P15661 Reciprocating Friction Tester Base Subsystem 1 P R E L I M I N A R Y D E T A I L E D D E S I G N R E V I E W 11/20/2014
Team Roles 2 Team Member Major Subsystem Role Alexandra Woodward Industrial Engineering Project Manager Sean Cummings Mechanical Engineering Mechanical Components Subsystem: Specimen Holder Ethan Hanson Mechanical Engineering Mechanical Components Subsystem: Linear Guide Tyler Nigolian Electrical Engineering Electrical Components Subsystem: Voice Coil Matt Lebowitz Electrical Engineering Electrical Components Subsystem: Encoder Project Guide: Gary Werth Customer: Dr. Iglesias Victoria
Engineering Requirements 3 Link to Test Plans on Edge
Heating the specimen Meeting with Dr. Iglesias on 10/30 Went over feasibility of adding heating of the specimen to 200 C Decided to go on the assumption that Heat will be implemented as a future MSD project. 4
Subsystems 5 Sub-System Voice Coil Specimen Holder Linear Guide Encoder Power Supply Interface with Armature Team Part number P15661-01-xxx P15661-02-xxx P15661-03-xxx P15661-04-xxx P15661-05-xxx P15661-06-xxx
Bill of Materials 6
System Layout 7
Specimen Holder Engineering Requirements 8 ID Eng. Reqt Units Value Risk L S I Risk Abatement SH1 Weight Kg 0.5 High Weight increases cost of voice coil 1 3 3 Model weight in Creo (.155 Kg w/o specimen) SH Mass Test Plan SH2 Cost $ TBD Over budget 1 1 1 See BOM SH3 Specimen diameter mm 20-50 should accept a range of diameters without extensive changes 1 3 3 See design in Creo SH Specimen Diameter Test Plan SH4 Specimen thickness mm 5-25 should accept a range of thicknesses without extensive changes 1 3 3 See design in Creo SH Specimen Thickness Test Plan SH5 Base is easy to clean s 45s Takes longer to clean than desired amount of time 3 3 9 Base Cleanability Test Plan SH6 Frequency Hz 1-10 holder should not overload the voice coil max force under all frequency ranges 1 3 3 used weight from Creo model to calculate force at 10Hz and is under the continuous force for the chosen VC
Specimen Holder Pin Fatigue Used Soderberg s Method Pin is Al-6061 σ e =.4(Ultimate Strength) = 423 Mpa σ m = Assume 1000N force = 126 Mpa S y = Yield Strength = 386 Mpa Solved for σ a = 163 Mpa F=129 N, we will only see a max of 16N (assume dia. 1/8 ) 9
Specimen Holder Design 10 Weight not including fasteners and specimen=.334kg
Test Plan Examples Test Plan: SH2, LG3 (Testing load range) Use weights to test if the Specimen Holder and Guide can withstand the normal forces they will experience Use a force gauge to measure the force required to move the guide block Test Plan S11 (Base is easy to clean) 11 Time multiple people how long it takes to remove the specimen and disconnect the specimen holder from the guide block Link to all Test Plans in EDGE
Specimen Strength Test 12 This test shows that the weaker material that was given will withstand load higher than our specimen holder design can reproduce
Linear Guide Engineering Requirements 13 ID Eng Reqt. Units Value Risk L S I Risk Abatement LG1 Stroke [mm] 10 Cannot meet project requirement LG2 LG3 Load Capacity Friction Coefficient [N] >25 Exceeded load capacity results in unexpected resistance to motion Friction causes resistance to motion 1 9 9 Guide purchased with a larger range of travel than what is required 1 9 9 Guide purchased with larger load capacity that what is required. 1 9 9 For load ranges that are less than specified load capacity, friction in negligible. LG4 Cost $ <100 Project is over budget 1 9 9 See BOM
Anaheim Automation Linear Guide Design CPC-MR15MLSSV0N-100-10-10 $64 6-7 week lead time 14 Slider Block Rail Dimensions Height [mm] Load Capacity Width [mm] Length [mm] Attachment screws Screw Pattern [mm] Weight [kg] Width [mm] Length [mm] 16 32 60 M3 x 5.5 25 x 25 0.090718474 15 100
Linear Guide System 15
Linear Guide with attached Specimen Holder 16
Voice Coil Engineering Requirements 17 ID Eng. Reqt Units Value Risk L S I Risk Abatement VC1 Provides enough force N 28 + 1N Cannot meet force requirements, subsystem fails 1 9 9 Ensure specs meet required conditions, test once acquired VC2 Cost $ 500 Cannot afford voice coil 9 1 9 see BOM VC3 Power Requirement W 33 +1 W Cannot provide correct power, subsystem fails 1 3 3 Ensure specs have required power, ensure power supply has enough to support as well as a limit so more than the max VC4 Reliability Hours 24 Subsystem fails and voice coil permanently damaged 3 9 27 Voice Coil Endurance Test VC5 Heat C 23 + 3 C Voice coil overheats causing subsystem failure and possibly failure of other subsystems 1 9 9 Heat analysis then determine cooling solution VC6 EM Field Gauss 300 + 10 Gauss Other subsystems fail 1 3 3 EM Test
Voice Coil Operation 18 Direct Drive Permanent magnet field and coil winding to produce force Force=kBLIN k= constant B=flux density I=current N=number of conductors L=length of conductors
