8 february 2013p135051 xerox bearing tester detailed design review [1]
TRANSCRIPT
8 February 2013 P13505 2
Project Team and StakeholdersCustomer
Erwin Ruiz Technical Specialist Project ManagerXerox Corporation
GuideWilliam Nowak Principle Engineer
Xerox Corporation
Faculty ConsultantJason Kolodziej RIT ME Faculty
Project TeamStephen Rugg Project ManagerWill Craig Co-lead EngineerAndrew Shuman Co-lead EngineerKevin Albino Team Facilitator/Project EngineerLauren Kaczor Project EngineerTyler Hill Project Engineer
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Meeting Agenda - Project Background 1:05-1:10- Updated Customer Needs & Specs (Lauren) 1:10-1:20
- Test Plan (Tyler)- MSA Plan (Tyler)
- System Assembly 1:20-2:10- Overall Design (Kevin)- Motor Design (Andrew)- Motor Torque Requirements (Will)- Mandrel (Andrew)- Alignment System (Lauren)- Clamp (Andrew)- Frequency Analysis of Rails (Steve)
- Data Acquisition 2:10-2:30- Accelerometer Mounting (Steve)- Signal Conditioner (Steve)- DAQ (Will)- LabVIEW (Will)
- Budget/BOM (Tyler) 2:30-2:40- Risk Assessment (Lauren) 2:40-2:45- Questions
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Project Background• There are 2 Bearings in the iGen Printer System supporting
the fuser roller• Every 200,000 prints the printers come in for remanufacturing• Bearing is reused a maximum of 5 times• Currently, there is no quantitative test to qualify bearings
– Current test is to hold the bearing up to your ear and see if you hear or feel anything
– Potentially leads to many good bearings being scrapped
• Customer wishes to test performance of other bearing manufacturers against current product
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Test Plans• SP1: Time To Train User
Ideal Value < 1 hourPlan: Gather a group of 10-15 people and teach them individually how to use the system. Document how long it takes each person to gain competence with the system. Ideally, the group will contain a broad range of knowledge bases with regards to vibration and mechanical systems. This will help to get a better estimation on the time it would take to train someone with no engineering background.
The individuals who were trained will be asked about areas that were unclear or difficult to understand. From their feedback, efforts will be made to streamline the process. This will occur whether or not the specification is met.
• SP8: Use Xerox’s Machine to Get a Pass Fail Readings on Test BearingsIdeal Value: Pass/FailPlan: Xerox’s Acoustic machine will be setup and run according to the manual specifications. Pass or fail values will be collected for all of the test bearings. Four tests will be conducted on each bearing to make sure the result is repeatable since the machine has failed an MSA.The purpose of collecting these readings will be to compare them against the results from the vibration test stand that is being developed.
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Test Plans• SP9: Measurement System Analysis on Vibration Machine
Ideal Value: PassPlan: A measurement system analysis (MSA) will be conducted on the vibration machine. If the vibration machine fails the MSA, efforts will be made to identify areas where there are inconsistencies. These inconsistencies will be fixed and the MSA will be conducted again. This process will iterate until the vibration machine passes the MSA or until we run out of time.
• SP10: Assess Health of Bearing
Ideal Value: Pass/FailPlan: The results of the vibration collection will be dependent upon the pass and fail criteria that is developed using the test bearings. Vibration measurements will be conducted on each of these bearings and they will be correlated to the tests that were already conducted by Arnprior. The developed pass and fail criteria will then be input into the LabView interface and a pass or fail reading will be output at the end of each test.
