SOUTHCO Vibration Fatigue Tester

1. SOUTHCOVibration Fatigue Tester TEAM 14 John Armitage Douglas DeVoto Brian Polkowski Marykate Wioncek

2. Southco • Global manufacturer of access hardware solutions • Fasteners, latches, hinges, handles, etc. • Industries served: • Computers, electronics, automotive, aerospace, marine, etc.

3. Project Goal • Design and build a vibration fatigue tester • Simulate off-highway service environment • Test compression latches

4. Compression Latches CUSTOM COLORS T-HANDLE HOUSING LOCK PLUG LOCK PLUG CUP PAWL CUP VERSIONS

5. BusinessBenefit • Quality assurance • Provide quality test data to customer • Aids in proper latch selection • Product improvement • Accurate data on failure conditions

6. Top 3 Wants: - Accurate Data - Adaptable to Different Kinds of Latches - Adjustable Forces and Hz Customers/Wants

7. Metrics

8. Current State/Future State • Outsourced to testing company • Used linear actuators (not designed for high speed testing)

9. Benchmarking • Existing vibration testers • Shaker tables • Instron machines • Other benchmarking • Actuators • Hammer drills

10. Concept Selection Cam and Follower Shaker Table Instron Actuator

11. Final Concept

12. How It Works

13. Subsystem: Fixed Parts • Pillow Blocks • Linear bearings • Bearing Mounting Plate

14. Subsystem: Motor system • Baldor Motor • Drive Belt • Sprockets • Cam • Cam Shaft

15. Subsystem: Secondary Spring System • 2 secondary springs • Roller follower • Alignment rods • Cam Follower Bracket

16. Subsystem: Primary Spring System • Primary Spring • Spanner Nut • Threaded Rod • Main Shaft • Pawl

17. Subsystem: Latch • Latch • Latch Plate • Latch Plate Mount • Base Plate

18. Subsystem: Frame • Safety Shield • Polycarbonate • 80/20 • Machine Base • Base Plate • Frame • Motor Mount • Alumilite Covers

19. Measurement and Control System

20. Prototype

21. Functioning Prototype

22. Prototype Testing Procedure • Used dummy latch with built in force sensor • Adjusted to 100lb preload • Ran machine with calibrated sensors at several speeds up to 3600 rpm to verify that the prototype achieved 3000N of force

23. Latch Testing Procedure • Bolt latch plate to base • Adjust spanner nut to apply the appropriate initial load • Confirm correct load using labview software • Turn on motor and change to correct speed • Record number of cycles to failure

24. Validation of Metrics

25. Metric: Adjustability

26. Additional Test Results • Measurement of Decibels • OSHA standards state that a worker can be exposed to 90 dB for an 8 hour work day. • Hearing Equipment is required in Southco testing facility

27. Project Management Schedule

28. Project Costs

29. Cost Analysis • Final cost of testing mechanism to Southco $15000 • Cost of latch testing • Previous testing - $625 per latch • Current testing – Cost of Latch • Save on shipping costs • Faster data acquisition

30. Implementation Plan • Hand off of Prototype to Southco Representatives: 12/4 • Plans: • Move Prototype to Southco facility • Begin testing of latches as soon as possible • Produce machines for other Southco facilities

31. Acknowledgements • Thank you to our Southco Sponsors: • Ratnesh Dwivedi • Ron Magidson • Mark DiAntonio • Jesus Albillos • Al Frattarola • Thank you to our Advisor: • Mr. Nate Cloud • Special Thanks to: • Ed Cicutti

32. Questions?

33. Resonance

34. Cam Torque

35. Cam Shaft Calculations

36. Cam Shaft Calculations Continued