Methods

1. FARO: Laser Subsystem Drop Test Device Brandon Zimmerman· Matthew Howard · Micah Uzuh · Connor O’Leary Advisor: Dr. Samuel Dyer Harris Problem Identification Design Requirements Requirements Concept Generation Background Acknowledgements Path Forward Testing and Validation Methods Final Prototype • FARO Technologies • FARO is a leading competitor in dimensional metrology, developing many portable 3D measurement devices including the Laser Tracker Vantage • Problem Definition • Drop test performed on laser subsystem before installation • Current test unreliable, inaccurate, prone to false positives • Creates difficulties and unnecessary expense for FARO • Project Scope • Design a system to allow FARO to perform accurate, repeatable drop tests on the laser subsystem for quality assurance before installation. • Key Issues of Current Setup • Motion occurs in non-testing directions • High variability per user and between users (±20g for 80g test) • Users affect shock response externally (friction, pull speed, etc.) • Rigid impact causes variable test-to-test response • Two Approaches • Eliminate variability in current design • Develop alternate mechanism • Design • Final prototype shown (left) • Laser subsystem represented by rectangular block of equal mass • Operation • Select desired height, adjust positioner plate via nuts on threaded rod • Raise V blocks with subsystem attached, engage latch • Place desired material pads on bottom blocks • Turn latch to release blocks and shock payload • Accelerometer can be attached to payload to measure shock value • Repeat as necessary Current Design (B) (A) Must Have (C) Modify Current Design Alternate Design Want to Have • Operator Error • Statistical analysis (one-way ANOVA with Tukey, * p<0.05) shows no significant difference between operators (A) – operator error eliminated • Shock Pulse • Optimized shock pulse (C) displays more ordered behavior than previously (B) • Validation with Top Metrics • Top wants/need achieved (Table); slightly off in percent error due to latch design ✔ ✔ ✔ ✗ ✔ ✔ ✔ ✔ Motion only in testing direction No intra- or inter-user variability Operators do not affect shock response Eliminate rigid impact variability • Identify cause of inaccuracies in current test • Current test involved withdrawing shim from between two blocks • Analyzed by one-way ANOVA with Tukey test, * p < 0.05 • The current prototype will be given to FARO Technologies with all necessary resources and any suggestions to bring the prototype to ideal performance. • The test results will highlight the correction factors needed to properly calibrate the model as well as any other changes that need to be made in future iterations of the model. • Further experimentation and iteration required to fully optimize design • Results indicate the error arose between users and within users We would like to thank Mr. Steve Beard, Dr. Harris and FARO Technologies.