design review ul vibration test apparatus
DESCRIPTION
Design Review UL Vibration Test Apparatus. May 13, 2013 1:30PM Est. Project & Team Information. Project: UL Vibration Test Apparatus Project Number: 13471 Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries) Customer Contacts: Joe Manahan Ed Leubner - PowerPoint PPT PresentationTRANSCRIPT
Design ReviewUL Vibration Test Apparatus
May 13, 20131:30PM Est.
UL Vibration Test Apparatus 2
Project & Team InformationProject: UL Vibration Test ApparatusProject Number: 13471
Customer: Eaton Corporation (previously Cooper Crouse-Hinds Industries)Customer Contacts: Joe Manahan
Ed Leubner
RIT Faculty Guide: Dr. Benjamin Varela
Project Team: Walter BergstromSean CootsSpencer CrandellMark Ellison
February 21, 2013
UL Vibration Test Apparatus 3
Presentation Overview
1) Detailed Design Review Overview
Appendix: UL Test Stand and Project Background
February 21, 2013
UL Vibration Test Apparatus 4
Detailed Design Review
• Discussed Design: – Adjustment Mechanism– Crank Arm
• Key Action Items:– Adjustment Mechanism Strength– Crank Arm
• Actions Taken:– Crank Arm to be a single piece
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Final Design
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Variations from Design
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Setup
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Testing• Displacement testing completed on the system• As motor implementation is not within the scope of this
project, frequency was not validated• Test frame rigidly fastened to testing table
– Angle steel welded into frame shape– Aluminum cantilever with flange connection
• Dial indicators used in two locations to verify the displacement across the system– Contacting linear slider box– Contacting collar at connection to vertical conduit
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Testing
February 21, 2013
Dial Indicator Contacting Slider Box Dial Indicator Contacting Conduit Collar
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• Test 1: Verify zero-displacement– Centering dowels mated between adjustment
mechanism and rotating disk to signify zero-displacement
– Dial indicators showed zero displacement for the system
• Test 2: Verify 3 displacement values– 0.016”: found that dial indicators give very
low value for displacement (.004-0.008”)– 0.100”: again found that measured values
were lower than expected (0.045-0.055”)– 0.250”: met expected displacement value
within ± 0.010”
• Test 3: Verify torque– Torque wrench used not ideal; not precise
enough to measure low torque range– Did verify that the required torque to drive
the steady-state system is below ~2 lbf-ft
February 21, 2013
Cantilever
Flange Connection
Vertical Conduit
Conduit Collar
Testing Table
Test Frame
UL Vibration Test Apparatus 11
Testing Conclusions• Zero-displacement point is validated• Displacement measurements do not agree at low eccentric
values, but they do at higher distances– Postulated that the dial indicators are not precise enough to
accurately measure low eccentric distances
• Torque measurement has a high degree of uncertainty due to the low level of precision associated with the torque wrench used during testing
• Recommended:– Purchase more precise dial indicator (re-test)– Purchase more precise torque wrench (re-test)
February 21, 2013
Frame Design
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44”34”
Frame Design
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Advantages:• Allows for a single technician to mount the luminaire• Extra support of U-channel decrease vibration of system• Rubber pads in-between supporting beams help in
dampening the system• More space efficient than current design• *Approximately 44” X 34” footprint• Footprint may become larger due to resonate frequency
of design (to be tackled by next senior design group)
Motor Selection• 3-Phase, 240V AC Motor
• Steady-state period– No acceleration of system
• lbfft• This corresponds to a motor horsepower of 0.41,therefore a 1hp motor is desired
– Where r= in (stroke of crank), θ is angle of rotation of the motor (
• Start-up period
• Where:
• Assuming 50-60 seconds to reach 2000RPM, Treq3 lbfft
February 21, 2013 UL Vibration Test Apparatus 14
February 21, 2013 UL Vibration Test Apparatus 15
• At 2000RPM, a general purpose 1HP AC Baldor motor will produce 90ozft 5.7lbft torque• Our estimated range for required start-up torque is highlighted in yellow• At ~5.7lbft torque, it is estimated that 2000RPM will be reached in approximately 30
seconds• A variable-frequency drive will be used to obtain the required 2000RPM speed
Recommended Motor
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February 21, 2013 UL Vibration Test Apparatus 17
Parameter Governing Equation Value Max Bearing Load
Upper bearing force 2450lbf 3150lbf
Lower bearing force 1225lbf 3150lbf
Se 1.10e4psi -
F.O.S. Shaft 10 -
F.O.S. Key 39 -
• Where ka, kb and kc are Marin factors for surface condition, size, and loading conditions, respectively.
