Journal Bearing Dynamic Similarity Test Rig

Transcription

1 ROCHESTER INSTITUTE OF TECHNOLOGY & DRESSER RAND Journal Bearing Dynamic Similarity Test Rig Detailed Design Review 12/10/2013

2 Table of Contents Detailed Design Review Agenda... 2 Team Members:... 2 Meeting Purpose:... 2 Attendees:... 2 Meeting Time & Location:... 2 Meeting Timeline:... 2 High-Level Project Summary... 3 Problem Definition Review... 4 Customer Needs:... 4 Engineering Specifications:... 5 Pareto Analysis:... 6 Systems Design... 7 Functional Decomposition:... 7 System Architecture:... 8 Detailed Design... 9 Concept Selection:... 9 Load Application System Design Test Bearing Design Lubrication System Design Structural Support System Design Drive System Design User Interface Design Bill of Materials Risk Assessment (Updated) MSD II Plans Appendix A: Detailed Drawings Appendix B: Assembly Plans Appendix C: Test Plans

3 Detailed Design Review Agenda Team Members: Steven Lucchesi Project Manager ME Shawn Avery Team Facilitator ME Steven Kaiser Project Engineer ME Josh Plumeau Project Engineer ME Luke Trapani Project Engineer ME Meeting Purpose: The purpose of this meeting is to present a detailed design and final bill of materials for the P14453 Journal Bearing Dynamic Similarity Test Rig and receive feedback moving forward into the build phase. Attendees: William Nowak Team Guide Dr. Jason Kolodziej Primary Customer RIT Mechanical Engineering Department Dr. Stephen Boedo Subject Matter Expert RIT Mechanical Engineering Department Scott Delmotte Point of Contact Engineering Manager, Dresser Rand Promit Bagchi Point of Contact Engineer, Dresser Rand Meeting Time & Location: Date: December 10, 2013 Time: 3:30pm 5:00pm Location: CIMS - Building 78 Room 2150 Meeting Timeline: Start Time 3:30pm 3:32pm 3:40pm 3:45pm 3:50pm 4:00pm 4:10pm 4:15pm 4:20pm 4:30pm 4:35pm 4:40pm 4:45pm 4:50pm 4:55pm Topic of Review Introductions High-Level Project Summary/Objective Problem Definition Review System/Subsystem Design Review Concept Selection Load Application System Design Test Bearing Design Lubrication System Design Structural Support System Design Drivetrain System Design User Interface Design Detailed Bill of Materials Updated Risk Assessment MSD II Plan/Next Steps Assembly & Test Plans 2

4 High-Level Project Summary 3

5 Problem Definition Review Customer Needs: Category Objective Number Customer Objective Description Importance Monitored Properties Controlled Properties Interface Ease of Use Health & Safety Cost Materials & Equipment CN 1.1 Measures Shaft Speed 9 CN 1.2 Measures Load 9 CN 1.3 Measures Oil Temperature (at sump & at points in bearing) 1 CN 1.4 Measures Bearing Dynamics 9 CN 1.5 Measures Bearing Wear 1 CN 1.6 Measure Oil Pressure at Bearing Inlet/Outlet 1 CN 1.7 Measures Vibration 9 CN 1.8 Measure Gap Between Journal & Sleeve 3 CN 1.9 Measures Oil Flow Rate In/Out 3 CN 1.10 Measure Torque Transmitted in the Fluid Film 1 CN 1.11 Measure Oil Pressure at Points in the Bearing 3 CN 1.12 Measure Speed of the Floating Ring (if applicable) 1 CN 2.1 Controls shaft speed 9 CN 2.2 Allows for variable load profile 9 CN 2.3 Allows for dynamic load profile 3 CN 2.4 Controls oil pressure 9 CN 2.5 Able to isolate bearing vibration from machine vibration 3 CN 2.6 Allows oil preheating 1 CN 3.1 Displays acquired data 3 CN 3.2 Allows for Input of test parameters 9 CN 3.3 Records test data 9 CN 4.1 Test rig has a small footprint 3 CN 4.2 Quick bearing replacement 3 CN 4.3 Simple oil replacement 3 CN 5.1 Bearing Oiling System is contained 9 CN 5.2 Guarded Rotating Assembly 9 CN 5.3 Hot Surfaces are to be insulated 9 CN 5.4 Low noise 1 CN 6.1 Fits within budget 3 CN 6.2 Low cost repairs 3 CN 6.3 Low cost replacement 3 CN 6.4 Low maintenance 3 CN 7.1 Compatible with existing DAQ equipment 9 CN 7.2 Minimum of 2 system sensors 3 CN 7.3 Variable bearing size/design accommodations 3 CN 7.4 Allows for replication of current ESH-1 compressor oiling system 3 4

