P14471 Vibration Testing Apparatus II
Subsystems Design Review
10/29/2013
Brett Billings
Jacob Gardner
Nick Greco
Ron Jimbo
Claire Kobal
Ryan Selig
Ashley Waldron
Agenda
 System Design Selection
 Subsystem Selection





Frame
Motor
Displacement Measurement
RPM Measurement
Display and Control System
 Test Plan
 Risk Analysis
 BoM / Cost Estimate
 Next Phase
System Design Selected
 Vertically mounted motor with v-belt offset for maximum






torque and speed control
Dial gauge to confirm displacement and verticality
Encoder and VFD to read and control speed
LCD Display of RPM and time elapsed
Safety: belt guard, polycarbonate guards, E-stop
Multiple diameter conduits with dedicated flanges and collars
for quick change-overs
Spray paint to prevent rust
System Design
Selected
Frame Design
Frequency Analysis
 Vibration Frequency:
 33.3 Hz (2000 RPM)
 Natural Frequency of Apparatus:
 42.3 Hz
 Maximum deflection
 .853” (shown in red)
Structural Analysis of Cantilever
 Maximum Stress:
= 6897 PSI
 Maximum Deflection
= .046 inches
Overall System Analysis
Motor Selection
Maximum Load= 150 lbs
Torque Necessary= 1.68 ft-lbs
We will be running the motor at full load torque to allow for a longer life.
𝑖𝑛𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑
3500
𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =
=
= 1.75
𝑜𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑 2000
Motor Continued
Motor Performance Data:
Baldor M3545
Total Cost: $472.00
V-Drive Selection
All information was gathered from the Dodge catalog
For the given gear ratio of 1.72, Type A, 1-Groove
Driver Datum Diameter: 3.4”
Outer Diameter= 3.4”+.37”= Approx. 3.75” P/N 118190
Driven Datum Diameter: 6.2”
Outer Diameter= 6.2”+.37”= Approx. 6.55” P/N 118204
Driver Taper Lock Bushing (1210), .5” Shaft Diameter: Keyway P/N 119191
Driven Taper Lock Bushing (1610), 1” Shaft Diameter: Keyway P/N 117159
Distance from center shaft to center shaft using donated belt guard: 9.5”
P/N A33
Belt Life: 25,000 hours (714 testing cycles)
Cost of V-Drive
Driver:
Sheave: $10-20
Bushing: $10-20
Driven:
Sheave: $30-35
Bushing: $10-25
Belt: $10
Total: $70-110
Dial Gauge Selection
 Digital Dial Gauge can




connect to final display
More reliable and less
expensive than a laser
$150
½” range
0.0005” resolution
Maintaining Displacement
 Clamping force:
 Provided by 2 screws - ½’’-13
 M = torque on screws
 Screw vs. T-Block (u=.2)
 210 M ft-1 (see Appendix)
 Frictional force (prevents slipping):
 2 possible locations:
 Adjustment Base vs. Adjustment Slider (u=.8)
 Adjustment Base vs. T-Block (u=.2 to .8)
 Assume worst case, u=.2
 42 M ft-1
 Maximum force applied (causes slipping):
 1.68 ft-lbs. (motor) at 1/32’’
 645 lbs.
 Required screw torque:
 Safety factor of 2
 31 ft-lbs.
Control System
Encoder Selection: TRD-S100-VD
 Inexpensive incremental (quadrature)
encoder
 Capable of sending (depending on exact
model) 100-1024 pulses per revolution
 Speed of motor can be determined based on
number of pulses received and time elapsed
 Hardware allows for maximum of 6000 RPM
– well above 2000 RPM expected
Micro-Controller
 Firsthand objective: proof of concept
 TI Launchpad
 Comes pre-equipped with on-board emulation and simple
outputs for ease of testing & debugging
 Control procedure can be implemented using pseudo-inputs
and pseudo-outputs to prove feasibility of concept
 In final design encoder sends signal to controller, which is
interpreted and fed in through VFD for feedback
 After concept is proven a permanent microcontroller can be
selected to optimize system integration
Test Plan
 Test Displacement
 Tighten adjustment screws to proper torque
 Measure displacement with dial gauge during setup
 Validate 1/32” total displacement
 Test Vibration Cycles
 Measure RPM with encoder and display for feedback
 Validate 2000 cycles/min
 Test fittings
 Do they fit the frame?
