TEAM 14John Armitage

Douglas DeVoto

Brian Polkowski

Marykate Wioncek

SOUTHCOVibration Fatigue Tester

SouthcoGlobal manufacturer

of access hardware solutionsFasteners, latches,

hinges, handles, etc.

Industries served:Computers,

electronics, automotive, aerospace, marine, etc.

Project GoalDesign and build a

vibration fatigue testerSimulate off-

highway service environment

Test compression latches

Compression Latches

T-HANDLECUSTOM COLORS

CUP LOCK PLUG

CUP VERSIONS

PAWL

HOUSINGLOCK PLUG

Business Benefit

Quality assuranceProvide quality test

data to customerAids in proper latch

selectionProduct

improvementAccurate data on

failure conditions

Customers/Wants

Top 3 Wants:- Accurate Data- Adaptable to Different Kinds

of Latches- Adjustable Forces and Hz

Metrics

Current State/Future StateOutsourced to testing company

Used linear actuators (not designed for high speed testing)

BenchmarkingExisting vibration testers

Shaker tablesInstron machines

Other benchmarkingActuatorsHammer drills

Concept Selection

Cam and Follower Shaker Table

Actuator Instron

Final Concept

How It Works

Subsystem: Fixed PartsPillow BlocksLinear bearingsBearing Mounting

Plate

Subsystem: Motor system Baldor MotorDrive BeltSprocketsCamCam Shaft

2 secondary springs

Roller followerAlignment rodsCam Follower

Bracket

Subsystem: Secondary Spring System

Subsystem: Primary Spring System

Primary SpringSpanner NutThreaded RodMain ShaftPawl

Subsystem: LatchLatchLatch PlateLatch Plate MountBase Plate

Subsystem: FrameSafety Shield

Polycarbonate80/20

Machine Base Base Plate FrameMotor MountAlumilite Covers

Measurement and Control System

Prototype

Functioning Prototype

Prototype Testing ProcedureUsed dummy latch with built in force sensorAdjusted to 100lb preloadRan machine with calibrated sensors at

several speeds up to 3600 rpm to verify that the prototype achieved 3000N of force

Latch Testing ProcedureBolt latch plate to baseAdjust spanner nut to

apply the appropriate initial loadConfirm correct load

using labview softwareTurn on motor and

change to correct speed

Record number of cycles to failure

Validation of Metrics

Goal Results

Adjustable to 60Hz √

Adjustable initial load up to 100lb √

Adjustable Dynamic load up to 3000N √

± 5% of desired load √

Metric: Adjustability

Additional Test ResultsMeasurement of Decibels

OSHA standards state that a worker can be exposed to 90 dB for an 8 hour work day.

Hearing Equipment is required in Southco testing facilityrpm dB

600 74.81200 79.81800 82.82400 84.33000 84.83600 88.1

Project Management Schedule

Project CostsMechanical Components Cost

Motor $4,000 Springs $170 Machine Table $1,300 Drive Belt $250 Linear Bearings $400 Roller Follower $200 Pillow Blocks $300 Cam Bushing $200 Raw Material $1,700

$8,520

Software Components CostForce Sensor $400 Accelerometer $365 Controllers $4000

$4,765

Total Costs CostMechanical Components $8,520 Software Components $4,765Machinist Time $6,500 Engineering Time $50,000

$69,785

Cost AnalysisFinal cost of testing

mechanism to Southco $15000

Cost of latch testingPrevious testing - $625

per latchCurrent testing – Cost

of LatchSave on shipping costsFaster data acquisition

Implementation PlanHand off of Prototype to Southco

Representatives: 12/4Plans:

Move Prototype to Southco facilityBegin testing of latches as soon as possibleProduce machines for other Southco facilities

AcknowledgementsThank you to our Southco Sponsors:

Ratnesh DwivediRon MagidsonMark DiAntonioJesus AlbillosAl Frattarola

Thank you to our Advisor:Mr. Nate Cloud

Special Thanks to:Ed Cicutti

Questions?

Resonance

w=sqrt(K/m) m kg k N/m w rad/s f hertzf=w/2Pi 4 400000 316.2278 50.32921

2 400000 447.2136 71.176254 700000 418.33 66.579292 700000 591.608 94.157331 437000 661.0598 105.2109

437N/mm 1 700000 836.66 133.15862500lb/in

Cam Torquespring force no preload follower displacment mm cam offset mm secondary k initial secondary force

2555.1778 2.776160148 1.388080074 1038 1380

theta v m/s a m/s^2 x mm k N/mm m F w T N*m T lbsf*ft Thp F of f Tf N*m Tf lbsf*ft Tf hp T total hp

0 0 197.266 0 920.4 6 3008.418 376.98 0 0 0 30.08418 2.292415 1.690798 1.158963 1.158963

5 0.045582453 196.5153433 0.121094405 3241.066 0.391893 0.289045 0.198127 32.41066 2.469692 1.821551 1.248588 1.446715

10 0.090817997 194.2690862 0.2419583 3464.288 0.834579 0.615554 0.421933 34.64288 2.639787 1.947007 1.334582 1.756516

15 0.135362361 190.544324 0.362361613 3677.737 1.320567 0.974 0.667631 36.77737 2.802436 2.06697 1.416811 2.084443

20 0.178876535 185.3694045 0.482075151 3881.135 1.841593 1.35829 0.931044 38.81135 2.957425 2.181284 1.495168 2.426212