6 Req. # Importance CN Source Function Engr. Requirement (metric) Unit of Measure Marginal Value Ideal Value ER Read/Select Load Profile Yes/No, Time Min. 2 1 ER Control Shaft Speed Measurement Range, Accuracy rpm 0 to to 2000 ER , 2.3 Control Load Measurement Range, Accuracy Lbf 0 to 50 0 to 2000 ER Control Oil Pressure Measurement Range, Accuracy Psi 0 to 5 0 to 40 ER Measure Shaft Speed Measurement Range, Accuracy rpm 0 to to 2000 ER Measure Load Measurement Range, Accuracy Lbf 0 to 50 0 to 2000 ER Measure Oil Pressure at Bearing Inlet/Outlet Measurement Range, Accuracy Psi 0 to 5 0 to 40 ER Measure Oil Temp. Measurement Range, Accuracy ᵒF 0 to 10 0 to 150 ER Measure Bearing Vibration Measurement Range, Accuracy Hz 0 to 10 0 to 500 ER Meaure Journal to Sleeve Clearance Measurement Range, Accuracy µm 0 to 1 0 to 50 ER Measures Oil Flow Rate In/Out Measurement Range, Accuracy in 3 /s 0 to to 5 ER Measure Torque Transmitted in the Fluid Film Measurement Range, Accuracy lbf-in 0 to to 5 ER Measure Oil Pressure at Points in the Bearing Measurement Range, Accuracy Psi 0 to 25 0 to 1500 ER Preheat Oil Measurement Range, Accuracy ᵒF 0 to to 70 ER , 2.1, 4.1 Display Shaft Speed Refresh Rate Hz ER , 2.2, 2.3, 4.1 Display Load Refresh Rate Hz ER , 2.4, 4.1 Display Oil Pressure Refresh Rate Hz ER , 4.1 Display Oil Temperature Refresh Rate Hz ER , 2.5, 4.1 Display Bearing Vibration Refresh Rate Hz ER , 4.1 Display Journal to Sleeve Clearance Refresh Rate Hz ER Replace Bearings Time Min. 120 <60 ER Replace Shaft Time Min. 120 <60 ER Replace Oil Time Min. 120 <60 ER 24 9 Implied Provide Component Power Voltage Range V N/A 110 to 240 ER Record/Save Data Delay Time Sec. 5 2 ER Vary Test Specimen Size Measurement Range In 1 to to 2.75 P14453 RIT MSD I Detailed Design Review Engineering Specifications: 5

7 Pareto Analysis: 6

8 Systems Design Functional Decomposition: 7

9 System Architecture: 8

10 Detailed Design Concept Selection: Proposed Concept Attributes: Drive System: o DC Drive motor o Dart Motor Controller o Vibration Dampening Coupling o Precision Roller Support Bearings o A2 Steel Step Shaft Load System: o Pneumatic Cylinders (2 perpendicularly Oriented) o Manually Adjusted Air Regulators o Futek Load Cells o Digital Load Cell Display Test Bearing: o 2.75 ID Cast Bronze Sleeve (Bunting Bearing) o Custom Bearing Test Housing Lubrication System: o 5 Quart Reservoir o PVC Pressure Charge Tank o Manual Pressure Regulator o Diaphragm Pump o Fram Oil Filter Structural System: o Blanchard Ground Steel Surface o Steel Tube Base Frame o Custom Bearing and Actuator Risers o Vibration Damping Motor Pad 9

11 3D Concept Layout: 10

12 Load Application System Design Load System Concept Comparison: Cost Power Screw Gear Box System: ~$1,000 Chain Drive System: ~$600 Electrohydraulic (EHA) ~$2,500 Pneumatics ~$1,000 (Static) ~$2,000 (Dynamic) Piezoelectric >$20,000 Size Load Capability Load Accuracy Either option will take up a considerable amount of space. Gearbox consolidates the chain drive system into a box, but will still exceed space requirements of both the EHA and Piezo systems. User preset Static Loading Only, will fulfill PRP requirements for load magnitude. Load accuracy will depend directly on gear reduction through chain drive or gearbox, and operator ability. Once preset, load should be locked in and remain the same for test duration. EHA is a selfcontained hydraulic actuation unit, thus having a much smaller footprint than the power screw system. The units will require custom mounting blocks and spacers due to their length. Larger than piezos. Can statically load to PRP requirements. Some minor (slow) dynamic loading may be possible with proper control system. Load accuracy is marginal at best just in the nature of how the units are designed. They are meant for tilt displacement rather than for accurate load replication. Pneumatic cylinder occupies roughly the same space as EHA units and will require slightly larger brackets. Mounting is more ideal for load application. Will be able to statically load to PRP requirements. Load capability is in direct relation to available air pressure feed and piston size. Some dynamic ability if proportional regulators added. With a regulator, user input and regulator accuracy affect load accuracy. Once set, load will remain constant for test duration. Smallest footprint of all load actuation systems. Fast enough reaction time to replicate simulated ESH-1 compressor load profile. High load magnitude capabilities. Highest load accuracy of all load actuation systems in both static and dynamic load profiles. 11

13 Repeatability Controls/User Interface Availability Power System Power Screw Since this system only delivers static loading. Test repeatability will be in direct relation to load accuracy. (see above) Manual lever to turn the gear box or chain drive assembly to load preset. Could be automated with servo motor. McMaster Carr parts, high availability. Purely mechanical, no additional power system required (exception: servo motor). Electrohydraulic (EHA) Oil heating during testing could affect load accuracy and repeatability. Monitored and controlled through the PLC. Proper relief/check valve calibration will be critical. PLC (programmable logic controller.) Programming (coding) will be the challenge here. Usability will be simple inputs. Would also allow for a closed loop feedback system. Parker Hannifin. Parts and service readily available, though not simple McMaster Carr items. Power amplifier necessary for Servo motor (load based) power needs. Pneumatics Again based on user-input and regulator accuracy and repeatability. Regulator and actuator calibration will be critical. No electronic user interface. Manual mechanical control via knob on regulator and the pressure dial gage make up the entire control system and user interface. (Static case) Dynamic option would consist of a proportional regulator. Parker Hannifin. Parts and service readily available, Regulators available through McMaster Carr. Air feed line into room or standalone air compressor. Piezoelectric Highlight of the piezoelectric system is the ability to provide an accurate dynamic load profile at a high level of repeatability. PLC. More advanced coding than EHA option. Simple user inputs. Cutting edge technology, made to order systems contribute to high costs and long lead times. Power amplifier needed for powering piezos themselves as well as necessary control system. 12

