HIGH SPEED LANYARD RELEASE TEST FIXTURE
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HIGH SPEED LANYARD RELEASE TEST HIGH SPEED LANYARD RELEASE TEST FIXTUREFIXTURE
PROJECT NUMBER 05423PROJECT NUMBER 05423
Michael Amos, Project Manager
Mechanical Engineer
Aaron Brechko
Mechanical Engineer
Joshua Carmer
Electrical Engineer
Dr. Benjamin Varela, Faculty MentorMechanical Engineer
Justin Grigonis
Industrial & Systems Engineer
Lindsay LaRocca
Mechanical Engineer
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OverviewOverview
Project OverviewProject Overview The ProcessThe Process Desired OutcomesDesired Outcomes Key RequirementsKey Requirements Major Design ChallengesMajor Design Challenges ConclusionsConclusions
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Amphenol Aerospace Amphenol Aerospace Operations (AAO)Operations (AAO)
““Accepted leader in providing quality Accepted leader in providing quality connectors… to the Industrial, connectors… to the Industrial,
Military, and Aerospace markets” Military, and Aerospace markets”
www.Amphenol-Aerospace.comwww.Amphenol-Aerospace.com
Sidney, New YorkSidney, New York
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Project OverviewProject Overview Mission StatementMission Statement
• To design a drive system, with supporting To design a drive system, with supporting documentation, for an actuation method documentation, for an actuation method to test the separation of AAO’s lanyard to test the separation of AAO’s lanyard release connectors.release connectors.
Executive SummaryExecutive Summary• WhatWhat• WhyWhy
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Lanyard-Release Connector Lanyard-Release Connector AssemblyAssembly
Main Components Main Components • LanyardLanyard• Operating SleeveOperating Sleeve• Plug ShellPlug Shell• ReceptacleReceptacle
Main electrical Main electrical interface between interface between aircraft and its aircraft and its storesstores
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The ProcessThe Process
Needs AssessmentNeeds Assessment Concept DevelopmentConcept Development
• Many conceptsMany concepts Feasibility AssessmentFeasibility Assessment
• Several ConceptsSeveral Concepts Preliminary Design ReviewPreliminary Design Review
• One design conceptOne design concept
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Desired Outcomes / Desired Outcomes / RequirementsRequirements
For AAO’s Selected Concept:For AAO’s Selected Concept:• Complete bill of materialsComplete bill of materials• Component and assembly drawingsComponent and assembly drawings• Provide detailed analysis of fabricated componentsProvide detailed analysis of fabricated components
Meet new Military Specification MIL-DTL-38999/31DMeet new Military Specification MIL-DTL-38999/31D• High speed separation of connectorHigh speed separation of connector
30 ft/s ± 10%30 ft/s ± 10% Variable Test VelocityVariable Test Velocity ReliableReliable RepeatableRepeatable EconomicalEconomical Low-Cycle TimeLow-Cycle Time SafeSafe
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Major Design ChallengesMajor Design Challenges
Motor SelectionMotor Selection• Torque vs. RPMTorque vs. RPM• AC Performance CharacteristicsAC Performance Characteristics
Overall System DynamicsOverall System Dynamics Component SelectionComponent Selection
• Clutch/BrakeClutch/Brake• ControlsControls
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DescriptionDescription
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Major ComponentsMajor Components
MotorMotor• 7.5 HP, 3 Phase AC Induction 7.5 HP, 3 Phase AC Induction
230 V SmartMotor 230 V SmartMotor Sprockets (6)Sprockets (6)
• DriverDriver 5.123” diameter, 24 teeth (1)5.123” diameter, 24 teeth (1)
• Driven:Driven: 9.911” diameter, 48 teeth (5)9.911” diameter, 48 teeth (5)
ChainChain• Size 50, 5/8” pitchSize 50, 5/8” pitch• Two-Single Strands for Upper Two-Single Strands for Upper
System (US)System (US)• One-Single Strand to connect One-Single Strand to connect
motor shaft to USmotor shaft to US
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Major Components – Cont’dMajor Components – Cont’d
Mounting Block Linear Bearing -
Track
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Component Selection Component Selection ProcessProcess
1.1. Choose MotorChoose Motor
2.2. Choose SprocketsChoose Sprockets
3.3. Determine force and velocity at Determine force and velocity at mounting blockmounting block
Re-iterateRe-iterate
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ConfigurationConfiguration
Requirements:Requirements: 30 ft/s30 ft/s 200 lb pull force on 200 lb pull force on
lanyardlanyard
At Motor - Driver:At Motor - Driver:• 1400 RPM1400 RPM
At Upper System – At Upper System – Driven:Driven:• 700 RPM700 RPM
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Overall System CalculationsOverall System Calculations
Acceleration:Acceleration:a=167.97 ft/sa=167.97 ft/s22
t=0.1786 st=0.1786 sd=2.68 feetd=2.68 feet3 feet3 feet
