High Torque Test Stand

1. Lightnin SPX High Torque Test Stand Aditya - Oriana - Don - Jesse - Ron - Dana - Geoff 05413

2. Aditya Sanghi, IE - Project Leader Dana Harris, IE Ron Mendolera, EE Jesse Warner, EE Dr. William Scarbrough, Project Coordinator Geoff Cusano, ME Oriana Starr, ME Don Strong, ME Dr. Alan Nye, Project Mentor Team Members

3. Project Overview • Sponsor: Lightnin SPX • Manufacture pumps, mixers, etc. • Gear reducer production moved to Rochester, NY from Wytheville, VA • Evaluate final assembly & testing processes • Identify & solve inefficiencies

4. 700/800 Series Overview • Sizes • Configurations • Hollow & Solid shafts • Weight • Assembly process Mixer Gear Reducer

5. Assembly Stand Side Front

6. Assembly Rotation Rotated 90° - back Rotated 90° - front

7. Spin Test & Assembly Area

8. Torque Stand Front Side

9. Project Mission Statement • Identify and eliminate process inefficiencies • Redesign & relocate the torque test stand • Propose process flow improvements • Adhere to constraints • time, cost, footprint & height • Avoid hazardous workstations

10. Initial Improvement Ideas • Obvious • Reduce long travel distance to torque test • Fork truck • Reduce travel time between stands • Crane • Fork truck • “Homerun”  3-in-1 stand • Assembly, spin test, torque test

11. Time Studies - Plan • Identified largest areas for improvement 1) Torque test stand setup: 135 min 2) Spin Test Stand setup: 25 min 3) Walk time during large assembly: 20 min 4) Transportation to torque test : 12 min • Justify discontinuing development of 3-in-1 concept • Torque test stand setup: examine further

12. Eliminate 3-in-1 Concept • Impossible to meet yearly production volume • 497 min. of build time per reducer, only 1 stand • Projected costs were prohibitive • Much more risk • Brand new, unique design • If the all-in-one stand breaks down, entire process halted • Customer visits interrupt production • Can only build one unit at a time

13. Input from Lightnin • Meeting with Management: December 2004 • 100% torque testing – Warranty issues • Remove waste • Relocate torque stand – reclaim dock • Ultimately: accomplish torque AND spin test in the time it currently takes just to spin • This would further encourage 100% torque testing

14. Final Improvement Ideas • Perform spin test on torque stand • Eliminate spin test stand & transport time • Reduce setup time for torque stand • Adjustable input motor • Universalized couplers with splines • Oil tanks with heater • Simplified operator controls • Reunite small & large assembly areas

15. Current large assembly area Use current assembly stand Redesign the torque test stand Reduce height & footprint Torque AND spin test capacity Make the process more efficient Standardize controls: direct labor NOT technician Final Design Concept

16. CURRENTTorque Test Stand Setup • Align shafts: motor output to reducer input • Manually adjust reducer height • Spacer plates • Adjust distance: motor output to reducer input • Bolt input shaft • Couple the reducer’s output shaft to the slave unit • Measure, bolt • Heat the oils • Cannot begin until setup is complete • Manually adjust air pressure regulator for torque control

17. NEW Torque Test Stand Setup • Align shafts: motor output to reducer input • Automatically adjust input motor height • Universal mounting plate • Scissor lift with elevation control • Adjust distance: motor output to reducer input • Rail, keyed couples • Couple the reducer’s output shaft to the slave unit • Splined couples • Heat the oils • Can begin before the reducer is craned onto the stand • Automatic electronic control • Adjust air pressure regulator for torque control • Automatic electronic control

18. Inline Input Motor • Same arrangement as current • Components • 25 HP motor • 40:1 Reducer • Clutch • 60 HP motor • Torque Sensor • Existing Mount

19. Horizontal Movement • Function • Allow input motor assembly to slide accommodate 8 different input configurations • Rails • Specs • Weight Capacity • Moment Capacity • Actuator • Specs • Overcome Friction Forces SKF Profile Rail Guides UNI-LIFT M1 Linear Actuator

20. Vertical Movement • Function • Allow input motor assembly to adjust to 8 different input heights • Hydraulic Lift • Specs • Weight Capacity • Transverse Load Capacity • 3’ X 7’ Platform • Mounting Substructure LK Goodwin Tandem Hydraulic Lift

21. Input Couple • Function • Connects Input Motor to Input Shaft of Testing Reducer • Improvements • Two Keyways reduces alignment. • No Bolting reduces setup time.