14 Force (N) Force (lbs) P14453 RIT MSD I Detailed Design Review Decision Summary: This project called for the design and build of a dynamic similarity journal bearing test rig. With the available budget of $5,000 the dynamic aspect is not feasible. Electro-hydraulic actuators (EHAs) were considered for their compact size and self-contained design. They were later dismissed due to their lack of control, high power requirements, and high cost. Remaining static options were a mechanical system in the form of a gearbox or chain drive power screw systems, with the gear box or chain drive being implemented for gear reduction, and a pneumatic system. Chain drive was dismissed due to space requirements, leaving the gear box and pneumatic options. Pneumatics were chosen due to their simple analysis, control, and low cost. The cheapest and simplest dynamic option would be an upgraded version of the static pneumatic system, replacing the manual control air regulators with proportional regulator units. This would provide simple dynamic load profiles but minimal control. The more load system control desired, the higher the cost. This is evidenced by the ideal dynamic load system; piezoelectric actuators, providing high load capability and control in both static and dynamic load profiles. The piezoelectric load actuation system was dismissed due to system cost far exceeding the project budget. ESH 1 Dynamic Load Profiles: Time (s) Crank Angle (degrees) Force X (N) Force Y (N) FX ML FIT FY ML FIT ( ) ( ) (Applied Test Bearing Force, X-Direction) ( ) ( ) (Applied Test Bearing Force, Y-Direction) 13

15 Piezoelectric Actuation Analysis Piezoelectric Load System Attributes: Load Accuracy Load Repeatability Load Range Dynamic loading Compact System design Meets all of PRP requirements Variable load profiles Piezoelectric Load System Drawbacks: $$$COST$$$ Programming for controls/user interface Power system Availability Complex system design Actuator pre-load required Piezoelectric Load System Analysis: ( ) ( ) (Applied Test Bearing Force, X-Direction) ( ) ( ) (Applied Test Bearing Force, Y-Direction) Above graph shows the curve-fit functions fit to the original experimental load profile data, portrayed as the smooth lines for X-direction and Y-direction (directions based on actual orientations in test rig), as well as the response of a Piezoelectric actuation system providing a fit to the functions at a response rate of 180Hz. Proof of a piezoelectric actuation system being the ideal choice for dynamic load profiles. 14

16 Lead Screw Actuation Analysis Lead Screw Load System Attributes: Load Range Cost Simple control Simple Analysis Load accuracy (gear box) Load repeatability (gear box) Lead Screw Load System Drawbacks: Weight System size (chain drive), adds cost Dynamic loading not feasible System design Load accuracy (chain drive) Load repeatability (chain drive) Lead Screw Load System Analysis: ( ( ) ( ) ) 15

17 Force lbf F Major Diameter in D Base Diameter in dr Mean Diameter in dm Pitch in p Lead 0.10 in l Friction (Steel on steel with machine oil) 0.15 f Alpha (Thread Angle) 0.25 rad a Number of Engaged Teeth 5 Count nt Input Torque Required On Screw* lb-in Tr(in) Thread Bearing Stress psi SigmaB Thread Bending Stress at Tooth Root psi Sigmamax Transverse Shear Stress at Center of root of Thread 6282 psi Taumax Material Tensile Stress psi Sut Material Yield Stress psi Sy Factor of Safety 4.79 Needed Total Travel Travel Distance for one rotation Gear Ratio Output Distance per Rotation (in) Output Distance per Rotation (µm) in in Torque Required At Output 140 lb-in User input 2.33 lb-in Power Screw Load System options: Required components 16

18 Drive Option1: Chain Drive Output Rotations Sprocket 1 Sprocket 2 Input Rotations Sprocket 3 Sprocket 4 Input Rotations Sprocket 5 Sprocket 6 Initial input rotations Option 2: 60:1 Gear Box Electrohydraulic Actuation Analysis Electrohydraulic Load System Attributes: Compact size; one piece housing Self-contained unit Load range Speed range Electrohydraulic Load System Drawbacks: Mounting (designed to pivot) Load control, Accuracy, and Repeatability Power requirements Dynamic loading not feasible High cost for minimal capability No benefit to future projects Slow response time 17

19 Electrohydraulic Load System Analysis: Shaft Operating RPM Shaft Cycle Time Shaft Frequency Piston Velocity Piston Displacement Displacement Time Cycle Time Frequency X-Direction Force Cycles X-Direction Force Frequency Y-Direction Force Cycles Y-Direction Force Frequency 360 RPM s 6 Hz 1.8 in/s 0.01 in s s 90 Hz 2 cycles/rotation 12 Hz 4 cycles/rotation 24 Hz *Analysis does not account for system response time Pneumatic Actuation Analysis Pneumatic Load System Attributes: Compact size Simple controls Simple Analysis Cost Load Range Load Accuracy Load Repeatability Free power system (air supply) Pneumatic Load System Drawbacks: Dynamic loading not feasible Slow response time Minimal adaptability to future projects 18

20 Pneumatic Load System Analysis: High load analysis (6 bore actuator) ( ) Low load analysis (3.25 bore Actuator) ( ) Both regulators are rated up to 100 PSI, which is sufficient for static loading. Selected Cylinders are of the 4MA Series with Standard Regulators 19

21 Test Bearing Design Journal Bearing Test Assembly: Contains the test bearing Creates a mounting point for both load actuators Bearing lubricating oil is fed through the top and down into the bearing Sheet metal splash guards prevent oil spray Designed such that various bearing sizes can be tested with the same equipment Journal Bearing Attributes: Outside Dimensions: Long X Dia. C93200 Brass (SAE 600) Oil feed port with oil groove Supplier: Bunting Bearing Quantity 1 Journal Bearing Analysis: Analyzed for minimum film thickness based on maximum load Best case minimum film thickness of 3.5 µm at design clearance of 7.5 µm with a range of acceptable design clearances from 5 µm to 50 µm 20

22 Sleeve Insert Attributes: X X with through hole 1020 Steel Quantity 1 Sleeve Insert Analysis: Forces applied outward from the center hole Outside surfaces fixed as compression only Static factor of safety = 15 Maximum deformation is 0.2 µm Sleeve Enclosure Attributes: X X steel Custom machined in two pieces Assembled with dowels and bolts Quantity 1 21

