Design Review UL Vibration Test Apparatus

1. Design ReviewUL Vibration Test Apparatus May 13, 2013 1:30PM Est.

2. 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 UL Vibration Test Apparatus

3. Presentation Overview • Detailed Design Review Overview Appendix: UL Test Stand and Project Background UL Vibration Test Apparatus

4. Detailed Design Review • Discussed Design: • Adjustment Mechanism • Crank Arm • Key Action Items: • Adjustment Mechanism Strength • Crank Arm • Actions Taken: • Crank Arm to be a single piece UL Vibration Test Apparatus

5. Final Design UL Vibration Test Apparatus

6. Variations from Design UL Vibration Test Apparatus

7. Setup UL Vibration Test Apparatus

8. 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 UL Vibration Test Apparatus

9. Testing Dial Indicator Contacting Conduit Collar Dial Indicator Contacting Slider Box UL Vibration Test Apparatus

10. Flange Connection Test Frame Cantilever • 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 Testing Table Vertical Conduit Conduit Collar UL Vibration Test Apparatus

11. 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) UL Vibration Test Apparatus

12. Frame Design 34” 44” UL Vibration Test Apparatus

13. Frame Design 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) UL Vibration Test Apparatus

14. Motor Selection • 3-Phase, 240V AC Motor • Steady-state period • No acceleration of system • lbfft • This corresponds to a motor horsepower of 0.41,therefore a 1hp motor is desired • Where r= in (stroke of crank), θis angle of rotation of the motor ( • Start-up period • Where: • Assuming 50-60 seconds to reach 2000RPM, Treq3 lbfft UL Vibration Test Apparatus

15. At 2000RPM, a general purpose 1HP AC Baldor motor will produce 90ozft 5.7lbft torque • Our estimated range for required start-up torque is highlighted in yellow • At ~5.7lbfttorque, it is estimated that 2000RPM will be reached in approximately 30 seconds • A variable-frequency drive will be used to obtain the required 2000RPM speed UL Vibration Test Apparatus

16. Recommended Motor UL Vibration Test Apparatus

17. Where ka, kb and kc are Marin factors for surface condition, size, and loading conditions, respectively. • l1=2 , l2=4 , σmin, σmax, Sy, Sut can be found in Appendix UL Vibration Test Apparatus

18. 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. UL Vibration Test Apparatus

19. Budget UL Vibration Test Apparatus

20. Questions For Customer UL Vibration Test Apparatus

21. Open Discussion • Any questions? • Design concerns not discussed? UL Vibration Test Apparatus

22. Appendix UL Test Standard and Project Background

23. 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. UL Vibration Test Apparatus

24. 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 UL Vibration Test Apparatus

25. 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. UL Vibration Test Apparatus

26. UL844 Vibration Test Standard UL Vibration Test Apparatus

27. Design Flaws Associated with Original Design • 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 UL Vibration Test Apparatus

28. UL Vibration Test Apparatus

29. PUGH Matrix: Rotational to Linear Motion Mechanism UL Vibration Test Apparatus

30. PUGH Matrix: Slider Mechanism UL Vibration Test Apparatus

31. PUGH Matrix: Displacement Adjustment Mechanism UL Vibration Test Apparatus

32. Risk Assessment UL Vibration Test Apparatus

33. UL Vibration Test Apparatus