Bishop Steering Technology IIBishop Steering Technology II

Precision MeasurementPrecision MeasurementDeviceDevice

Hong ZhuHong ZhuKyle PowellKyle Powell

David K. SpaethDavid K. SpaethPatrick RichardsonPatrick Richardson

Reason for the DesignReason for the Design

Present measurement techniques are not Present measurement techniques are not accurate enough accurate enough Ensure consistent measurements between Ensure consistent measurements between the various tiers involved in the industrythe various tiers involved in the industryImproper measurement can result in a part Improper measurement can result in a part being accepted that will fail when the being accepted that will fail when the whole steering system is testedwhole steering system is testedProperly measured parts facilitate Properly measured parts facilitate cooperation between supplierscooperation between suppliersFewer returned parts will reduce costsFewer returned parts will reduce costs

Main RequirementsMain Requirements

Client needs two measurement systems to Client needs two measurement systems to measure components of a rack and pinion measure components of a rack and pinion steering system steering system

Measurements must not have a difference Measurements must not have a difference greater than +/- 3microns from true valuegreater than +/- 3microns from true value

Device must not be overly complicatedDevice must not be overly complicated

How Small is Three Microns?How Small is Three Microns?

The average skin cell is four microns in diameterThe average skin cell is four microns in diameter

The average human hair is 70 microns in The average human hair is 70 microns in diameterdiameter

Input ShaftInput Shaft

Input SleeveInput Sleeve

How the Parts InterfaceHow the Parts Interface

How steering system worksHow steering system works

Problems with poorly Problems with poorly measured shafts and sleevesmeasured shafts and sleevesIf the shaft and sleeve are not accurately If the shaft and sleeve are not accurately machined, the flow of hydraulic fluid machined, the flow of hydraulic fluid through them will not be eventhrough them will not be even

The car may turn even though the steering The car may turn even though the steering wheel is in the neutral (center) positionwheel is in the neutral (center) position

The car may be more difficult to turn in The car may be more difficult to turn in one direction than the otherone direction than the other

Increased costs due to repairs and bad Increased costs due to repairs and bad partsparts

Process ControlProcess Control

The measuring process must be The measuring process must be consistent consistent Because of the high accuracy required, Because of the high accuracy required, the test facility must be in a pristine, the test facility must be in a pristine, laboratory-like environmentlaboratory-like environmentThe environment must be controlled and The environment must be controlled and free of dust and other fugitive material that free of dust and other fugitive material that could be detrimental to the measuring could be detrimental to the measuring processprocess

Thermal ControlThermal Control

Any variation in temperature cause the Any variation in temperature cause the size of a shaft or sleeve to change by size of a shaft or sleeve to change by more than three micronsmore than three microns

Transfer of human body heat to the shafts Transfer of human body heat to the shafts and sleeves must be minimizedand sleeves must be minimized

The ambient room temperature must be The ambient room temperature must be kept constantkept constant

SensorsSensors

It is necessary to record both linear and It is necessary to record both linear and angular displacementsangular displacements

The challenge was to find a way to record The challenge was to find a way to record both displacements at the same timeboth displacements at the same time

Linear Distance SensorLinear Distance Sensor

For the shaft measurement we propose For the shaft measurement we propose the use of a Keyence LK-011 laserthe use of a Keyence LK-011 laser

Linear Distance SensorLinear Distance Sensor

For the sleeve we propose the Philtec Fiber For the sleeve we propose the Philtec Fiber Optic linear displacement sensorOptic linear displacement sensor

Angular Displacement SensorAngular Displacement Sensor

The angular encoder can measure the angular The angular encoder can measure the angular rotation of a shaft to within 0.00005° accuracyrotation of a shaft to within 0.00005° accuracy

Sensor MountingSensor Mounting

Sensors are very sensitive, and must be Sensors are very sensitive, and must be stationary stationary

So, the shafts and sleeves must be rotated So, the shafts and sleeves must be rotated

so all the notches can be measured by the so all the notches can be measured by the sensorssensors

Why not design one device that holds both Why not design one device that holds both sensors stationary and measure both shafts sensors stationary and measure both shafts and sleeves?and sleeves?

Device StandDevice Stand

Positioning and AlignmentPositioning and Alignment

Measurement = Position +AlignmentMeasurement = Position +Alignment

By definition, linear and angular By definition, linear and angular measurements require exact positioning measurements require exact positioning and alignmentand alignment

Precision measurement requires precision Precision measurement requires precision equipmentequipment

X-Y TablesX-Y Tables

Micrometer driven tables allow for accurate Micrometer driven tables allow for accurate positioningpositioning

Movable on one or two axesMovable on one or two axes

Bellows Type Flexible CouplingsBellows Type Flexible Couplings

Rotation of shaft or sleeve must be the same as Rotation of shaft or sleeve must be the same as rotation of encoderrotation of encoderUnique design ensures that rotation is the same Unique design ensures that rotation is the same at top and bottom of coupling and that shafts are at top and bottom of coupling and that shafts are alignedaligned