23 Sleeve Enclosure Analysis: Forces applied at actuator mount points Internal faces fixed as compression only surfaces Static factor of safety = 2.1 in threaded region, 15 for loaded region Maximum deformation from load is 1.4 µm Higher deformation from bolt pre-load in the region around the bolt holes Oil Shield Attributes: 4.5 X Gauge Galvanized Sheet Metal Available in Machine Shop Quantity 2 Lubrication System Design Table Surface Attributes: Supplier: U.S. Plastic Corp. Material: High Density Polyethylene Dimensions: L x W x 12.9 H Volume: 5 Quart Temperature: 180-deg F Working Press: 5 PSI 22

24 Oil Filter Attributes: Supplier: FRAM Part. Rating: 18 microns Relief Pressure: 22 psi Filter Housing Specifications: Supplier: FRAM Material: Aluminum Ports: ½ NPT Compatibility: HP1, HP3, HP7 or HP10 FRAM filter Oil Pump: Supplier: SHURflo Power: 12 VDC Pressure: 25psi (turn on) - 40psi (shutoff) Flow Rate: 1 gpm (@ open) 0.49 gpm (@ 30psi) Duty: Intermittent Charge Tank Attributes: Supplier: Lowes (Charlotte Pipe) Diameter: 4in Pressure: 133 psi Max temp: 140-deg F 4 in PVC Pipe 4 in PVC Cap 4 in PVC Female Thread 4 in PVC Male Cap 23

25 Adjustable Pressure Regulator Attributes: Supplier: Origin Motorsports Material: Billet Aluminum Pressure: psi Max inlet Pressure: 300 psi Additional Port: Pressure-Adjustment Port Oil Line (Inlet) Attributes: Supplier: Excelon GO-1480 (vinyl compound) ID: ½ in Pressure max: 55 psi. Temp. max: 170-deg F Oil Line (Return) Attributes: Material: Braided Stainless Steel Temp. Max: 350-deg F Pressure Max: 1500 psi Connector Attributes: Bulkhead Material: Anodized Aluminum Female AE Connector Material: Anodized Aluminum 24

26 Structural Support System Design Table Surface Attributes: Blanchard Ground ASTM A36 Steel Outside Dimensions: 36 x Custom Cut Locating Holes Supplier: Nifty Bar Quantity 1 Table Surface Analysis: Forces applied at: o Bearing Mounts o Actuator Mounts Fixed at 4 corners Static Factor of Safety: Max. Vertical Deformation = 48 microns First Resonant Frequency: 162 Hz. Table Base Attributes: 3 x3 x0.25 Square Tubing Frame Welded Assembly Parts Supplier: Klein Steel Quantity 1 25

27 Horizontal Cylinder Mount Attributes: 9 x 8 x 12 Angle Plate Gray Iron Existing Plate Available in Machine Shop Quantity 1 Horizontal Cylinder Mount Analysis: Force applied at Cylinder Bolt Holes Fixed at Table Bolt Holes Static Factor of Safety = 2.63 Max. Horizontal Deformation = 44 microns Vertical Cylinder Riser Attributes: Outside Dimensions: 1.5 x 3 x Steel Quantity 2 26

28 Vertical Cylinder Riser Analysis: Force applied at Cylinder Bolt Holes Fixed at Table Bolt Holes Static Factor of Safety = 15 Max. Vertical Deformation = -3.5 microns First Resonant Frequency: 1612 Hz. Horizontal Cylinder Coupling Attributes: AISI Rod Male Thread to Load Cell Female Thread to Cylinder Quantity 1 27

29 Horizontal Cylinder Coupling Analysis: Force applied at Female End Fixed at Male End Static Factor of Safety = 1.8 Max. Horizontal Deformation = 2.9 microns First Resonant Frequency: Hz. Vertical Cylinder Coupling Attributes: AISI Rod Male Thread to Load Cell Female Thread to Cylinder Quantity 1 28

30 Vertical Cylinder Coupling Analysis: Force applied at Female End Fixed at Male End Static Factor of Safety = 1.86 Max. Vertical Deformation = 8.98 microns First Resonant Frequency: Hz. Support Bearing Riser Attributes: 14.5 x 2.5 x Steel Dowel pin Locating Holes Quantity 2 Support Bearing Riser Bolt Analysis: 3/4 16 Hex Head Cap Screw 3/4 Plain Steel Washer Torque Requirement = 100 ft-lb Goodman Factor of Safety = 38.9 Yield Factor of Safety =

31 Motor Vibration Mat: Neoprene Mat Custom Cut 7.5 x Drive System Design Drive Motor Attributes: Leeson ½ h.p. DC motor, capable of 1750 rpm Acquired from a previous senior design group Tested for proper and reliable function Quantity 1 Shaft Coupling Attributes: BKH/30/77 bellows type coupling Custom bores adapt to both the motor and shaft Completely separable clamps for easy installation and removal without removing the shaft or motor Backlash free operation up to 10,000 rpm and 1500 N-m of torque High torsional rigidity with allowance for shaft misalignment Supplier: R+W Quantity 1 Shaft Attributes: long with major outside diameter A2 Tool Steel Custom machined and surface ground on major diameter after heat treat Quantity 1 30

32 Shaft Analysis: Maximum load resultant bearing force applied on large center section of shaft Smaller diameters fixed as bearing supports Minimum Factor of safety = 5.37 Maximum displacement 5.06 µm First resonant frequency = 259 Hz Support Bearing Attributes: Two USRB C pillow block roller bearings utilized One fixed and one expansion bearing allow the shaft to expand without moving High precision units 31