22. Output Couple • Function • Connect output shaft of tested reducer to slave • Design • Time Savings • Indexing • No Height Adjustments • Specs • Universal Female 800 Series Spline 700 Series Spline Female Spline

23. Coupling Analysis • Stress Analysis • 782/882 Coupling • Tmax = 310,000 in-lb

24. Fatigue Analysis

25. Spline Development • 30o Flat root profile • Size restriction • 6/12 Pitch • Analysis

26. Overall Structure • Function • Support loads • Set height for slave and new couplers • Universal mounting plate • Actuator mount • Design • Two tier design • Footprint: 9’ x 19’ • Clearance

27. Stand Analysis • Member Analysis • Critical members • Size Recommendations • Mount Requirements • Actuator Assembly • Universal Plate • Loads • Weights • Output Torque

28. Controls • Oil temperatures • Elevation of input motor • Torque

29. Oil Temperature Control • Heat oils up to operating temperature before test unit is place on stand • Tanks are insulated and temperature-controlled • 80-gallon tank for lube oil • 50-gallon tank for brake transmission oil

30. Elevation Control • Eliminates the need to make manual height adjustments with spacer plates. • Uses a programmed PLC with a position sensor in the feedback loop to control the hydraulic pump motor.

31. D/A Conversion Table Elevation Control Algorithm Position Sensor

32. Torque Control • Eliminates the need to make manual adjustments of air pressure regulator to control brake pressure which determines torque. • Uses a programmed PLC with a torque sensor in the feedback loop to control an electronic air pressure regulator.

33. Torque Control Algorithm Electronic Air Pressure Regulator Torque Sensor

34. Electronic Database • Eliminates the need to search through hard copies for previous test data. • Visual basic used to create a user-friendly Microsoft Access database

35. Old vs. New Process Comparison • Estimated time saved: over 1.5 hours!

36. Final Layout Options • Two locations • Current large assembly • “Back bay” area • Options • Just replace spin stand with torque stand • Move ALL final assembly operations to the back bay area

37. Layout Option 1 • Easiest to implement, less change • Rearrange assembly stand • Still have wasted transport time from having small & large assembly separated

38. Current Large Assembly

39. Redesigned Large Assembly

40. Layout Option 2 • Requires greater willingness to change • Move all to back bay, reunites small & large assembly areas, eliminates wasted transportation time • Slight downtime, but current production volumes/build times indicate that it could be done during off-times without delaying shipments • More room to work, both for reducer assembly, and the areas near current large assembly • Flow

41. Back Bay Layout

42. Simulation • Results of simulation, given the new design • Greatly reduced torque test time, not enough to accomplish ultimate goal • Still takes 20-30 minutes longer to do torque & spin vs. just spin • May still be worthwhile to implement the design • Reclaim dock, improve flow, save time • Future Lean activities may make up the remaining time • Standardization, kaizen, etc.

43. Cost of Implementation • BOM • Cost to Build the stand - $10,000 • Sum total = 35,368

44. Incremental Revenue/Savings • Incremental Revenues • Revenue by selling extra torque testing as a service (20 units @ $2k/unit) • Revenue by marketing selling extra units due to improved reliability (10@$30k) • Incremental Savings • Warranty Costs saved due to the 100% testing (25k in Yr2 and 50k thereafter) • Labor Savings (3 hrs @$75/hr /torque tested unit) • Moving from the shipping dock ($10/sq ft)

45. Final Recommendations • Build stand • Lean, kaizen, process improvements activities “It is very difficult early on to turn the flywheel of improvement, especially from a dead stop, or worse yet a negative rotation.”Good to Great by Jim Collins

46. Acknowledgments • SPX Process Equipment, Lightnin Division • Dave Engel, Lightnin SPX • Al Aponte, Lightnin SPX • Jeff Flint, Lightnin SPX • Production staff at Lightnin • Dr. Hany Ghoneim, ME Department • Dr. Elizabeth DeBartolo, ME Department • Bob Thomas, Rochester Gear

47. Questions ?

48. Initial Concept Development • Transportation • Rail system, wheels, rotary arm, trolley, etc. • Slave unit • Pump, two gears, electric generator, etc. • Attachment of test unit to stand • Clamps, magnets, pins, bolts, etc.

49. Needs Assessment • Order Qualifiers & Winners • Cost to build SHALLNOTexceed $200,000 • Return On Investment • Labor savings • Design software to be compatible with Autodesk Inventor • Utilize existing equipment • Scope

50. Simulation Model