BearingBearing

Browning Spherical Roller BearingBrowning Spherical Roller Bearing

Low radial runoutLow radial runout of 1.5 micronsof 1.5 microns

Use of a Stock Motor and Gear Use of a Stock Motor and Gear ReducerReducer

Small motors capable Small motors capable of turning the shafts of turning the shafts and sleeves at and sleeves at constant speed are constant speed are common and common and available for purchaseavailable for purchase

We will use a Parker We will use a Parker Automation stepper Automation stepper motor and a Daedel motor and a Daedel gear reducergear reducer

Data Acquisition and AnalysisData Acquisition and Analysis

Both the Keyence laser and Philtec fiber optic Both the Keyence laser and Philtec fiber optic sensor are sold with electronics that acquire and sensor are sold with electronics that acquire and process the data process the data Output is usually digital, but analog output devices Output is usually digital, but analog output devices with graphical displays are availablewith graphical displays are available

Patents and TrademarksPatents and Trademarks

We have found no exact matches for the We have found no exact matches for the proposed designs proposed designs

There are patented designs for similar There are patented designs for similar components, but no design that components, but no design that incorporates them into a single systemincorporates them into a single system

The Laser Micro100 by BLUM is the The Laser Micro100 by BLUM is the closest in theory to what we are attemptingclosest in theory to what we are attempting

Design ModelingDesign Modeling

This project called for research and This project called for research and design, but not the building of a prototypedesign, but not the building of a prototype

Pro-Engineer is a powerful software Pro-Engineer is a powerful software program that allows us to model the program that allows us to model the designdesign

The components in our design are only The components in our design are only representations of the actual parts representations of the actual parts

Gauge Plate InterfaceGauge Plate Interface

Sleeve MeasurementSleeve Measurement

Shaft MeasurementShaft Measurement

Shaft Rear ViewShaft Rear View

ConclusionConclusion

We met the engineering requirements forWe met the engineering requirements for

accuracy and surpassed our task of accuracy and surpassed our task of

designing a machine that could measure designing a machine that could measure

either the shaft or the sleeve…either the shaft or the sleeve…

OUR DESIGN MEASURES BOTH!OUR DESIGN MEASURES BOTH!

The technology to produce thisThe technology to produce this

measurement machine is available now measurement machine is available now

RecommendationsRecommendations

We suggest that a prototype of this design We suggest that a prototype of this design

be made and tested.be made and tested.

Possible alternatives to our method of Possible alternatives to our method of adjusting the gauge plate be investigated.adjusting the gauge plate be investigated.

ConsultantsConsultants

Dr. Jie Chen - IUPUIDr. Jie Chen - IUPUI

Jason Wou – Bishop SteeringJason Wou – Bishop Steering

Daniel Crafton – Bishop SteeringDaniel Crafton – Bishop Steering

Andy Hartsock – Parker AutomationAndy Hartsock – Parker Automation

Dr. A.K. Naghdi – IUPUIDr. A.K. Naghdi – IUPUI

Sales Support – Heidenhain Sales Support – Heidenhain

Dr. Vermuri – IUPUI, Physics DepartmentDr. Vermuri – IUPUI, Physics Department

ReferencesReferences

The Mechanical Design ProcessThe Mechanical Design Process By David G. Ullman By David G. Ullman

MCG, 2002MCG, 2002

Introduction to Laser TechnologyIntroduction to Laser Technology By Hitz, C. Breck, Hitz, Breck, Ewing, J. J.,Hecht, Jeff By Hitz, C. Breck, Hitz, Breck, Ewing, J. J.,Hecht, Jeff

John Wiley & Sons Inc, 2001John Wiley & Sons Inc, 2001

An Introduction to Fiber OpticsAn Introduction to Fiber OpticsBy R. Allen Shotwell, E. StewartBy R. Allen Shotwell, E. Stewart

Prentice Hall, 1996  Prentice Hall, 1996 

Electronic ReferencesElectronic Referenceswww.keyence.comwww.keyence.comwww.howstuffworks.comwww.howstuffworks.comwww.philtec.comwww.philtec.comwww.newport.com/www.newport.com/www.isotech.netwww.isotech.netwww.scantron-net.co.uk/applications.htm#fibreswww.scantron-net.co.uk/applications.htm#fibreswww.eng.warwick.ac.uk/~espbc/index.htmwww.eng.warwick.ac.uk/~espbc/index.htmwww.microphotonics.com/www.microphotonics.com/www.beemerprecision.com/info.html www.beemerprecision.com/info.html www.hephaist.co.jp/e/index.htmlwww.hephaist.co.jp/e/index.htmlwww.eminebea.com/usa/www.eminebea.com/usa/www.hansen-motor.com/www.hansen-motor.com/www.mstores.umich.edu/www.mstores.umich.edu/