chart (Option 3)
Screws
Horizontal Motor with
Flexible, Speed
Reducing Coupling
Laser
Laser
Software
LED Screen
Enclosure
Enclosure
Spray Paint
Option 1 Option 2 Option 3 Design Element
Screws Screws Screws Attach Luminaire
Vertical Motor with Belt Vertical Motor with Speed Reducer Horizontal Motor with 90° Coupler Move Crankshaft
Laser Laser Laser Measure Vibration Displacement
Laser Laser Laser Measure Vibration Frequency
Software Software Software Measure Elapsed Time
LED LED LED Display Feedback
Ear Plugs Ear Plugs Enclosure Protect Operator - Sound
Guard Plate + Belt Guard Guard Plate Enclosure Protect Operator - Moving Parts
Electroplate Paint Paint Rust Protection
Evaulation Criteria Option 1 Option 2 Option 3Time required + -Cost efficient 0 -Safe to operate + +Easy to setup 0 -Technical difficulty + 0Maintenance required - -Range of luminaires 0 -Appearance - 0Expandability 0 -Accuracy 0 0
Total + +3 +1Total - -2 -6
Net +1 -5
DATUM
System Pugh Chart
Why?
Paint
Selected Concept
Risk Assessment of Selected
Concept
ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due
15 Laser vibratesUnable to get accurate
displacement and frequencyNot properly damped 3 1 3
Attach laser to wall to avoid
vibration of machineJake MSDII
16Laser isn't compatible
with display
Can't get feedback for
displacement and frequency
Software and Feedback
problems2 2 4
Look at software requirements
and compatibilityRon 10/30/2013
Transportation damage 2 1 2Look at other options or
possible solutionsNick 10/30/2013
Scratches 2 1 2Look at other options or
possible solutionsNick 10/30/2013
18 Belt is too lose Vibration frequency too low Motor positioning 1 2 2 Make motor mount adjustable Ashley 10/30/2013
19Operators don't wear
earplugsHearing loss
Absence of hearing
protection1 2 2
Accept Risk - exposure duration
is still low--- ---
20 Motor is too loud Hearing lossEarplugs aren't enough
alone2 2 4
Buy motor enclosure if
necessaryBrett MSDII
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
Electroplating is
damagedMachine rusts17
Architecture
Central System
Power supply Motor system
Sensors
Display/user
interface
Luminaire
connection
Crankshaft
connection
Safety
features
Test Plan
Test Displacement
Validate the 1/32” total displacement
Test Vibration Cycles
Validate 2000 cycles/min
Test fittings
Do they fit the frame?
Test User Interface
Check connections
Ease of use
Safety Evaluation
Engineering Analysis: Frame
Analysis
Modeling frame in ANSYS Workbench
Using Modal Analysis to determine Natural
Frequency
Next, stress and fatigue analyses will be
performed on frame
Goal: 1. Prevent resonance in the frame
2. Prevent material failure
3. Prevent fatigue at connections
Engineering Analysis: Motor A v-belt speed reducing system was selected because of its
ability to provide the torque and speed necessary to run the machine at the standard and because of cost.
A direct coupling would have needed a 3500 RPM motor to run at less than 60% speed for 35 hrs at a time. This just isn’t possible with most motors.
Most speed reducing apparatuses are used to drastically increase torque output and don’t provide the speed ratio needed to run the crankshaft at 2000 RPM. They are also much more expensive than the belt system.
Concept: Because of an increase in the
radius, the driven pulley will be able to
rotate at 2000 RPM while the driver pulley
rotates at 3500 RPM when the proper ratio
of radii is selected.
