Critical Design Review: Integrated

DesignsTeam 14:

Team Lead: John Leung,Solution Analyst: Edgar Lozano,Safety Officer: Bernie GabrielChief Financial Officer: Nicholas BalabanCad Designer: Josh McHugh

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Mission Statement

Integrated Designs aims to create a functional and viable solution to Cal Weld’s Position welder by incorporating a system to engage and disengage the turntable. Our project plans to assist the welders for a more comfortable and efficient way of working to provide their consumers with quality products.

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Table of Contents

I. Project Background

II.Project Plan

III.Prototype Design Concept

IV.Design Analysis

V.Project Schedule

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I.Project Background

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About Universal Calweld

●Been around for over 35 years located in Fremont, California

●Designs high purity components, subsystems, and components

●Provide manufacturing and engineering service to a variety of industries

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Project Background

Sponsor: Greg RozemaFaculty Advisor: Ala QattawiDesign Challenge:● Skilled workers from Cal

Weld need precision equipment (Turntables) to weld components

● High Precision and purity welds used for semiconductors and production 6

http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf

Project Background

Cobra Digital Turntable Framework

http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf 7

Constraints/Requirements

http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf

● Cannot redesign the entire system because of the cost

● Integrated clutch must fit within the given housing assembly

● Design has to be cost effective

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Design Constraints/Requirements

● Given width for worm gear housing: 56.3mm

● Given length for worm gear housing: 34.5mm

● Given depth for worm gear housing: 50mm

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Objective

● Current Turntable lacks a mechanism or clutch that disengages the turntable.

● Our design must not interfere with the welding process and maintain free mobility

● Must also satisfy all constraints

"The Engineering Design Process." The Engineering Design Process. N.p., n.d. Web. 20 Feb. 2016. <http://www.sciencebuddies.org/engineering-design-process/engineering-design-process-steps.shtm 10

II: Project Plan

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Why solution one wasn’t chosen

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● Difficult to maintain overtime

● Isn’t user friendly because of constant movement of the motor

● Orientation of worm makes solution not possible

Why solution two was chosen

"LEGO Technic Transmission Driving Ring and Clutch Gear." YouTube. YouTube, n.d. Web. 20 Feb. 2016. <https://www.youtube.com/watch?v=mMsUIhGick0>.

● User friendly by using lever rod to shift gear

● Practical way to disengage the motor

● Minimal and simple maintenance

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Solution- Implementation

Dog Clutch will be implemented above the worm gear

Sharing the same shaft

The shifter fork assembly will be on a shaft parallel to the dog clutch shaft.

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Solution- Clutch

Picture of how the dog-clutch will look like● Dog Clutch will have set of

teeth to lock with worm gear.

● Dog clutch will be connected to the turntable shaft through splines

● C-clip will be used to keep gear in place

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Solution- Lever

Engaging and Disengaging Dog Clutch:

Fork shifter is fixed to an external shaft

Locks in place using a detent ball and spring mechanism

Fork shifter -> Dog ClutchActuates the dog clutch to engage

the worm gear driven by the motor

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III: Prototype Design Concept

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Prototype Design

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Prototype Design

Dog Clutch Disengaged with lever

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Dog Clutch Engaged with lever

IV: Design Analysis

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Calculations● Based on our

measurements at CalWeld

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Calculations

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Lead of worm: 5.3mmLead angle (γ): 3.86 °Circular Pitch of Worm- 5.3mmPitch Diameter of Worm - 25mmPitch Diameter of Worm Gear- 45mmSliding Velocity (Vs): 51.64 ft/minPressure angle (ϕ)- 14.5°Tangential speed of worm gear (VG): 4.642 ft/minTangential force on worm gear (WG

t ): 11468.45 lbf

WGt with nd of 1.2: 13762.14 lbf

Reliability assumed by AGMA equation: 12hrs/day, 5days/week ---- 8 yearsTorque at worm gear (TG): 31.90 lbs*inHorsepower of the Motor: 0.8 HpDiametral pitch for worm gear (Pt ): 0.4444 teeth/mm

● Using our measurements taken, we were able to understand the dynamic system we are interacting with.

● With our new gear design, we aim to replicate these parameters with the creation of a new gear or by modifying the old one

Fork Shift Calculations

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Fork Shift CalculationsDeflection with nd = 1

● xsl = -0.000025319

Deflection with nd = 1.2

● xsl = -0.000030383

Deflection with nd = 1.5

● xsl = -0.000037979

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Selected dimensions for width, thickness and length satisfy both our space and reliability constraints.

Detent Ball-Spring Lock Calculations

S= Side Force Required to push the ball out of it’s groove.

F=Force of the spring onto the detent ball

R= Reaction Force from the groove onto the ball.

A= Countersink angle

25https://www.carrlane.com/catalog/index.cfm/29425071F0B221118070C1C513906103E0B05543B0B012009083C3B285356444A2D020609090C0015312A36515F57425B

We plan to use:

3/16” detent ball

Spring rate=20.3lb/inmax compressed length = 0.5in

initial length of 15/16”

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Detent Ball-Spring Lock Calculations

Simulation

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Pressure on Fork Shift: 10 N/m2

Simulation Analysis

The deflection of the fork Negligible

Area of the fork shift near the shaftArea will experience the most stress and wear on the fork

Maintenance discretion:

Replace fork shift

Machine the cracks

Tolerance of fork is 0.0015”28

Prototype Equipment List

●Dog Clutch

●New Worm Gear

●Fork Shift

●Shaft for Fork

●Plate for Lever Assembly

●Detent ball/Spring

●C-clips

●Machined Splines

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Cost Analysis

●6061 Aluminum Plate Stock. 1”x6”x6” $69.40

●304 Stainless Steel Plate Stock. ⅜”x6”x6” $59.90

●302 Stainless Steel Precision Ball. 3/16” Diam. $9.66 (pack of 100)

●Compression Spring. 20.3 lb/in.$16.22

●316 Stainless Steel Rod. ⅜” Diam. 1’ L $3.41

●Retaining Ring. Bore Diam 20mm$5.26

●Worm Gear (estimation)$1950.00

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Economy to Scale

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V: Project Schedule

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Project Block DiagramCompleted

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In-Progress ScheduledCAD Drawing

Stress Analysis

Calculations

Purchasing:(Lever Assembly)

Purchasing:(Clutch Parts)

Final Report

Machining

Prototype Testing

Josh McHugh

Bernie Gabriel

Nick Balaban

Edgar Lozano/Nick Balaban

Nick Balaban

John Leung

Outsource/Bernie Gabriel

Entire Team

Final Poster

Entire Team

GANTT Chart

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Measures Taken

Quality: Material chosen (strong steels)

Reliability: Analysis of interference, tolerances, stresses, and Lifetime

Safety: Depth of splines and machine shop protocols

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Questions?

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http://gph.is/1gSo4RG