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MSA Plan• 16 Samples, 6 Operators, 3 Replicates
– Typically 10 Samples, 3 Operators and 2 Replicates is used– As we do not have historical data to compare to, more samples would be better if
we could obtain more bearings in various states of wear– More operators will result in an improved precision for the reproducibility
estimate[2]
• Every operator will test each of the 16 samples, 3 times• The order of the tests will be done based off of a randomly generated
schedule• Minitab or another statistical package will be used to analyze the data
using the ANOVA method• The output value, pass/fail or some number, will be determined based
upon the failure criteria which is still to be determined
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Motor Mount•Motor will be mounted on a large aluminum block•The aluminum block will rest on a rubber gasket•This is done in an effort to attenuate any vibration
Motor
Face Mounting Plates
Motor Clamps
Aluminum Block
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Motor Clamps• These will wrap around the
motor so that it is not cantilevered
• The top bolt can be used to further tight the clamp once it has been bolted down
• Trying to make the structure as rigid as possible
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Motor Torque Requirements• Tested the required motor torque for our bearings• Preliminary drop test predicted 37 in*lb at 1800 rpm based
on Newton’s Viscosity law – extrapolated from 43 rpm• New test with motor at 2000 rpm showed required torque
of 2.7 in*lb for high resistance bearing
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Motor Test Results
0 500 1000 1500 20000
0.5
1
1.5
2
2.5
3
Torque Required To Rotate Test Bearings
High Resistance BearingLow Resistance Bearing
Angular Velocity (RPM)
Req
uire
d To
rque
(in*
lbs)
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Xerox Acoustic Machine• Xerox machine has a slip fit mandrel• Found that the bearing slipped on the mandrel
when the motor rotated• Show video
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Clamp Alignment System
Brake (2)Bearing Clamp
80/20 Rails (4)
Carriage (2)
Rail Adapter (2)
BearingAccelerometer (2)
L-Bracket (8)
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T-adapters• Aluminum
– Easy to machine– Higher damping coefficient than
steel• Transfers holes from horizontal
to vertical position• Connects lower half clamp to
the carriage
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Outer Race Bearing Clamp• Will be made out of
steel to improve vibration transmission
• Because of tight tolerances the Brinkman Lab is going to manufacture it
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ANSYS Clamp Analysis
• ANSYS analysis shows a very small deflection: 0.0002 in
• This proves that displacement control is not a feasible option and a force control method should be implemented.
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80/20 Natural Frequency Calculations
4 5 6 7 8 9 10 11 12500
1000
1500
2000
2500
3000
3500
4000
4500
5000
Length of Beam (in)
Nat
ural
Fre
quen
cy (
Hz)
Natural Frequency v. Length (Mass of Center)
Assumptions:•Applied mass is larger than the beam mass•Applied mass is located at 0.80*L•Both ends are clamped•Constant loading can be simulated as additional mass
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80/20 Natural Frequency Calculations
4 5 6 7 8 9 10 11 120.2
0.4
0.6
0.8
1
1.2
1.4
1.6
1.8
2
2.2x 10
4
Length of Beam (in)
Nat
ural
Fre
quen
cy (
Hz)
Natural Frequency v. Length (No Mass)
First Mode
For the first mode: Β1l=4.7300
ρ=mass per unit lengthA=cross-sectional areaL=beam lengthE=Elastic modulusI=Moment of Inertia
•No mass applied other than the beam mass•This is the highest natural frequency that could be reached without stiffening the beam
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Accelerometer Mounting• 100 mV/g • ICP Accelerometer• Frequency Range:
0.5-10,000 Hz• Attach with wax or glue• If needed the
accelerometer could be stud mounted [3]
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Accelerometer Mounting - Feasibility• Outer support accelerometer mounting has been successfully
applied in industry and other test stands
[4] [5]
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SKF Condition Monitoring• Accelerometer Signal
Conditioner• Power ICP Circuit
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LabView 6210 DAQ• 16 analog inputs• 250kS/s• 4 voltage ranges• Maximum voltage range
accuracy: 2.69 mV• Minimum voltage range
accuracy: 0.088 mV[7]
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LabView Feasibility TestCurrent LabVIEW code has been tested in the systems lab
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Budget• Overall Budget - $1500-$3000• Original Total $3171.96• Savings from:
– Custom Signal Conditioner $327.10– Provided Motor and Controller $611.80
• Final Cost Breakdown– Data Collection $1467.90– Physical Structure $445.16– Manufacturing Costs $200.00– Shipping $120.00– Total $2233.06
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References1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/
B0071ARFWS2. http://www.minitab.com/support/documentation/Answers/Assistant
%20White%20Papers/GageRR_MtbAsstMenuWhitePaper.pdf3. http://www.pcb.com/products.aspx?m=352C334. Machinery Messages Research Test Results Part 1: Performance of REBAM
during ball bearing failure5. The application of spectral kurtosis on Acoustic Emission and vibrations
from a defective bearing By: B. Eftekharnejad n, M.R. Carrasco, B. Charnley, D. Mba
6. http://www.anaheimautomation.com/3D/pdf/brushless/BLK32%20Series.PDF
7. http://sine.ni.com/nips/cds/view/p/lang/en/nid/203223