Engineering Analysis: Control
System
Open Loop
System
Closed Loop
System
Engineering Analysis: Open Loop
Control System
Two component system:
User input
Motor speed control
Multiple methods to control speed output:
Vary input voltage to the motor
Alter frequency of input signal to the motor
Change the number of stator poles
Engineering Analysis: Closed Loop
Control System
Cycles per minute directly proportional to RPM
Three core components required for control:
Vibration speed sensor
Motor speed correction
Motor speed controller
Laser distance sensor to simultaneously measure
vibration speed and displacement
Variable-Frequency Drive (VFD) to adjust speed
Microcontroller to accept sensor output measurement
and feed corrected motor speed into VFD
Digital display for reading back measurements
Engineering Analysis: Closed Loop
Feedback
Laser Feedback System
Accuracy & precision on order of microns
Measurement frequency on order of kilohertz
Line of sight coincident with linear motion
Accurately sense each 1/32" displacement
Two consecutive changes in distance = 1 cycle
Analog output to feed into corrective circuit
Engineering Analysis: Control
System Comparison
Open Loop System
Requires user input to adjust motor speed
Does not self correct with changing loads
Does not require a feedback system
Simple design to implement
Closed Loop System
Self correcting (no user input required)
Higher design budget
Integrates measuring devices with control system
Engineering Analysis: Sound
L = dBA Sound Level
T = 8 hour exposure limit
C = actual exposure hours
Dosage Calculation: D = 100 * (C1/T1 + C2/T2 + C3/T3 +…)
D > 50% requires hearing protection
D > 80% requires engineering intervention
https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736
http://www.industrialnoisecontrol.com/comparative-noise-examples.htm
http://www.coopersafety.com/noisereduction.aspx
Maximum 8 Hour Exposure:
dbA hours Comparison
40 8192 Library
50 2048 Conversation at home
60 512 Conversation at restaurant
70 128 Radio or TV
80 32 Average Factory
85 16 Hearing protection required
90 8 Blender
100 2 Motorcycle
110 0.5 Live Rock Music = Pain Threshold
120 0.125 Thunderclap
130 0.03125
140 0.0078125
150 0.001953125 Jet Take-Off (25m) = Eardrum Rupture
Engineering Analysis: Machine Guarding General Industry (29 CFR 1910)
1910.211(d)(44)
"Pinch point" means any point other than the
point of operation at which it is possible for a
part of the body to be caught between the
moving parts of a press or auxiliary
equipment, or between moving and stationary
parts of a press or auxiliary equipment or
between the material and moving part or
parts of the press or auxiliary equipment.
1910.212(a)(1)
Types of guarding. One or more methods of machine guarding shall be
provided to protect the operator and other employees in the machine area
from hazards such as those created by point of operation, ingoing nip points,
rotating parts, flying chips and sparks. Examples of guarding methods are-
barrier guards, two-hand tripping devices, electronic safety devices, etc.
Plus specifics for Electrical Markings, Lubrication Access, Belts, and more
Engineering Analysis: Costs
Category Cost
Raw Materials $850
Motor $900
Belt-Drive System $100
Control system $1,000
Display $250
System to calibrate
displacement $300
Rust Prevention $300
Total $3,700
Schedule for Next Phase
Questions?
Appendix /Reference Information
Laser Sensor Long Range/High Accuracy
Sensor LK-G152/G157 Series
Range: 150 +/- 40mm Accuracy: +/-0.05%
Sensor Speed: 50kHz Repeatability: 0.5µm
Sources http://www.keyence.com/products/me
asure/laser-1d/lk-g3000/applications/application-04.jsp
http://www.ia.omron.com/products/category/sensors/displacement-sensors_measurement-sensors/index.html
More Motor Information
V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-
pt.com/products/pt_components/belts/belts.html
Alternatives Considered:
Design Element:
Evaluation Criteria Brake Pads AC Clutch Dynamic Spring
Time to stop 0 0 0
Durability + + +
Cost - - -
Technical difficulty + + -
Maintenance + + 0
Total + +3 +3 +1
Total - -1 -1 -2
Net 0 +2 +2 -1
Braking System
DATUM
DATUM
Full Risk Assessment ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due
Mechanical Failure 3 2 6 Make it adjustable Jake 10/30/2013