33 User Interface Design 32

34 P14453 PN Part Name Description Manufacturer Supplier/Distributor Cost Cost Unit Quantity Total Cost 1 Motor Leeson DC 1/2 HP 1750 rpm Leeson Previous Project $ - each 1 $ - 2 Motor Controller Dart Controls MD10P Dart Controls Previous Project $ - each 1 $ - 3 Coupling R+W Bellows BKH/30/77/0.625"/1" R+W R+W $ each 1 $ Shaft (Machining) High Precision Grinding - Shaft Completion?? $ - each 1 $ - 5 Vertical Actuator Parker Pneumatic Cylinder (6.00J4MAU14A1.000) Parker Mitten Horizontal Actuator Parker Pneumatic Cylinder (3.25J4MAU14A1.000) Parker Mitten USRB C (Expansion) Spherical Roller Bearing - Split Housing - 2" Dia. Expansion Seal Master Applied Industrial USRB C (Non-expansion) Spherical Roller Bearing - Split Housing - 2" Dia. Non-Expansion Seal Master Applied Industrial Journal Bearing (sleeve) Cast Bronze Sleeve Bunting Bearings Bunting Bearings - 10 Sleeve Insert 4.25"x4.25"x2.75" 1020 Steel - 11A Sleeve Enclosure Bottom 7.25"x7.25"x3.5" 1020 Steel - 11B Sleeve Enclosure Top 7.25"x7.25"x3.5" 1020 Steel Socket Head Cap Screw Journal Bearing Oil Shield Hardware McMaster-Carr McMaster-Carr /16"-18 Hex Head Cap Screw Journal Bearing Housing Hardware (PN: 92620A778) McMaster-Carr McMaster-Carr /16" Plain Steel Washer Journal Bearing Housing Washers (PN: 91083A034) McMaster-Carr McMaster-Carr /8" JB Housing Dowel Pins Journal Bearing Housing Alignment Pins McMaster-Carr McMaster-Carr 9.33 $ each 1 $ $ each 1 $ $ each 1 $ $ each 1 $ $ each 1 $ - $ each 1 $ - $ each 1 $ - $ each 1 $ - $ 100 pc box 1 $ 8.08 $ 10 pc box 1 $ 9.01 $ 43 pc box 1 $ 3.00 $ 10 pc box 1 $ Table Test Surface 36"x 28.25" Blanchard Ground (ASTM A36) Nifty-Bar Nifty-Bar $ each 1 $ Support Bearing Riser (Stock) 2.5"x1"x28" 1020 Steel (Or closest larger standard) Klein Steel Klein Steel - 18 Shaft (Stock) A2 Steel 3" diameter X 16" Klein Steel Klein Steel - $ each 1 $ - $ each 1 $ - 19 Table Base Steel Tube Stock, Precut to Length (all pieces) Klein Steel Klein Steel $ each 1 $ Encoder Photocraft HS20BQZ-720/8-30 Photocraft Previous Project - 21 Load Cell (High Load Axis) Futek LCB Lb. Capacity Tension & Compression Load Cell Futek Previous Project - $ each 1 $ - $ each 1 $ - 22 Load Cell (Low Load Axis) Futek LCB Lb. Capacity Tension & Compression Load Cell Futek Futek $ each 1 $ /2" Bearing Riser Dowel Pins Bearing Mount Locating Pins (PN: 97395A764) McMaster-Carr McMaster-Carr /4"-16 Hex Head Cap Screw Bearing Mount to Test Surface Hardware (PN: 92620A872) McMaster-Carr McMaster-Carr /4" Plain Steel Washer Bearing Mount to Test Surface Washers (PN: 91083A036) McMaster-Carr McMaster-Carr /8"-18 Hex Head Cap Screw Bearing to Bearing Mount Hardware (PN: 92620A817) McMaster-Carr McMaster-Carr /8" Plain Steel Washer Bearing to Bearing Mount Hardware (PN: 91083A035) McMaster-Carr McMaster-Carr /16"-18 Hex Head Cap Screw Motor to Test Surface Mounting Hardware (PN: 92620A583) McMaster-Carr McMaster-Carr /16" Plain Steel Washer Motor to Test Surface Mounting Washers (PN: 91083A030) McMaster-Carr McMaster-Carr Motor Dampener W1322 Premium Anti-vibration Pad - Black Shop Fox Amazon.com Machine Guard (shield) Extruded Aluminum Frame with plexi shielding and door MiniTec Framing MiniTec Framing - 32 Oil Tank 6 Quart Natural Tank w/mounting Tabs U.S. Plastic Corp. U.S. Plastic Corp Oil Trank Cap 2-14/" Vented Blavk Nylon Cap U.S. Plastic Corp. U.S. Plastic Corp Bulkhead 1/2" PVC Bulkhead Grainger Grainger /2" NPT to Barb 1/2" NPT x 1/2" Barb HDPE adapter U.S. Plastic Corp. U.S. Plastic Corp FRAM Remote Mount Oil Filter FRAM High Performance Remote Mount Oil Filter Base O'reilly Autoparts O'reilly Autoparts /2" to 3/8" adapter 1/2" to 3/8" adapter U.S. Plastic Corp. U.S. Plastic Corp /2" x 1/2" x 1/2" Boom tube 1/2" NPT x 1/2" Barb HDPE Tee U.S. Plastic Corp. U.S. Plastic Corp SLV10-AA41 SLV10-AA41 Pump Surplus Center Surplus Center " Dia. PVC (10') 3" Dia. PVC (10') Charlotte Pipe Lowes " Dia Female Thread 3" Dia Female Thread Charlotte Pipe Lowes " Dia Male Thread 3" Dia Male Thread Charlotte Pipe Lowes " Dai. Cap 3" Dai. Cap NDS Lowes /2" - 1/2" HDPE elbow connector 1/2" - 1/2" HDPE elbow connector U.S. Plastic Corp. U.S. Plastic Corp Oil Regulator Oil Pressure 0psi-80psi China Ebay Stain. Steel Braided Return Line - 47 VA Riser 3.5" x 14.5" x 1.5" 1020 Steel Klein Steel Klein Steel - 48 HA Angle Mount Angle Plate with Ribs RIT MS RIT MS - 49 Vertical Cylinder Coupling AISI 4340 Coupling Klein Steel Klein Steel - 50 Horizontal Cylinder Coupling AISI 4340 Coupling Klein Steel Klein Steel /16" - 20 x 1.5" Socket Head Cap Screws Horizontal Cylinder to Mount McMaster-Carr McMaster-Carr /16" - 12 x 1.5" Socket Head Cap Screws Vertical Cylinder to Riser McMaster-Carr McMaster-Carr Vertical Cylinder Air Regulator Vertical Cylinder Air Regulator Parker Previous Project - 54 Horizontal Air Regulator Horizontal Air Regulator (PN: 5447T4) McMaster-Carr McMaster-Carr BNC Port BNC Female to Female Panel Mount Coupler N/A Ebay #10-24 Socket Head Cap Screw Encoder Loacating Tab to Table Hardware N/A RIT MS - 57 Encoder Locating Tab Bent Sheet Metal Mounting Tab N/A RIT MS - 58 Oil Shield Sheet Metal Shield N/A RIT MS - 59 Display Panel 2' x 3' Plywood w/ Sheet Metal Display Panel - 60 Test Assembly Locator Sheet Metal Guide for Test Bearing Assembly /2" - 13 x1" Socket Head Cap Screws Table Top to Base and Display to Base Mounts (PN: 91251A712) McMaster-Carr McMaster-Carr /4" - 20 x 3/8" Socket Head Cap Screws Encoder Locating Tab to Encoder Mount N/A RIT MS /4" - 20 Nylock Nut Encoder Locating Tab to Encoder Mount N/A RIT MS - $ each 1 $ 6.50 $ 5 pc box 3 $ $ 21 pc box 1 $ 3.00 $ 10 pc box 1 $ $ 36 pc box 1 $ 3.00 $ 50 pc box 1 $ 9.77 $ 192 pc box 1 $ 4.28 $ each 1 $ $ each 1 $ - $ each 1 $ 9.59 $ each 1 $ 1.79 $ each 1 $ $ each 7 $ 2.45 $ each 1 $ $ each 2 $ 0.54 $ each 1 $ 0.63 $ each 1 $ $ each 1 $ $ each 1 $ 3.37 $ each 1 $ 1.49 $ each 1 $ 1.06 $ each 3 $ 1.53 $ each 1 $ $ inch $ - $ each 2 $ - $ each 1 $ - $ each 1 $ - $ each 1 $ - $ 10 pc box 1 $ 6.88 $ each 4 $ $ each 1 $ - $ each 1 $ $ 10 pc box 1 $ 6.89 $ each 3 $ - $ each 1 $ - $ each 2 $ - $ $ - $ $ - $ 10 pc box 1 $ 9.02 $ each 1 $ - $ each 1 $ - Total: $ 3, P14453 RIT MSD I Detailed Design Review Bill of Materials 33