25 0.221029351 178.7837119 0.600871031 4074.27 2.388809 1.761895 1.207697 40.7427 3.104594 2.289831 1.569572 2.777268

30 0.2615 170.8373673 0.718523118 4257.002 2.952958 2.17799 1.49291 42.57002 3.243836 2.39253 1.639967 3.132877

35 0.299980476 161.5908472 0.834807457 4429.254 3.524563 2.599584 1.781893 44.29254 3.375092 2.48934 1.706326 3.488219

40 0.33617792 151.1145231 0.949502692 4591.015 4.094111 3.019661 2.069836 45.91015 3.498354 2.580253 1.768643 3.838479

45 0.369816847 139.4881263 1.062390494 4742.337 4.652225 3.431305 2.351999 47.42337 3.61366 2.665299 1.826938 4.178936

50 0.400641244 126.8001406 1.173255976 4883.328 5.189831 3.827822 2.623793 48.83328 3.721096 2.744539 1.881253 4.505046

55 0.428416519 113.1471293 1.281888098 5014.155 5.698304 4.202853 2.880859 50.14155 3.820786 2.818067 1.931653 4.812512

60 0.452931286 98.633 1.388080074 5135.036 6.169607 4.550468 3.119133 51.35036 3.912898 2.886005 1.978221 5.097354

65 0.473998973 83.36821402 1.49162976 5246.239 6.596403 4.865257 3.334906 52.46239 3.997634 2.948503 2.021061 5.355967

70 0.491459241 67.46894559 1.592340044 5348.075 6.972149 5.142393 3.524869 53.48075 4.075233 3.005737 2.060292 5.585161

75 0.505179207 51.05619775 1.690019219 5440.893 7.291172 5.377692 3.686156 54.40893 4.14596 3.057903 2.096049 5.782205

80 0.515054455 34.25488142 1.784481345 5525.08 7.548721 5.567651 3.816364 55.2508 4.210111 3.105218 2.128482 5.944845

85 0.521009827 17.19286475 1.875546611 5601.05 7.741 5.709468 3.913573 56.0105 4.268 3.147915 2.157748 6.071321

90 0.523 1.2084E-14 1.963041666 5669.243 7.865176 5.801056 3.976352 56.69243 4.319963 3.186241 2.184019 6.160371

95 0.521009827 -17.19286475 2.04679996 5730.118 7.91938 5.841034 4.003755 57.30118 4.36635 3.220454 2.207471 6.211226

100 0.515054455 -34.25488142 2.126662054 5784.148 7.902677 5.828715 3.995311 57.84148 4.407521 3.25082 2.228285 6.223596

105 0.505179207 -51.05619775 2.202475926 5831.814 7.815033 5.764072 3.951001 58.31814 4.443842 3.27761 2.246648 6.197649

110 0.491459241 -67.46894559 2.27409726 5873.601 7.657264 5.647707 3.871239 58.73601 4.475684 3.301095 2.262746 6.133985

115 0.473998973 -83.36821402 2.341389721 5909.991 7.430976 5.480806 3.756836 59.09991 4.503413 3.321547 2.276765 6.033601

120 0.452931286 -98.633 2.404225213 5941.459 7.138502 5.265089 3.608972 59.41459 4.527392 3.339232 2.288887 5.897859

125 0.428416519 -113.1471293 2.462484126 5968.468 6.782828 5.002757 3.429155 59.68468 4.547973 3.354412 2.299293 5.728448

130 0.400641244 -126.8001406 2.51605556 5991.465 6.36752 4.696442 3.219191 59.91465 4.565496 3.367337 2.308152 5.527342

135 0.369816847 -139.4881263 2.564837539 6010.871 5.896656 4.34915 2.981139 60.10871 4.580284 3.378244 2.315628 5.296767

140 0.33617792 -151.1145231 2.608737205 6027.086 5.37475 3.964212 2.717281 60.27086 4.59264 3.387357 2.321874 5.039156

145 0.299980476 -161.5908472 2.647670991 6040.476 4.806687 3.54523 2.430089 60.40476 4.602843 3.394882 2.327033 4.757122

150 0.2615 -170.8373673 2.681564785 6051.374 4.197661 3.096036 2.122188 60.51374 4.611147 3.401007 2.331231 4.453419

155 0.221029351 -178.7837119 2.710354067 6060.077 3.553119 2.620646 1.79633 60.60077 4.617779 3.405899 2.334584 4.130914

160 0.178876535 -185.3694045 2.733984037 6066.84 2.878708 2.123226 1.455372 60.6684 4.622932 3.409699 2.337189 3.792561

165 0.135362361 -190.544324 2.752409713 6071.875 2.180231 1.608056 1.102247 60.71875 4.626769 3.412529 2.339129 3.441376

165 0.135362361 -190.544324 2.752409713 6071.875 2.180231 1.608056 1.102247 60.71875 4.626769 3.412529 2.339129 3.441376

170 0.090817997 -194.2690862 2.76559602 6075.351 1.463609 1.079502 0.739948 60.75351 4.629417 3.414483 2.340468 3.080416

175 0.045582453 -196.5153433 2.773517858 6077.388 0.734846 0.541995 0.371512 60.77388 4.630969 3.415627 2.341253 2.712764

180 6.40753E-17 -197.266 2.776160148 6078.058 1.03E-15 7.62E-16 5.22E-16 60.78058 4.63148 3.416004 2.341511 2.341511

Cam Shaft Calculations

Cam Shaft Calculations Continued