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HIGH SPEED LANYARD RELEASE TEST FIXTURE

HIGH SPEED LANYARD RELEASE TEST FIXTURE. Michael Amos, Project Manager Mechanical Engineer Aaron Brechko Mechanical Engineer Joshua Carmer Electrical Engineer. Dr. Benjamin Varela, Faculty Mentor Mechanical Engineer Justin Grigonis Industrial & Systems Engineer Lindsay LaRocca

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HIGH SPEED LANYARD RELEASE TEST FIXTURE

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  1. HIGH SPEED LANYARD RELEASE TEST FIXTURE Michael Amos, Project Manager Mechanical Engineer Aaron Brechko Mechanical Engineer Joshua Carmer Electrical Engineer Dr. Benjamin Varela, Faculty Mentor Mechanical Engineer Justin Grigonis Industrial & Systems Engineer Lindsay LaRocca Mechanical Engineer PROJECT NUMBER 05423

  2. Overview • Project Overview • The Process • Desired Outcomes • Key Requirements • Major Design Challenges • Conclusions

  3. Amphenol Aerospace Operations (AAO) “Accepted leader in providing quality connectors… to the Industrial, Military, and Aerospace markets” www.Amphenol-Aerospace.com Sidney, New York

  4. Project Overview • Mission Statement • To design a drive system, with supporting documentation, for an actuation method to test the separation of AAO’s lanyard release connectors. • Executive Summary • What • Why

  5. Lanyard-Release Connector Assembly • Main Components • Lanyard • Operating Sleeve • Plug Shell • Receptacle • Main electrical interface between aircraft and its stores

  6. The Process • Needs Assessment • Concept Development • Many concepts • Feasibility Assessment • Several Concepts • Preliminary Design Review • One design concept

  7. Desired Outcomes / Requirements For AAO’s Selected Concept: • Complete bill of materials • Component and assembly drawings • Provide detailed analysis of fabricated components • Meet new Military Specification MIL-DTL-38999/31D • High speed separation of connector • 30 ft/s ± 10% • Variable Test Velocity • Reliable • Repeatable • Economical • Low-Cycle Time • Safe

  8. Major Design Challenges • Motor Selection • Torque vs. RPM • AC Performance Characteristics • Overall System Dynamics • Component Selection • Clutch/Brake • Controls

  9. Description

  10. Major Components • Motor • 7.5 HP, 3 Phase AC Induction 230 V SmartMotor • Sprockets (6) • Driver • 5.123” diameter, 24 teeth (1) • Driven: • 9.911” diameter, 48 teeth (5) • Chain • Size 50, 5/8” pitch • Two-Single Strands for Upper System (US) • One-Single Strand to connect motor shaft to US

  11. Major Components – Cont’d • Mounting Block • Linear Bearing - Track

  12. Component Selection Process • Choose Motor • Choose Sprockets • Determine force and velocity at mounting block • Re-iterate

  13. Requirements: 30 ft/s 200 lb pull force on lanyard Configuration • At Motor - Driver: • 1400 RPM • At Upper System – Driven: • 700 RPM

  14. Overall System Calculations • Acceleration: a=167.97 ft/s2 t=0.1786 s d=2.68 feet a3 feet • Deceleration: a=-434.64 ft/s2 t=0.069 s d=1.035 feet

  15. Drive Motor Baldor 7.5 HP, 3 Phase Induction SmartMotor • SmartMotor: Integrated Control Board Saves: • $$$ & Man Hours • Programmable Velocity Profiles • Accuracy = 2.9% • Breakdown Torque: • 69.9 ft lbs

  16. Baldor Keypad • Remote control (up to 100 ft) • Indicator lights • Clear LCD Display • Simple • Programmable

  17. Clutch and Brake Component • Enclosed Uni-Module model 215 • One On / One Off Design • 230 VAC Powers up either clutch or brake at any given time • CBC-150-2 Controller

  18. Switch Locations 4. Home 2. Past Test Position 3. Reverse Switch (user activated) 1. At Speed (1400 rpm) Signal From Motor

  19. Control Components • Switches • Emergency Stop • Track • Rocker

  20. Emergency Stop Switch • DPST NO/NC switch • Efficient for control system • Necessary in event of failure of lanyard to disengage

  21. Track Switch • Tells control system the location of the carriage • Makes control system logic simple • SPST maintained contact • Requires ramped contact surface on bottom of carriage

  22. Rocker Switch • Manually switched after each test • Functions as second input needed to control the clutch/brake • Necessary due to limited motor controller outputs • Simple and inexpensive solution

  23. Control Logic / Power Application • Four Switches • Signals Feed Clutch / Brake Decision Logic based on state of each switch • Logic output control feeds gate of Power Switching Transistor to pass 230VAC to power up either Clutch or Brake • Emergency Stop Button included as Safety Measure

  24. Resulting Motion Profile

  25. Mounting Block Description • Shall Provide • Power transmission between chain and lanyard • Mounting surface for lanyard • Mounting surface for additional components • Should be light weight and rigid

  26. Mounting Block Final Design • 6061 aluminum • Connector mounting surface is perpendicular to plane of motion • 0.25 in fillets on edges to reduce stress concentration • Weight  5 lb (excess material removed) • Mounting points for carriage, chain, and receptacle

  27. Linear Bearing – Track • Provide supporting surface for mounting block movement • Light weight • Withstand acceleration and velocity of the test

  28. Linear Bearing Final Design • INA LFL 32 Linear Bearing • Carriage Weight - 3.5 lbs • Able to withstand nearly 5g’s acceleration

  29. Mounting Block / Linear Track

  30. Chain and Sprocket Enclosures • Protect outside environment if failure occurs • Keep drive system components clean • Help prevent human contact • Allow air flow to cool the motor • Allow for easy access for routine services

  31. Chain and Sprocket Enclosures Final Design • 13 ga. sheet metal • 13 ga. expanded sheet metal on sides • Maintenance / Access door to motor • Removable panels for full system service

  32. Provides mounting locations 2” X 2” X 0.125” 6061 Aluminum Welded construction Length determined using basic kinematic equations 192” L x 36” H x 30” D Chain System Frame

  33. Purpose: Support upper chains Mounted via aluminum right angle brackets Polyethylene U-Channel

  34. Ergonomic Analysis • Test Table Height and Width • 95th percentile male / 5th percentile female • Motor access accomplished via side door in test machine frame • Noise • Ear plugs may be necessary

  35. Safety Considerations • Track/sprocket/chain enclosures • Prevent entanglement • Mesh covering over the motor • Allows heat to dissipate • Shock absorbers • Prevents carriage contact with sprockets

  36. Conclusions • MEETS and EXCEEDS Requirements • Velocity (38 ft/s MAX) • Impulsive Pull force (334 lbs MAX) • Strong, Durable and Accurate (2.9%) • Easily Maintained • Variable Velocity Profiles • Mechanical Components Totally Enclosed • $9,000 Total Component Cost

  37. Special Thanks to Amphenol Aerospace for their support

  38. Questions or Comments?

  39. Acceleration/Deceleration

  40. AC Motor Torque Characteristics

  41. Frame Stresses / Displacement

  42. Baldor Induction SmartMotor - Accuracy • MIL-DTL-38999 allows 30 ft/sec 10% (3 ft/sec) • Accuracy = 20 RPM (provided by factory representative)

  43. Connections Block Diagram

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