Deceleration:Deceleration:a=-434.64 ft/sa=-434.64 ft/s22
t=0.069 st=0.069 sd=1.035 feetd=1.035 feet
ClutchofTorqueBrakingTIM BTotal
2
2
1mrI
FrontBackMotorEquiv IIN
II
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MotorofTorqueIM MEquiv
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Drive MotorDrive MotorBaldor 7.5 HP, 3 Phase Baldor 7.5 HP, 3 Phase
Induction SmartMotorInduction SmartMotor SmartMotor: Integrated SmartMotor: Integrated
Control Board Saves:Control Board Saves:• $$$$$$ & Man Hours & Man Hours
Programmable Programmable Velocity ProfilesVelocity Profiles
Accuracy = Accuracy = 2.9%2.9% Breakdown Torque:Breakdown Torque:
• 69.9 ft lbs69.9 ft lbs
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Baldor KeypadBaldor Keypad Remote control (up Remote control (up
to 100 ft)to 100 ft) Indicator lightsIndicator lights Clear LCD DisplayClear LCD Display SimpleSimple ProgrammableProgrammable
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Clutch and Brake ComponentClutch and Brake Component
Enclosed Uni-Enclosed Uni-Module model 215Module model 215
One On / One Off One On / One Off DesignDesign• 230 VAC Powers up 230 VAC Powers up
either clutch or either clutch or brake at any given brake at any given timetime
CBC-150-2 CBC-150-2 ControllerController
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Switch LocationsSwitch Locations
4. Home2. Past Test Position
1. At Speed (1400 rpm) Signal From Motor
3. Reverse Switch (user activated)
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Control ComponentsControl Components
SwitchesSwitches1.1. Emergency StopEmergency Stop
2.2. TrackTrack
3.3. RockerRocker
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Emergency Stop SwitchEmergency Stop Switch
DPST NO/NC switchDPST NO/NC switch Efficient for control systemEfficient for control system Necessary in event of failure of Necessary in event of failure of
lanyard to disengagelanyard to disengage
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Track SwitchTrack Switch
Tells control system the location of Tells control system the location of the carriagethe carriage
Makes control system logic simpleMakes control system logic simple SPST maintained contactSPST maintained contact Requires ramped contact surface on Requires ramped contact surface on
bottom of carriagebottom of carriage
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Rocker SwitchRocker Switch
Manually switched after each testManually switched after each test Functions as second input needed to Functions as second input needed to
control the clutch/brakecontrol the clutch/brake Necessary due to limited motor Necessary due to limited motor
controller outputscontroller outputs Simple and inexpensive solutionSimple and inexpensive solution
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Control Logic / Power Control Logic / Power ApplicationApplication
Four SwitchesFour Switches• Signals Feed Clutch / Signals Feed Clutch /
Brake Decision Logic Brake Decision Logic based on state of each based on state of each switchswitch
Logic output control Logic output control feeds gate of Power feeds gate of Power Switching Transistor to Switching Transistor to pass 230VAC to power pass 230VAC to power up either Clutch or up either Clutch or BrakeBrake
Emergency Stop Button Emergency Stop Button included as Safety included as Safety MeasureMeasure
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Resulting Motion ProfileResulting Motion Profile
0 5 10 150
5
10
15
20
25
30
35
40Sled Speed vs. Displacement (Concept)
Vel
ocity
(ft
/sec
)
Displacement (ft)
Clu
tch
Eng
aged
, Bra
ke O
ff
Lanyard Pull Test
Clu
tch Dise
ngaged, B
rake A
ctivated
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Mounting Block DescriptionMounting Block Description
Shall ProvideShall Provide• Power transmission between chain and Power transmission between chain and
lanyardlanyard• Mounting surface for lanyardMounting surface for lanyard• Mounting surface for additional Mounting surface for additional
componentscomponents Should be light weight and rigidShould be light weight and rigid
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Mounting Block Final Mounting Block Final DesignDesign
6061 aluminum6061 aluminum Connector mounting surface is Connector mounting surface is
perpendicular to plane of motionperpendicular to plane of motion 0.25 in fillets on edges to reduce stress 0.25 in fillets on edges to reduce stress
concentrationconcentration Weight Weight 5 lb (excess material removed) 5 lb (excess material removed) Mounting points for carriage, chain, and Mounting points for carriage, chain, and
receptaclereceptacle
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Linear Bearing – TrackLinear Bearing – Track
Provide supporting surface for Provide supporting surface for mounting block movementmounting block movement
Light weightLight weight Withstand acceleration and velocity Withstand acceleration and velocity
of the testof the test