35 Risk Assessment (Updated) Risk # Risk Item Effect Cause Reason Likelihood Severity Importance a No power Shaft doesn t rotate 2 3 Unexpected premature bearing failure Will not measure Cannot Run test, makes test rig deliverable impossible No usable data No usable data 4 Electrical Hazard Operator hazard, fire hazard b Seized motor c No controller signal d Drive mechanism failure a Poor shaft alignment b Incorrect load profile c Lack of lubrication d Particulates in lubricant e incorrect shaft installation a Sensor failure or disconnect b Improper shaft setup c Significant outside noise d DAQ malfunction a Damage to electronics b Improperly designed enclosure c Improper maintenance d Exposed Electrial Components a No heat shielding, improper maintenance, damage to shielding, improper design, exposed extreme temperature components Burn hazard Operator hazard, fire hazard 6 Rotating element hazad Operator hazard/death Will not output data Improper/no shaft loading Power outage Lubrication system failure Motor overheats Test rig structural failure CPU Failure Loss of Motor Speed Control Support Bearing Failure Exceeding Project Budget Failure to meet Project Requirements Excess Rig Vibrations During Testing No data No useful data, test rig destruction Test interruption Damage to test specimen, damage to system Fire, test rig damage, test interrupted, bad data No test data, operator hazard No data collection, no ability to run tests, no operator control Invalid or skewed test data, Motor or rig damage Damage to test specimen, damage to system, Operator Hazard Unsatisfed Customer Unsatisfed Customer Component damage, No useable test data b Improper maintenance c Lubrication system failure d Damage to shielding a Exposed rotating element b Improper maintenance c Damage to guards a Sensor malfunction b DAQ disconnect c DAQ malfunction d Power failure a Operator error b Load input error c EHA Malfunction a System unplugged b Environmental power failure c System short a Loss of pump power b Leak in system c Obstruction in flow a Test runs too long b Internal temp control failure c Load application too high d Improper cooling/lack of air flow a Improper Design b Improper Assembly c Improper maintenance a Hardware failure b Power failure a Incorrect input b Power Surge c Controller Disconnected a Applied Loads are too high b Improper Shaft Alignment c Improper Bearing Installation a Excess Parts b High cost of "Buy" parts c Some project requirements not feasible a Time Costraints, Semester time completion b Budget Constraints a Improper component installation b Actuator Malfuntion c Test bearing or support bearing failure

36 MSD II Plans Prior to Christmas Break o Order critical components with long lead times to be received over break Subsystem Level Prep/Build (1/28 2/6) o Discussion board to capture issues o Testing resources/test bench setup o Test Plan and Project Plan o Prepare for Critical Design Review (If failed gate review) Build/Test: Subsystem Level (2/11 2/27) o Build/Test subsystem components o Issues on Discussion board o Subsystem Functional Demo o Update Test Plan Build/Test/Integrate: Subsystem and System Level (3/4 3/20) o Build/Test/Integrate subsystem and system components o Preliminary Integrated System Functional Demo o Update Test Plan o Complete initial technical paper outline Build/Test/Integrate: Systems Level (4/1 4/17) o Prepare technical paper o Full integrated system demo with Customer. o Complete Project Poster Verification and Validation (4/22 5/8) o Complete testing o Complete Paper and Poster o Complete documentation/updates to EDGE o Prepare Elevator Speech o Participate in Imagine RIT o Prepare Final Presentation Final Presentations (5/13 Exams) o Poster Presentation and Open House o Prepare for Gate Review o Finalize EDGE 35

