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P14471 Vibration Testing Application

P14471 Vibration Testing Application. Team Introductions. 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

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P14471 Vibration Testing Application

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  1. P14471 Vibration Testing Application

  2. Team Introductions

  3. Agenda • Background • System Analysis • Alternatives considered • Selected system • Test Plan • Engineering Analysis • Next Phase

  4. 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

  5. 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

  6. Customers Needs

  7. Engineering Requirements

  8. Engineering Requirements:The Design Drivers

  9. Benchmarking

  10. Functional Decomposition

  11. Risk Assessment

  12. Morph Chart Overview

  13. Alternatives Considered: Consider Systems Level Consider Systems Level

  14. Alternatives Considered:

  15. Alternatives Considered:

  16. Alternatives Considered: Consider Systems Level Consider Systems Level

  17. Morph Chart (Option 1) Screws Vertical Motor with Belt Laser Laser Software LED Screen Ear Plugs Belt Guard + Guard Plate Electroplating

  18. Morph Chart (Option 2) Screws Vertical Motor with Speed Reducer Laser Laser Software LED Screen Ear Plugs Guard Plate Spray Paint

  19. Morph Chart (Option 3) Screws Horizontal Motor with Flexible, Speed Reducing Coupling Laser Laser Software LED Screen Enclosure Enclosure Spray Paint

  20. System Pugh Chart Why? Paint

  21. Selected Concept

  22. Risk Assessment of Selected Concept

  23. Architecture Display/user interface Safety features Luminaire connection Sensors Central System Crankshaft connection Motor system Power supply

  24. 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

  25. 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

  26. 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.

  27. Engineering Analysis: Control System Open Loop System Closed Loop System

  28. 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

  29. 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

  30. 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

  31. 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

  32. 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

  33. 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

  34. Engineering Analysis: Costs

  35. Schedule for Next Phase

  36. Questions?

  37. 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/measure/laser-1d/lk-g3000/applications/application-04.jsp • http://www.ia.omron.com/products/category/sensors/displacement-sensors_measurement-sensors/index.html

  38. More Motor Information V-Belt Life: 25,000 hours (714 testing cycles) http://www.dodge-pt.com/products/pt_components/belts/belts.html

  39. Alternatives Considered:

  40. Full Risk Assessment

  41. Safety Checklist

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