Detailed Design Review

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1 Detailed Design Review Reciprocating Friction Tester : Armature Subsystem Thursday December 4th,

2 : Armature Subsystem Eric Kutil (ME): Project Manager Specialty: Solid Modeling and Machining Chris Karamanos (IE): Data Manager Specialty: Process Improvement Reba Conway (ME): Note Taker Specialty: Solid Modeling and GD&T Kolby Irving (EE): Gatekeeper Specialty: Lab-View Software Emeka Okoye (EE): Supply Manager Specialty: Electronic Hardware Gary Werth: Project Guide 2

3 Agenda Review Arm Assembly System Arm Analysis 3 Problem Statement Customer Requirements Engineering Requirements Requirements Flowdown Action Items Deflection Beam Tolerance Strain Gauge Position Fatigue Life Vibration Natural Frequency Counter Balance Weight Tolerance Stackup Strain Gauge Analysis Sensor Set-up Wiring Analysis Interface Calibration Arm Base System Complete Armature Adjustments Assembly Process Action Items Risks Problems Encountered Course Feedback Peer Reviews Moving Forward

4 Review 4

5 Problem Statement & Deliverables Current State: The reciprocating friction testers are too expensive, or not the current testing application Desired State: Fully functional reciprocating friction tester by the end of MSDII! Project Goals: Design and build an armature which will be attached to the reciprocating base made by P15561 team Constraints: The armature must provide constant & accurate vertical Normal Force Weight of armature can t affect normal force Single point contact force variable from 0N to 20N All data obtained must be stored and displayed Budget of $1500, $2500 shared between both teams 5

6 Customer Requirements 6

7 Engineering Requirements 7

8 Requirements Flowdown 8

9 Action Items from Previous Presentation Beam Tolerance Strain Sensitivity Analysis Strain Gauge Position Sensitivity Analysis Natural Frequency Sensitivity Analysis Tolerance Stack-up for Normal Force Weights Set Screw Size Consistency Strain Gauge Calibration Procedure Bearing Analysis Tolerance Stack-up for Z-axis (Ball to Plate Specimen) Ball Holder Removal Clearance

10 Assembly System: Arm 10

11 Arm BOM 11 Total cost of arm: $74.02

12 Arm Assembly Rear Block Subsystem Normal Force Subsystem Strain Gauge Rod Subsystem Counterbalance Subsystem Front Block Subsystem 12

13 13

14 Arm Analysis 14

15 Deflection Analysis Review 15 Faculty SME Sign Off: Dr. Kempski

16 Beam Tolerance Sensitivity Analysis (Action Item 1) Even with the tight tolerances of the beam, they still has a large effect on strain with +9.92% and -8.87% on the nominal value. Will this affect our project? No, the exact dimensions of the beam will be measured using precision calipers when bought Analysis will then be recalculated with those dimensions 16

17 Strain Gauge Position Sens. Analysis (Action Item 2) With the strain gauge tolerance of +/- 0.1mm from the 16mm distance to the rear block the strain changes by 0.17% 17

18 Natural Frequency Sens. Analysis (Action Item 3) Calculating the natural frequency with the max and min tolerance of the beam results to about +/- 6% from the nominal values. Since our max expected frequency is 10 Hz, we will not hit natural frequency in any case. 18

19 Counterbalance Analysis 19 Faculty SME Sign Off: Dr. Leipold

20 Weights Tolerance Stack-up (Action Item 4) 20

21 Strain Gauge Analysis 21

22 Sensor Interface Diagram 22

23 Sensors! 23

24 Extra Sensors 24 As of this morning, given access to professor Rob Kraynik s secret stash Important because pre-wired sensors could prevent many human errors Gave Kraynik gave us go ahead for early February application (Told him we needed by 9th) Go through selection criteria used for previous sensors to verify new ones will function as we need Opens up new test plan idea

25 Strain-Voltage-Force Analysis 25 Signed off by Dr James Moon(EE)

26 Test Plans 26

27 Continued.. 27

28 Location Drawing 9/30/14

29 ORIENTATION 9/30/14

30 Calibration(Shunt) Simulating input of strain by changing resistance of one arm of the bridge by some known amount Done by connecting a large resistor across one arm of the bridge Output of bridge measured is compared to expected output voltage Use result to correct span errors in the whole measurement path Advantages: 30 Simple and cheap to implement Versatile in application Places no several tolerance requirements on the shunting resistor.