37 Appendix A: Detailed Drawings 36

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56 Appendix B: Assembly Plans NOTE: All threaded fasteners should be installed with properly applied, non-permanent thread locking compound to prevent loosening due to vibration. NOTE: Numbers contained within [ ] reference part numbers. Numbers contained within ( ) reference quantity. NOTE: Always start fasteners by hand to ensure that there are no issues, and that nothing cross threads. 1) Test Rig Base: a) Place the table test surface [16] on the table base. Ensure that the table orientation matches that of the base, and that the (4) thru holes in the corners align with threaded holes in the base. b) By hand, install each of (4) ½-13 socket head cap screws in the (4) holes. Torque each fastener to 40 lb-ft. c) Re-torque each fastener to 60 lb-ft. 2) Bearing Support Risers: a) Drive the (4) ½ dowel pins [23] into the table using a hammer and brass drift. Ensure that at least 0.25 pin length protrudes from the top of the table. b) In turn, set each of (2) bearing risers [17] over the dowel pins, ensuring that the holes align with the pins. Drive each riser onto the pins using a soft faced hammer. Do so by tapping once or twice over one pin, and then the other, slowly driving the riser on without causing it to tip. c) By hand, install each of (4) ¾-16 hex head cap screws [24] with (4) ¾ washers [25] into the holes in the risers. d) In turn, torque each screw to 100 lb-ft, be sure to tighten the bolts incrementally in a distributed pattern in order to ensure the load is evenly distributed. 3) Vertical Cylinder Risers: a) Place each of (4) ¾-16 hex head cap screws [24] with (4) ¾ washers [25] into the holes in the table for the vertical cylinder risers [47]. b) One at a time, hold the vertical risers under the table, aligning them with the screws. Thread each by hand until they are able to hold the risers in place. c) In turn, torque each screw to 100 lb-ft, be sure to tighten the bolts incrementally in a distributed pattern in order to ensure the load is evenly distributed. 4) Shaft Encoder Locating Tab: a) Place the shaft encoder locating tab [57] over the three screw holes in the table. b) Install and tighten the (3) #10-24 socket head cap screws [56]. 55

57 5) Bearing Test Assembly: a) Press the journal bearing [9] into the sleeve insert [10], ensuring that it is centered and does not deform during installation. b) Drive the (2) 3/8 dowel pins [15] into the bottom sleeve enclosure [11A] using a hammer and brass drift if necessary. c) Set the sleeve insert into the channel in the bottom sleeve enclosure. d) Set the top sleeve enclosure [11B] over the dowel pins, ensuring that they line up with the holes and that the sleeve insert lines up with the channel in the top sleeve enclosure. Tap the top sleeve enclosure onto the dowel pins using a soft faced hammer. e) By hand, install (2) 9/16-18 hex head cap screws [13] with (4) 9/16 washers [14] through the top sleeve enclosure. Tighten them hand tight. f) Flip the assembly over and install the other (2) 9/16-18 screws in the same manner. g) Torque all (4) screws to 30 lb-ft. h) Torque all (4) screws to 50 lb-ft. i) Torque all (4) screws to 64 lb-ft. j) Holding it in place by hand, align one of the oil shields [58] with the holes in the test enclosure. k) Install and tighten all (4) 4-40 socket head cap screws [12]. l) Repeat for the oil shield on the other side. 6) Test assembly and shaft installation: a) Place each test block locator [60] on the table between the bearing risers, aligning them with the mounting holes. b) Screw in and tighten the (4) 5/16-18 [28] screws. c) Lubricate the contact face of each test block locator with SAE 30 oil. d) Lubricate the inside of the journal bearing with SAE 30 oil. e) Slide the non-expansion support bearing [8] onto the shaft on the end with the 1 inch OD, ensuring that it is aligned properly. Butt it up against the largest shaft diameter. f) While holding the support bearing in place, slide the test assembly onto the largest shaft OD, being mindful not to nick or ding the journal bearing. Be sure that the mounting point for the horizontal actuator is aligned properly. g) Slide the expansion support bearing [7] over the end of the shaft, butting it up against the largest OD and capturing the test housing between the two support bearings. h) Set the assembly on the table, with the support bearings on the support bearing risers and the slots in the bearings centered above the threaded holes in the risers. i) By hand, install the (4) 5/8-18 hex head cap [26] screws with (4) 5/8 washers [27] into the holes. j) Tighten the two bolts in the non-expansion bearing to 25 lb-ft, then 50 lb-ft, 75 lb-ft, and finally 100 lb-ft. 56

58 k) Ensuring that the expansion bearing is still aligned by carefully and slowly spinning the shaft. If the shaft spins freely, tighten both expansion bearing screws in the same manner used for the non-expansion bearings. l) Screw the high-load load cell [21] into the underside of the test assembly. m) Screw the low-load load cell [22] into the side of the test assembly. 7) Motor Installation: a) Set the vibration dampening mat [30] onto the table, aligning its holes with the motor mounting holes. b) Set the motor [1] on the dampening mat, aligning the mounting slots with the holes in the mat and table. c) By hand, install all (4) 5/16-18 hex head cap screws [28] with (4) 5/16 washers [29], ensuring that the motor is still free to move horizontally. d) Install the shaft coupling [3] onto both the motor and test shaft, ensuring that it is oriented such that the larger counter bore is aligned with the shaft and the smaller with the motor. e) Torque the motor mounting screws to 10 lb-ft. 8) Vertical Actuator Installation: a) Thread the vertical actuator coupling [49] onto the end of the vertical actuator [5] shaft. b) Fully compress the actuator. c) Align the vertical actuator mounting holes with the threaded holes in the risers on the underside of the table. d) By hand, thread in the (4) 9/16-12 socket head cap screws [52]. e) Torque each screw to 25 lb-ft. f) Torque each screw to 45 lb-ft. g) Torque each screw to 64 lb-ft. h) Carefully extend the vertical actuator and thread the coupling into the corresponding load cell. 9) Horizontal Actuator Installation: a) Set the horizontal actuator angle mount [48] on the table, aligning it with the threaded holes in the table. b) By hand, thread the (4) ¾-16 hex head cap screws [24] with (4) ¾ washers [25] into the holes. c) In turn, torque each screw to 100 lb-ft, be sure to tighten the bolts incrementally in a distributed pattern in order to ensure the load is evenly distributed. d) Thread the horizontal actuator coupling [50] onto the end of the horizontal actuator [6] shaft. e) Fully compress the actuator. 57