 Test User Interface
 Check connections
 Ease of use
 Safety Evaluation
Risk Analysis
ID Risk
Effect
Cause
Severity Likelihood
Score
1 Displacement is not equal to 1/32in
Apparatus doesn't meet UL844
Poor design
3
2
6
1 Displacement is not equal to 1/32in
Apparatus doesn't meet UL844
Disp. changes during test
3
2
2 Vibration is not 2000 cycles per min
Apparatus doesn't meet UL844
Crankshaft slipping
3
2 Vibration is not 2000 cycles per min
Apparatus doesn't meet UL844
RPM changes during test
12 Frame falls apart
Test fails, costly to fix
12 Frame falls apart
Action Item
Owner
Due
Make it adjustable
Brett
DONE
6
Calculate torque required on bolts so
displacement won't slip.
Brett
DONE
2
6
Evaluate previous team's design
Nick
DONE
3
2
6
Design closed loop feedback and VFD
to adjust RPM
Ryan
DONE
Vibration is same as natural
frequency
3
2
6
Perform ANSYS Analysis, add supports
Nick
to change natural frequency
DONE
Test fails, costly to fix
Poor material selection
3
2
6
Perform ANSYS Stress Analysis
Nick
DONE
12 Frame falls apart
Test fails, costly to fix
Luminaire is too heavy
3
2
6
Perform ANSYS Stress Analysis
Nick
DONE
10 Can't mount all configurations types
Customer is not able to test some
configurations
Project scope
2
2
4
Use current fixtures
Claire
DONE
15 Project deadline is not met
Customer is dissatisfied, Students
receive poor course grade, RIT's
reputation is negatively impacted
Materials are delivered late
2
2
4
Order before Christmas
Nick
12/20/2013
18
Unable to integrate measurement devices Machine is just as difficult to setup
Lack of knowledge
with display
and monitor as before
2
2
4
Research integration requirements
and prepare LabView backup
Ryan
11/20/2013
19
Can't get items (Motor, VFD, etc.) from
Eaton in available time
3 Motor burns out
Need to purchase items instead,
increased cost of project
Lead time is too long
2
2
4
Request items by specified date from
CCH and ask for delivery date. Have
backup supplier prepared.
Ron
11/20/2013
Costly to replace, test fails
Motor burns out
3
1
3
Calculate required torque and RPM,
select appropriate motor
Ron
DONE
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
BoM & Costs
Item
Cost
Item
Cost
Materials for Frame
$700
Rust Protection
$200
Materials for Conduits / Flange / Collar
$250
Welder Fees
$200 (est.)
Digital Dial Gauge
$150
Electrician Fees
$0
Motor
$470
Shipping Costs (for testing)
$200 (est.)
VFD
$480
Upgraded displacement adjustment
$50
Encoder
$100
Polycarbonate Sheet ¼’’x36’’x24’’
$70
LCD Display
$100
Belt Guard
$0
Micro-controller & components
$100
Electrical Lockout
$40
Electrical Box
$200 (est.)
V-Drive
$90
Total
$3400
Next Phase
Questions for Cooper-Crouse Hinds
 Electrical wiring done by students and checked by CCH?
Questions?
