Systems Level Design Review UL Vibration Test Apparatus

Design ReviewUL Vibration Test ApparatusMay 13, 20131:30PM Est.

Project & Team InformationProject: UL Vibration Test ApparatusProject Number: 13471

Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries)Customer Contacts: Joe Manahan Ed Leubner

RIT Faculty Guide: Dr. Benjamin Varela

Project Team:Walter BergstromSean CootsSpencer CrandellMark Ellison

February 21, 2013UL Vibration Test Apparatus2Presentation OverviewDetailed Design OverviewFinal DesignTestingImprovements & Future WorkBudgetAppendix: UL Test Stand and Project Background

February 21, 2013UL Vibration Test Apparatus3Design Review DiscussionDiscussed Design: Adjustment MechanismCrank ArmKey Action Items:Adjustment Mechanism StrengthCrank ArmActions Taken:Crank Arm to be a single piece

February 21, 2013UL Vibration Test Apparatus4Final DesignFebruary 21, 2013UL Vibration Test Apparatus5

5Final Design (video)February 21, 2013UL Vibration Test Apparatus6

Adjustment MechanismFebruary 21, 2013UL Vibration Test Apparatus7

Allows for adjustment in eccentricity in order to account for tolerance stack-ups and wear

Set screw used for fine adjustmentTwo socket head cap screws for locking the system in place

Nord Lock washers to prevent loosening of adjustment mechanism5/8-11 Nord Lock WashersRated for maximum locking at 197 ft-lbs with 20900lb clamping forceAllows for reusable hardware February 21, 2013UL Vibration Test Apparatus8

pelicanparts.com

Pushrod ConnectionFebruary 21, 2013UL Vibration Test Apparatus9

Extension rod is threaded into both the pushrod and pipe collar to allow for adjustment

Pushrod position can vary in shaft supports to allow for additional adjustmentPushrod is robust and will not deflect during operation

Nuts used to lock threaded portion at the end of the pushrod in placeTestingDisplacement testing completed on the systemAs motor implementation is not within the scope of this project, frequency was not validatedTest frame rigidly fastened to testing tableAngle steel welded into frame shapeAluminum cantilever with flange connectionDial indicators used in two locations to verify the displacement across the systemContacting linear slider boxContacting collar at connection to vertical conduit

February 21, 2013UL Vibration Test Apparatus10TestingFebruary 21, 2013UL Vibration Test Apparatus11

Dial Indicator Contacting Slider BoxDial Indicator Contacting Conduit CollarTest 1: Verify zero-displacementCentering dowels mated between adjustment mechanism and rotating disk to signify zero-displacementDial indicators showed zero displacement for the systemTest 2: Verify 3 displacement values0.016: found that dial indicators give very low value for displacement (.004-0.008)0.100: again found that measured values were lower than expected (0.045-0.055)0.250: met expected displacement value within 0.010Test 3: Verify torqueTorque wrench used not ideal; not precise enough to measure low torque rangeDid verify that the required torque to drive the steady-state system is below ~2 lbf-ft February 21, 2013UL Vibration Test Apparatus12

CantileverFlange ConnectionVertical ConduitConduit CollarTesting TableTest FrameTesting ConclusionsZero-displacement point is validatedDisplacement measurements do not agree at low eccentric values, but they do at higher distancesPostulated that the dial indicators are not precise enough to accurately measure low eccentric distancesTorque measurement has a high degree of uncertainty due to the low level of precision associated with the torque wrench used during testingRecommended:Purchase more precise dial indicator (re-test)Purchase more precise torque wrench (re-test)February 21, 2013UL Vibration Test Apparatus13Frame DesignFebruary 21, 2013UL Vibration Test Apparatus14

4434Frame DesignFebruary 21, 2013UL Vibration Test Apparatus15Advantages:Allows for a single technician to mount the luminaireExtra support of U-channel decrease vibration of systemRubber pads in-between supporting beams help in dampening the systemMore space efficient than current design*Approximately 44 X 34 footprintFootprint may become larger due to resonate frequency of design (to be tackled by next senior design group)

Motor SelectionFebruary 21, 2013UL Vibration Test Apparatus16February 21, 2013UL Vibration Test Apparatus17

Recommended MotorFebruary 21, 2013UL Vibration Test Apparatus18

February 21, 2013UL Vibration Test Apparatus19Where ka, kb and kc are Marin factors for surface condition, size, and loading conditions, respectively.l1=2 , l2=4 , min, max, Sy, Sut can be found in AppendixIdentified ImprovementsInstall a brakePlate or coat steel parts (zinc plating)Development of 2 section maintenance compartmentRemovable tapered dowels for gaugingPossible addition of counter weightFixed dial gauge for reading smaller deflectionsIsolate motor from drive shaft

2 Section Maintenance hatch

Needed Before Running Final TestingReassemble using LoctiteUse lock nuts or lock washers with hardware holding linear bearings in placeEnsure all bearings are properly lubricatedBolt system to floor

Next Steps of ProjectManufacture frameInstall motor with motor baseChoose shaft coupling and installChoose and install brakeChoose motor control and installDevelop other features designated by customer input (LabView integration)

Things We LearnedConsult machinist before diving into manufacturing part/systemMany parts may need to be machined as an assemblyDowels are useful for location and assembly but have limitations in their useCheck hardness of steel from scrap bin before machining them!!!