59 f) Slip the horizontal actuator shaft through the large center hole in the angle mount and align all of the thru holes with the threaded holes on the angle mount. g) By hand, thread in all (4) 7/16-20 socket head cap screws [51]. h) Torque each screw to 15 lb-ft. i) Torque each screw to 25 lb-ft. j) Torque each screw to 32 lb-ft. k) Carefully extend the horizontal actuator and thread the coupling into the corresponding load cell. 10) Shaft Encoder Installation: a) Slip the shaft encoder [20] over the end of the shaft and tighten the set screws. b) Align the tab on the encoder with the encoder locating tab and pass the ¼-20 socket head cap screw [62] through, threading the ¼-20 nyloc nut [63] onto the screw. Tighten the nut onto the screw. 11) Lubrication System Installation: a) Insert the male end of the NPT bulkhead into the oil reservoir, then place the bulkhead so that the threaded portion is coming out of the hole cut into the bottom of the tank. Ensure that the gaskets are in place. Fasten the female end of the NPT bulkhead onto the male end according to the torque specified by the supplier. If no torque spec is supplied hand tighten. Additionally thread the -6 AN bulkheads into the top of the tank in a similar fashion. b) Thread the vented cap onto the reservoir and thread the ½ barb ½ NPT fitting into the bulkhead. c) Using PVC cement and primer connect the bottom end-cap to the 4 dia. PVC pipe, on the other end connect the 4 female thread via the same method. d) Using PTFE tape thread in the ½ x ½ Bard x ½ NPT tee into the bottom cap and the male thread into the female thread top-cap. e) Using two strap clamps and four bolts fasten the assembled charge tube to the back of the instrument panel, ensure that the straps are tight and the charge tank is immobile. f) Using the ¼ bolts fasten the pump and remote oil filter to their respective locations on the back of the instrument panel, make sure to thread the ½ NPT x ½ barb fittings into both of the fixtures. Screw the oil filter into the filter housing according to manufacturer specification. g) Now using 10 ¼ bolts fasten the oil reservoir to the front of the instrument panel, make sure to tighten them in a crisscrossing fashion to ensure uniform tightness. h) Using the supplied bracket fasten the APRV (adjustable pressure regulator valve) to the front of the instrument panel. i) Thread the ½ barb x ½ NPT fitting to the top portion of the test bearing housing block, additionally attach the ¼ NPT to AN fittings to the bottom of the test block. 58

60 j) Connect all upstream components using the yellow fuel-oil line and connect the AN oil drain ports to the AN bulkheads via the braided steel cables. k) Before running a test, be sure to turn on the lubrication system to allow the system to charge, the pressure to equalize, and the lubricant to begin flowing through the bearing. 12) Instrument Panel: a) Run the mains, encoder output, BNC 1 wires, and motor leads through the DART controller hole in the instrument panel. Run the mains, load cell output, and BNC 2 and 3 wires through the Load Cell Display hole. The mains wires through the emergency stop hole. b) Wire the DART controller up according to the manufacturers specifications and connect the encoder wires to the BNC 1 port. Then feed the wires and DART controller back into the instrument panel and tighten the two support screws to fasten the DART. c) Wire the Load Cell Display according to the manufacturer s specifications and connect the load cell outputs to BNC 2 and BNC 3. Then feed the wires back into the panel and press the display into place. d) Using ¼ bolts fasten the two pneumatic regulators to the back of the instrument panel then connect the upstream valves to air supply and the downstream valves to the actuators. e) Wire the e-stop button to the mains power and feed the wires back into the panel. Then use the two mounting bolts to fasten the button. f) Attach any additional sensors or outputs to the remaining BNC connectors. g) Attach the instrument panel to the table frame via the 4 main mounting bolts. 59

61 Appendix C: Test Plans Component/System Tested Specification Tested Responsibility Completion Date Motor/Shaft w/o Bearing (Unloaded) Speed Team 2/28/2014 Motor/Shaft w/bearing (Unloaded) Speed Team 3/20/2014 Oil Flow Rate (Unloaded) Flow Rate Team 3/20/2014 Oil Temperature (Unloaded) Temperature Team 3/20/2014 Oil Pressure at Bearing Inlet/Outlet (Unloaded) Oil Pressure at Points in Bearing (Unloaded) Pressure Team 3/20/2014 Pressure Team 3/20/2014 Bearing Vibration (Loaded) Frequency Team 4/17/2014 Journal to Sleeve Clearance (Loaded) Distance Team 4/17/2014 Transmitted Torque (Loaded) Torque Team 4/17/2014 Motor/Shaft w/bearing (Loaded) Speed Team 4/17/2014 Oil Flow Rate (Loaded) Flow Rate Team 4/17/2014 Oil Temperature (Loaded) Temperature Team 4/17/2014 Oil Pressure at Bearing Inlet/Outlet (Loaded) Oil Pressure at Points in Bearing (Loaded) Pressure Team 4/17/2014 Pressure Team 4/17/2014 High Load Force Team 4/17/2014 Low Load Force Team 4/17/2014 Bearing Vibration (Loaded) Frequency Team 4/17/2014 Journal to Sleeve Clearance (Loaded) Distance Team 4/17/2014 Notes: Transmitted Torque (Loaded) Torque Team 4/17/