31 Calibration Analysis (Action Item 6) 31 Precision resistors (±0.02%) in these and other values are available from Micro-Measurements If the gage factor is other than 2.000, or if a nonstandard calibration resistor is employed, the simulated strain magnitude will vary accordingly. The true magnitude of simulated strain can always be calculated by substituting the exact values of GF and Rc into equation 5

32 Calibration Process Sheet 32

33 Assembly System: Base 33

34 Base Assembly Mounting Subsystem X-Axis Subsystem 34

35 35

36 Base BOM 36 Total cost of base: $632.40

37 Bearing Analysis (Action Item 7) The bearings have to be off by 9.2mm in order with be within the 5 degrees of misalignment correction. 37

38 Complete Armature 38

39 Complete Assembly 39

40 40

41 Total Cost TOTAL BUDGET: $1500-$300 = $1200 Arm Assembly Cost: $74.02 Arm Base Assembly Cost: $ Cover: $100 Taxes & Shipping and Handling: ~$200 TOTAL COST: $ $ LEFTOVER 41

42 Z-Axis Adjustment (Nominal) Min Ball Height: mm from base Max Ball Height: mm from base Total of 33.8mm of Z-Axis adjustment. Thats an extra of mm of travel on both extremes! Min Plate Height: mm from base 42 Max Plate Height: mm from base

43 Z-Axis Tolerance Stack-up (Action Item 8) Dimension 1: +/ mm Dimension 2: +/ mm Dimension 3: +/ mm Dimension 4: +/ mm Dimension 5: +/ mm Dimension 6: +/ mm Dimension 7: +/ mm Total Z-Axis Tolerance at Ball Location: +/ mm

44 Plate to Ball Tolerance (Action Item 8) Worst case scenario with smallest plate specimen without spacer and lower extreme tolerance. Worst case scenario with largest plate specimen with spacer and upper extreme tolerance. Min Plate Height: mm from base The min height of the ball from the base is / mm. Therefore the worst case senario is mm. The clearance is 3.332mm! 44 Max Plate Height: mm from base The max height of the ball from the base is / mm. Therefore the worst case senario is mm. The clearance is 3.279mm! No Interference!!!!

45 Y-Axis and X-Axis Adjustment Y-Axis: Total of 49mm of adjustment Procedure: 1. Loosen set screw on arm 2. Adjust arm to desired position 3. Torque set screw to 15 Nm 45 X-Axis: Total of 37.7mm of adjustment Procedure: 1. Loosen locking handle 2. Adjust mounting base with crank wheel 3. Tighten locking handle

46 Ball Holder Removal Clearance (Action Item 9) Pin Changing Procedure 1. Slide mounting assembly all the way back 2. Slide arm full left 3. Tilt arm back 4. Loosen 4 set screws 5. Remove pin and replace Ball Holder has adequate clearance with base when removing and replacing! 46

47 Base Process Sheet 47

48 Action Items Left in MSD1 48 Setup gate review with guide Next Tuesday the 9th at 11:00am? Last peer reviews of MSD1 Within our team With the other team!! With Gary!! Figure out team merging roles and responsibilities Both teams will function as one in MSD2 Purchasing Finishing touches on documents and Edge Website Drawing Package Test Plans Analysis, Etc.

49 Future Action Items Create process sheets for fabrication of parts Chris Verify each process is correct Everyone Determine who will be assembling Reba, Eric Purchase Requisition Documents Emeka Get Exact Date for Rob Kraynik to Install Strain Gauges Kolby, Emeka Begin fabricating force weights and aluminum blocks 49 Eric, Chris

50 Risks 50

51 Risks Mitigation Chart 51

52 Problems Encountered Having to wait until design is finalized Working on sub-versioned files at the same time Professor scheduling conflicts to obtain SME approvals Team Interfacing (Ball to Plate Height Specifically!) Lessons Learned 52 More peer reviews together as a team Seek assistance from teammates when swamped with work Seek assistance from guide as necessary Schedule more time for senior design work Account for being busy like doing interviews and other work in classes

53 Course Feedback Schedule Flexibility Purchasing / Acquisition Workshop Have a set list of workshops for people to sign up for instead of making them mandatory (EE specifically) Workshops in general should be earlier in the semester Better standardization among guides for expectations and grading scheme 53

54 Peer Reviews 54 Slow go in the beginning phase Towards end of semester, actually talked face to face to teammates about how they are doing Overall Good work Everyone procrastinates, so need to keep each other in line Everyone kept a positive attitude Everyone kept a professional manner to all other teammates

55 Moving Forward: MSD2 55

56 Moving Forward: MSD2 56

57 Questions? 57

58 Appendices 58

59 Subsystem: Rear Block Description: Rear Block that supports arm Machined out of 6061 aluminum Description: Clamps strain gauge rod to front and rear block Machined out of 6061 aluminum

60 Subsystem: Strain Gauge Rod Mechanical Requirements Electrical Requirements Rod Strain Gauge

61 Fatigue Life Analysis 61 Faculty SME Sign Off: Dr. Kempski

62 Vibration Analysis Review 62 Faculty SME Sign Off: Dr. Ghoneim

63 Subsystem: Front Block Description: Front block which the holds the Pin and supports normal force weights Machined out of 6061 aluminum Description: Pin that holds the ball specimen Supplied by our customer Description: Clamps strain gauge rod to front and rear block Machined out of 6061 aluminum

64 Subsystem: Counterbalance

65 Subsystem: Normal Force 20N 10N 5N 1N 0.5N 0.25N 65 2N x 2

66 Mount Assembly Part Drawings for parts we are machining are found later in powerpoint 66

67 X-Axis Assembly 67 Part Drawings for parts we are machining are found later in powerpoint

68 PDF Links Manufactured Part Drawings Purchased Part Drawings Assembly Drawings Assembly Process Sheets 68

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