Voice Coil Selection 19 Component Weight Specimen Holder.334 Voice Coil Cost [$] Max Weight of Moving Parts [kg] Remaining weight (screws, interface, etc.) 385.38.046 400.4813.1473 420 1.4185 1.0845 455 1.4894 1.1554
Voice Coil Data 20 MOTICONT LVCM-051-051-01
Voice Coil Design 21 Linear voice coil actuator with no shaft There are two female 10-32 thread holes on each end of the voice coil for interfaced The voice coil will need to be assembled on a heat sinking material
Voice Coil Testing 22 Testing to be done on voice coil Reliability S2, S7, S8 (Strength, Stroke, Heat) Duration S3 Electromagnetic Field Generated VC 6
Closed loop operation Voice Coil Control reduce errors by automatically adjusting the systems input improve stability of an unstable system increase or reduce the systems sensitivity enhance robustness against external disturbances to the process produce a reliable, repeatable performance 23
System with Voice Coil 24
Controller Requirements 25 ID Eng. Reqt Units Value Risk L S I Risk Abatement 1 LabVIEW n/a n/a Cannot communicate with PC 1 9 9 2 Motor Compatibility V 12 + 5V Cannot effectively control voice coil 3 3 9 3 Encoder n/a n/a Cannot provide positioning 3 9 27 4 Homing n/a n/a Cannot return to test start/end 3 1 3 Controller comes with LabVIEW VI Best performance is with motor rated at about ½ of supply voltage An encoder of 400-1000 lines/channel, giving 1600-4000 quadrature encoder counts per revolution is recommended Homes to an Opto or Encoder Index with a single command
All-Motion EZSV17SK Kit Controller Selection Motor Driver Board RS485 USB Converter EZ Bus Cable OptoSensor and Push Button 26
Controller Operation 27
Wiring Diagram 28
G-option mounting ears H-option cover Encoder Mounting 29 Must be centered on self-supporting shaft
Encoder Design 30
Encoder Operation 31 Sensor does not emit or receive interference, optical sensing Direction is given by which signal (A/B) leads (Quadrature signal) Pulse frequency corresponds to speed Pulse count corresponds to distance
Encoder Resolution 12.7mm diameter contact wheel = 39.9mm circumference To achieve stroke accuracy of 0.5mm, CPR > 80 1000CPR gives the system accuracy of 0.039mm, more precision at minimal extra cost. 32 =39.9mm d=12.7mm
Connecting Friction Signal to DAQ 33 SCXI-1001 Chassis SCXI-1520 (Strain module) SCXI-1314 (Strain Front Panel) SCXI-1180 (Signal Feedthrough) SCXI-1302 (Terminal Panel) NI-DAQmx Software Set with strain gauge parameters Connection diagrams to verify
System with Encoder 34
Power Supply Requirements 35 ID Eng. Reqt Units Value Risk L S I Risk Abatement 1 Input Voltage V 120 + 5V Does not sufficiently convert power from AC to DC 1 9 9 Converter is within specification, will test for endurance 2 Output Voltage V 3 Max Current A 30 + 10V 2.5 + 1A Does not power voice coil, encoder, or additional sensors correctly Incorrect current is drawn causing issue or failure of voice coil 1 9 9 1 3 3 Converter is within specification, will test for endurance Converter is within specification, will test for endurance 4 Power W 33 (minimum) Subsystem fails and voice coil permanently damaged 1 3 3 Converter is within specification, will test for endurance 5 Housed n/a n/a Unsafe and poor heat dissipation 1 3 3 Converter is housed and can be cooled properly by convection alone, will test for ambient heat effects
TDK-Lamda LS50-24 Power Supply Selection 36
Power Supply Testing Input/Output Parameters PS 1, PS 2, PS 3, PS 4 Heat PS 5 37
LabVIEW Program 38
LabVIEW Strain Parameters 39 Strain Range Gage Factor Gage Resistance Initial Voltage -0.001<m<0.001 R/R L/L 350Ω Vex 0-10v Strain Configuration Lead Resistance = Acquired from rotating friction tester 0V Typically, Offset to calibrate for lead resistance and nonzero bridge voltage. Quarter Bridge for single strain gauge application Measured with multimeter during assembly
AllMotion EZServo Syntax 40 Example Command Function Z2000 A125 P62 D62 V4135 Set speed to 4135 33 gp62d62g0 T Travel 2000 ticks or until limit switch is interrupted, then set location as home/zero location Move to absolute position 5mm from home Move positive direction by 2.5mm Move negative direction by 2.5mm encoder ticks/second -> 5mm/sec -> F=1hz for above Repeat move positive 2.5mm move negative 2.5mm until interrupted Terminate Program
Risk Mitigation 41
Action Items (rest of MSDI) Complete Process Sheets Fill out and submit purchase orders for all parts* Create more detailed version of MSDII Project Plan (assign resources to tasks) 42
MSDII Preliminary Project Plan 43
MSDII Testing 44
Learnings/Challenges One design change affects the whole system Voice coil changed the voice coil block We can finally see the iterative process Sharing of CAD models between teams (updates) 45
Course Feedback 46 Let us know before had if there will be a meeting on Tuesday (Even if it is only 1 hour before the meeting) If we were given a project plan from past MSD groups