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Linear Bearing Final DesignLinear Bearing Final Design
INA LFL 32 Linear BearingINA LFL 32 Linear Bearing Carriage Weight - 3.5 lbsCarriage Weight - 3.5 lbs Able to withstand nearly 5g’s Able to withstand nearly 5g’s
accelerationacceleration
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Mounting Block / Linear TrackMounting Block / Linear Track
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Chain and Sprocket Chain and Sprocket EnclosuresEnclosures
Protect outside environment if failure Protect outside environment if failure occursoccurs
Keep drive system components cleanKeep drive system components clean Help prevent human contactHelp prevent human contact Allow air flow to cool the motorAllow air flow to cool the motor Allow for easy access for routine Allow for easy access for routine
servicesservices
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Chain and Sprocket Chain and Sprocket Enclosures Final DesignEnclosures Final Design
13 ga. sheet metal13 ga. sheet metal 13 ga. expanded 13 ga. expanded
sheet metal on sheet metal on sidessides
Maintenance / Maintenance / Access door to Access door to motormotor
Removable panels Removable panels for full system for full system serviceservice
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Chain System FrameChain System Frame
Provides mounting Provides mounting locationslocations
2” X 2” X 0.125” 2” X 2” X 0.125” 6061 Aluminum6061 Aluminum
Welded Welded constructionconstruction
Length Length determined using determined using basic kinematic basic kinematic equationsequations
192” L x 36” H x 30” D
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Polyethylene U-ChannelPolyethylene U-Channel
Purpose: Purpose: • Support upper Support upper
chainschains Mounted via Mounted via
aluminum right aluminum right angle bracketsangle brackets
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Ergonomic AnalysisErgonomic Analysis
Test Table Height and WidthTest Table Height and Width• 9595thth percentile male / 5 percentile male / 5thth percentile percentile
femalefemale Motor access accomplished via side Motor access accomplished via side
door in test machine framedoor in test machine frame NoiseNoise
• Ear plugs may be necessaryEar plugs may be necessary
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Safety ConsiderationsSafety Considerations
Track/sprocket/chain enclosuresTrack/sprocket/chain enclosures• Prevent entanglementPrevent entanglement
Mesh covering over the motorMesh covering over the motor• Allows heat to dissipateAllows heat to dissipate
Shock absorbersShock absorbers• Prevents carriage contact with sprocketsPrevents carriage contact with sprockets
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ConclusionsConclusions MEETSMEETS and and EXCEEDSEXCEEDS Requirements Requirements
• Velocity (Velocity (38 ft/s MAX38 ft/s MAX))• Impulsive Pull force (Impulsive Pull force (334 lbs MAX334 lbs MAX))
Strong, Durable and Accurate (Strong, Durable and Accurate (2.9%)2.9%) Easily MaintainedEasily Maintained Variable Velocity ProfilesVariable Velocity Profiles Mechanical Components Totally EnclosedMechanical Components Totally Enclosed $9,000$9,000 Total Component Cost Total Component Cost
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Special Thanks to Amphenol Special Thanks to Amphenol Aerospace for their supportAerospace for their support
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Questions or Comments?
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Acceleration/DecelerationAcceleration/Deceleration
Table 1 Front Assembly Inertia Values
Component mg r Quantity Unit
Inertia Total Inertia
lb in lb-in-s2 lb-in-s2 Sprocket 7.20 4.96 3 0.22903 0.68709
Shaft 10.46 0.63 1 0.00529 0.00529 Total 0.69238
Table 1 Back Assembly Inertia Values
Component mg r Quantity Unit
Inertia Total Inertia
lb in lb-in-s2 lb-in-s2 Sprocket 7.20 4.96 2 0.22903 0.45806
Shaft 10.46 0.63 1 0.00529 0.00529 Total 0.46335
Table 1 Motor Inertia Value
Component mg r Quantity Unit
Inertia Total Inertia
lb in lb-in-s2 lb-in-s2 Sprocket 3.60 2.56 1 0.03060 0.03060
Shaft/Motor 10.46 0.63 1 0.00529 0.00529 Total 0.03589
taVV xif
xaVV xif 222
FrontBackMotorEquiv IIN
II
21
4040
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AC Motor Torque CharacteristicsAC Motor Torque Characteristics
4141
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Frame Stresses / DisplacementFrame Stresses / Displacement
4242
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Baldor Induction SmartMotor - Baldor Induction SmartMotor - AccuracyAccuracy
MIL-DTL-38999 allows 30 ft/sec MIL-DTL-38999 allows 30 ft/sec 10% (10% (3 ft/sec)3 ft/sec) Accuracy = Accuracy = 20 RPM (provided by factory representative)20 RPM (provided by factory representative)
sec/87.012
1sec/38.10
sec/38.102
911.9sec/09.2
sec/09.2sec
min
3020
ftin
ftin
inin
rad
radREV
radRPM
4343
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Connections Block DiagramConnections Block Diagram