Appendix
More Motor Information
V-Belt Life: 25,000 hours (714 testing cycles)
http://www.dodge-pt.com/products/pt_components/belts/belts.html
Safety Checklist
Item
Safety Item
1 Is lockout/tagout procedure posted?
2 Can all energy sources be locked out? (electrical, air, hydraulic, water, etc.)
3 Are all electrical devices labeled with voltage and power source?
4 Are all machine controls labeled?
5 Are all machine hazards adequate guarded to prevent bodily contact? (motion, heat, light, ejection, etc.)
6 Do machine interlocks/light curtains inhibit motion?
7 Are E-Stops located at all operator stations?
8 Are utilities routed to avoid trip hazards?
9 Have any potential waste materials been identified? Do they have a disposal procedure?
10 Is there adequate egress from area?
11 Is a fire extinguisher located within 75 ft?
12 Is there adequate access for all operations? (maintenance, setups, operation, etc.)
13 Is machine designed to minimize overhead and extended reaching, pulling, bending, and twisting?
14 Is all required training complete and documented? (LOTO, maintenance, setup, operation, etc.)
Yes No N/A Owner Due Date
Functional Decomposition
Full Risk Analysis
ID Risk
Effect
1 Displacement is not equal to 1/32in
Apparatus doesn't meet UL844
2 Vibration is not 2000 cycles per min
Apparatus doesn't meet UL844
3 Motor burns out
Costly to replace, test fails
4 Machine is too loud
Hearing conservation or
engineering intervention is
required
5 Machine operates when moving parts exposed
Operator injury could occur
6 Machine starts during maintenance
Operator injury could occur
7 Emergency stop doesn't work
Operator injury could occur
8 Pinch points exist
Operator injury could occur
9
Operator injury could occur
Apparatus is not ergonomically safe to setup
11 Oil spill on motor connection
Customer is not able to test some
configurations
Motor failure/smoke
12 Frame falls apart
Test fails, costly to fix
10 Can't mount all configurations types
13 Project runs over budget
14 Apparatus is larger than existing one
15 Project deadline is not met
16 Electrical shock from apparatus
17 RPM can't be measured accurately
18 Unable to integrate measurement devices with display
19 Can't get items (Motor, VFD, etc.) from Eaton in available time
Cause
Poor design
Disp. changes during test
Poor calibration
Crankshaft slipping
RPM changes during test
Belt slips
Motor inefficiencies
Belt is too loose
Frame misalignment
Motor burns out
Crankshaft improperly lubricated
Motor is too loud
Vibration of frame
Luminaire breaks and rattles
Operators don't wear earplugs
Fixed guard not in place
Machine not properly guarded
Energy source not isolated
Lockout not observed
Button is broken
Electrical failure
Existence of pinch point
Setup requires awkward positioning
Luminaire is too heavy
Score
6
6
2
6
6
4
3
2
2
3
3
2
2
2
2
3
3
3
3
3
3
6
4
2
Action Item
Make it adjustable
Calculate torque required on bolts so displacement won't slip.
Define calibration procedure and schedule
Evaluate previous team's design
Design closed loop feedback and VFD to adjust RPM
Use v-belt and belt guard (for oil drip)
Accept Risk
Design motor mount to be adjustable
Write procedure to verify conduit is 100% vertical
Calculate required torque and RPM, select appropriate motor
Define maintenance procedure and schedule
Add motor enclosure, sound damping, hearing protection
Add sound damping, add hearing protection
Accept Risk - test will be ended early
Accept Risk - exposure duration is still low
Place warning labels on apparatus
Install polycarbonate guard and belt guard
Install location to lockout machine
Accept Risk
Define maintenance schedule
Use certified electrician
Guard all pinch points
Design conduit to be assembled first, then attached all at once
Specify use of lift assist or 2nd operator, Design for use
Owner
Due
Brett
DONE
Brett
DONE