Project CostCooper has paid as of now: $3,000.00Cost of project to date: $3,076.26Estimated total cost: ~$8,000.00Open DiscussionAny questions?Design concerns not discussed?Implementation of LabView?

February 21, 2013UL Vibration Test Apparatus26AppendixUL Test Standard and Project BackgroundProject BackgroundTo pass safety requirements for certification the luminaires must meet a series of Underwriters Laboratories Inc. Standards.A Vibration Test Stand is currently being used by Cooper Crouse-Hinds to test pendant mount luminaires according to section 33 of the UL844 Standard. The Current Vibration Test Stand is outdated, has multiple design flaws, and design documentation and drawings are non-existent.Cooper Crouse-Hinds would like a new modernized Vibration Test Stand to be developed that addresses some of the design flaws of the current system while maintaining UL844 Test Standards. This new Design must also have a LabView interface and control capability integrated into the system.

February 21, 2013UL Vibration Test Apparatus28Design Goals over Winter/Spring MSDNote: It has been decided that this apparatus will be developed in multiple Senior Design Sequences.

Provide customer with two design concepts for vibration mechanismDevelop a final design of the vibration mechanism.Design a steel test frame that will support the vibration mechanism and the vertical conduit.Design but do not develop steel frame for entire vibration test machine.Develop a full set of engineering drawings.Calculate and select the required drive train system components.Purchase materials, machine components, and assemble the vibration mechanism and test frame.Test the mechanism to ensure that it meets 1/32 deflection requirement

February 21, 2013UL Vibration Test Apparatus2929Summary of UL844 Vibration Test StandardLUMINAIRES FOR USE IN HAZARDOUS (CLASSIFIED) LOCATIONS UL 844Section 33 Vibration Test Standards

Luminaire is to be subjected to 35 hours of vibration testing.Luminaire assembly is to be attached to a 26-1/2 long conduit via NPT threading. The other end of the NPT threaded pipe is to be secured to the hub of a rigid mounting frame so that the conduit hangs vertically. The conduit should correspond to the smallest size of threaded conduit hub that is designed to attach to the Luminaire being tested.The horizontal force to be applied to the system in order to obtain the deflection must me located 4 above the location of the conduit where the Luminaire attaches.The deflection must be 1/32 with 1/16 total deflection per cycle.The system must run at 2000 cycles/min.February 21, 2013UL Vibration Test Apparatus30UL844 Vibration Test StandardFebruary 21, 2013UL Vibration Test Apparatus31

Design Flaws Associated with Original DesignFebruary 21, 2013UL Vibration Test Apparatus32Difficult for one technician to set up testLubricant not containedMachine components exposed to contaminantsBelts used (slipping)Uses single speed motor with a speed reducerFrequency adjustment dial held in place with ropeNo displacement adjustment Attachment collar may experience minor bucklingDoes not accounted for part wear and tolerance stack up

Customer Design NeedsNeed #ImportanceHigh 3 2 1 LowDesign CriteriaMeasure of EffectivenessCN13Obtain vibration frequency of 2000 cycles/minStroboscopeCN23Create displacement of 1/32 at 22.5 bellow pipe flangeDial GaugeCN32Adjustment of attachment collar position for perpendicularity___CN42240 V electrical input___CN52System envelope size is maintained or decreased from original system___CN61Mounts to current anchor points in floor___CN73Capability to adjust for different pipe sizes___CN81Use current flange mounting for pipes___CN92Design in an easily removable collar___CN103Will support multiple types of Luminaires___CN112Easy to mount the Luminaires1 Technician can run entire testCN121Ease of lubrication___CN132Containment of LubricantLook for leaking of LubricantCN143System to not run near resonate frequencyDoes not shake itself apartCN151Minimize noise of systemUnder 85 decibels(OCIA standard for requiring ear protection)February 21, 2013UL Vibration Test Apparatus33PUGH Matrix: Rotational to Linear Motion MechanismFebruary 21, 2013UL Vibration Test Apparatus34

PUGH Matrix: Slider MechanismFebruary 21, 2013UL Vibration Test Apparatus35

PUGH Matrix: Displacement Adjustment MechanismFebruary 21, 2013UL Vibration Test Apparatus36

February 21, 2013UL Vibration Test Apparatus37Risk Assessment

February 21, 2013UL Vibration Test Apparatus38

LubricationDrive Shaft Bearings: Double sealed flange mount bearings with easy access grease zerk fittings.Linear Bearings: Double sealed closed bearings with easy access grease zerk fittings.Crank Arm Bearings: Double Sealed roller bearings pre-packed with grease . Easy access for lubrication by taking off Polycarbonate cover.February 21, 2013UL Vibration Test Apparatus39