Poor calibration 2 1 2 Define calibration procedure and schedule Jake MSDII
Speed reducer slipping 2 2 4 Splash guard/maintenance Jake 10/30/2013
Frame misalignment 2 1 2 Verify conduit is 100% vertical Claire 10/30/2013
Motor inefficiencies 3 1 3 Accept Risk --- ---
Crankshaft slipping 3 2 6 Evaluate previous teams design Ashley 10/7/2013
Frame fall apart 3 1 3 Use certified welder, test and adjust natural frequency Ashley MSDII
Motor burns out 3 1 3 Run at full speed/cool it Ryan MSDII
Motor is too loud 2 1 2 Add motor enclosure, add sound dampening Brett MSDII
Vibration of frame 2 1 2 Add sound dampening, add hearing protection Brett MSDII
Luminaire breaks 2 1 2 Accept Risk --- ---
Crankshaft improperly
lubricated3 1 3 Define maintenance procedure and schedule Ryan MSDII
Operator injury could occur Interlocks fail 3 1 3 Use multiple interlocks as backup Ron 11/20/2013
Operator injury could occur Machine not properly guarded 3 1 3 Perform safety inspection prior to customer delivery Brett MSDII
Operator injury could occur Safety features bypassed 3 1 3 Place warning labels on apparatus Brett MSDII
Button is broken 3 1 3 Define maintenance schedule Ron MSDII
Electrical failure 3 1 3 Define maintenance schedule Ron MSDII
7 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6 Design guarding, enclosure, and/or warning labels Brett 10/30/2013
Luminaire is too heavy 2 1 2 Specify use of lift assist or 2nd operator, Design for use Brett 10/30/2013
Setup requires awkward
positioning2 2 4 Evaluate setup with ergonomic lifting equations Brett 10/30/2013
Fixture doesn't work with frame 1 1 1 Change frame and/or fixture design Claire MSDII
Project scope 2 2 4 Use current fixtures Claire 10/7/2013
10 Oil spill on motor connection Motor failure/smoke Leakage 1 2 2 Offset motor/isolate connection Ryan 10/7/2013
11 Apparatus can not support luminaire weight Fixture falls, Test fails Poor material selection 3 1 3 Analysis and testing Ashley 10/30/2013
12 Over budgetCustomer is dissatisfied, engineering
requirements must be sacrificedUnforeseeable expenses 2 2 4 Proper budgeting/compare prices/buy standard sizes Nick Ongoing
13 Apparatus is larger than existing one Customer is dissatisfiedNew holes must be drilled in
concrete floor1 2 2 Accept Risk --- ---
Poor planning 2 1 2 Maintain accurate project plan and adjust as needed Brett Ongoing
Materials are delivered late 2 2 4 Order before Christmas Nick 12/20/2013
Member doesn't finish assigned
work2 1 2 Refer to Norms and Values - seek help or adjust workload ALL Ongoing
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 Nick MSDII
15 Laser vibratesUnable to get accurate displacement
and frequencyNot properly damped 3 1 3 Attach laser to wall to avoid vibration of machine Jake MSDII
16 Laser isn't compatible with displayCan't get feedback for displacement
and frequency
Software and Feedback
problems2 2 4 Look at software requirements and compatibility Ron 10/30/2013
Transportation damage 2 1 2 Look at other options or possible solutions Nick 10/30/2013
Scratches 2 1 2 Look at other options or possible solutions Nick 10/30/2013
18 Belt is too lose Vibration frequency too low Motor positioning 1 2 2 Make motor mount adjustable Ashley 10/30/2013
19 Operators don't wear earplugs Hearing loss Absence of hearing protection 1 2 2 Accept Risk - exposure duration is still low --- ---
20 Motor is too loud Hearing loss Earplugs aren't enough alone 2 2 4 Buy motor enclosure if necessary Brett MSDII
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
Electroplating is damaged Machine rusts17
9 Can't mount all configurations typesCustomer is not able to test some
configurations
14 Project deadline is not met
Customer is dissatisfied, Students
receive poor course grade, RIT's
reputation is negatively impacted
8 Apparatus is not ergonomically safe to setup Operator injury could occur
3 Test duration does not reach 35 hours Apparatus doesn't meet UL844
4 Machine is too loudHearing conservation or engineering
intervention is required
5 Machine operates when moving parts exposed
6 Emergency stop doesn't work Operator injury could occur
1 Displacement is not equal to 1/32in Apparatus doesn't meet UL844
2 Vibration is not 2000 cycles per min Apparatus doesn't meet UL844
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.)