Jake
MSDII
Nick
DONE
Ryan
DONE
Ashley
DONE
--DONE
Ashley 11/20/2013
Claire 11/20/2013
Ron
DONE
Ron
MSDII
Brett
MSDII
Brett
MSDII
--DONE
--DONE
Brett
MSDII
Brett
MSDII
Brett
MSDII
--DONE
Ryan
MSDII
Ron
MSDII
Brett
DONE
Claire
DONE
Brett 11/20/2013
Project scope
2
2
4
Use current fixtures
Claire
DONE
Leakage
Vibration is same as natural frequency
Improper construction
Poor material selection
Luminaire is too heavy
1
3
3
3
3
2
2
2
2
2
2
6
6
6
6
Offset motor so oil can't drip on it
Perform ANSYS Analysis, add supports to change natural frequency
Use certified welder
Perform ANSYS Stress Analysis
Perform ANSYS Stress Analysis
Ashley
Nick
Nick
Nick
Nick
DONE
DONE
MSDII
DONE
DONE
2
2
4
Proper budgeting/compare prices/buy standard sizes
Nick
Ongoing
1
3
2
2
2
6
Accept Risk
Participate in milestone design reviews
--ALL
--Ongoing
2
2
4
Schedule machine time 1 week in advance with Tool Shop
Ashley
MSDII
2
3
3
2
2
1
4
6
3
Order before Christmas
Use certified electrician
Add damping
Nick
Ron
Jake
12/20/2013
MSDII
MSDII
2
2
4
Research integration requirements and prepare LabView backup
Ryan
11/20/2013
2
2
4
Request items by specified date from CCH and ask for delivery date. Have
backup supplier prepared.
Ron
11/20/2013
Customer is dissatisfied,
engineering requirements must be Unforeseeable expenses
sacrificed
Customer is dissatisfied
New holes must be drilled in concrete floor
Correction of mistakes
Customer is dissatisfied, Students
receive poor course grade, RIT's
Delay in Tool Shop
reputation is negatively impacted
Materials are delivered late
Operator injury could occur
Improper wiring
Apparatus doesn't meet UL844
Tachometer vibrates too much
Machine is just as difficult to setup
Lack of knowledge
and monitor as before
Need to purchase items instead,
increased cost of project
Severity Likelihood
3
2
3
2
2
1
3
2
3
2
2
2
3
1
1
2
2
1
3
1
3
1
2
1
2
1
2
1
1
2
3
1
3
1
3
2
3
1
3
1
3
1
2
3
2
2
2
1
Lead time is too long
Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe
Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely
Architecture
Safety features
Luminaire
connection
Crankshaft
connection
Central System
Motor system
Display/user
interface
Sensors
Power supply
Conduit Pipe Size Considerations
Flange
Collar –
crankshaft
connection
Collar – set
screws
• Concept: each conduit size will
have its own:
• Flange
• Collar
• This concept allows for easier
usage by operator
• Plan:
• Provide the 1st and possibly
the 2nd most used size
conduit
• Provide the drawings/files
necessary for the fabrication
of the remaining conduits
Conduit Verticality
 Attempt to keep the conduit as vertical as possible
 Based on conversations with an operator – verticality is not
very critical
 Very basic method:
 Place a vertical level in the same place every time and using the
adjustable crankshaft to make minor adjustments
Safety Features
 Fixed polycarbonate guards on drive system
 Clear, light-weight
 Excellent impact strength, ¼’’ thick
 “Split” type belt guard
 Left and right half for easy removal
 Lock-out on electrical box for maintenance
 http://www.eriecustomproducts.com/beltguards/
Adjustment Mechanism
Setup Improvements
 Additional holes in connecting plate
 Access to adjustment bolts
 U-bolt to lock system in place during adjustment
 Finer set screw
 3x finer than current
 8-32: ¼’’ turn ~ 1/128’’ displacement
New Connecting Plate
UL844 Vibration Test Standard
Maintaining
Displacement
Calculations
Maintaining
Displacement
Calculations
Maintaining
Displacement
Calculations
Design characteristics for VFD
 HP : VFD must be rated for the appropriate HP.
 Full Load Amps : Motors Full Load Amps must not exceed
VFD’s continuous amp load.
 Voltage : number of phases and voltage must be matched as
well with the VFD.
 Load Type: Constant vs. variable Torque during operation.
 Programmability: programmable parameters of a VFD