• l1=2 , l2=4 , σmin, σmax, Sy, Sut can be found in Appendix
𝜎 𝑎=|𝜎𝑚𝑎𝑥−𝜎𝑚𝑖𝑛
2 | 𝜎 𝑚=𝜎𝑚𝑎𝑥+𝜎𝑚𝑖𝑛
2
Lubrication
• Drive Shaft Bearings: Double sealed flange mount bearings with easy access grease zerk fittings.
• Linear Bearings: Double sealed closed bearings with easy access grease zerk fittings.
• Crank Arm Bearings: Double Sealed roller bearings pre-packed with grease . Easy access for lubrication by taking off Polycarbonate cover.
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Budget
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Questions For Customer
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Open Discussion
• Any questions?• Design concerns not discussed?
February 21, 2013 UL Vibration Test Apparatus 21
AppendixUL Test Standard and Project Background
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Project Background• To pass safety requirements for certification the luminaires must meet a series of
Underwriters Laboratories Inc. Standards.• A Vibration Test Stand is currently being used by Cooper Crouse-Hinds to test
pendant mount luminaires according to section 33 of the UL844 Standard. • The Current Vibration Test Stand is outdated, has multiple design flaws, and design
documentation and drawings are non-existent.• Cooper Crouse-Hinds would like a new modernized Vibration Test Stand to be
developed that addresses some of the design flaws of the current system while maintaining UL844 Test Standards. This new Design must also have a LabView interface and control capability integrated into the system.
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Design Goals over Winter/Spring MSDNote: It has been decided that this apparatus will be developed in multiple Senior Design Sequences.
• Provide customer with two design concepts for vibration mechanism• Develop a final design of the vibration mechanism.• Design a steel test frame that will support the vibration mechanism and
the vertical conduit.• Design but do not develop steel frame for entire vibration test machine.• Develop a full set of engineering drawings.• Calculate and select the required drive train system components.• Purchase materials, machine components, and assemble the vibration
mechanism and test frame.• Test the mechanism to ensure that it meets 1/32” deflection requirement
February 21, 2013
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Summary of UL844 Vibration Test Standard
LUMINAIRES FOR USE IN HAZARDOUS (CLASSIFIED) LOCATIONS – UL 844Section 33 – Vibration Test Standards
• Luminaire is to be subjected to 35 hours of vibration testing.• Luminaire assembly is to be attached to a 26-1/2” long conduit via NPT threading.
The other end of the NPT threaded pipe is to be secured to the hub of a rigid mounting frame so that the conduit hangs vertically. The conduit should correspond to the smallest size of threaded conduit hub that is designed to attach to the Luminaire being tested.
• The horizontal force to be applied to the system in order to obtain the deflection must me located 4” above the location of the conduit where the Luminaire attaches.
• The deflection must be 1/32” with 1/16” total deflection per cycle.• The system must run at 2000 cycles/min.
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UL844 Vibration Test Standard
February 21, 2013
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Design Flaws Associated with Original Design
February 21, 2013
• Difficult for one technician to set up test• Lubricant not contained• Machine components exposed to contaminants• Belts used (slipping)• Uses single speed motor with a speed reducer• Frequency adjustment dial held in place with rope• No displacement adjustment • Attachment collar may experience minor buckling• Does not accounted for part wear and tolerance stack up
Customer Design Needs
Need # ImportanceHigh 3 – 2 – 1 Low
Design Criteria Measure of Effectiveness
CN1 3 Obtain vibration frequency of 2000 cycles/min Stroboscope
CN2 3 Create displacement of 1/32” at 22.5” bellow pipe flange Dial Gauge
CN3 2 Adjustment of attachment collar position for perpendicularity ___
CN4 2 240 V electrical input ___
CN5 2 System envelope size is maintained or decreased from original system
___
CN6 1 Mounts to current anchor points in floor ___
CN7 3 Capability to adjust for different pipe sizes ___
CN8 1 Use current flange mounting for pipes ___
CN9 2 Design in an easily removable collar ___
CN10 3 Will support multiple types of Luminaires ___
CN11 2 Easy to mount the Luminaires 1 Technician can run entire test
CN12 1 Ease of lubrication ___
CN13 2 Containment of Lubricant Look for leaking of Lubricant
CN14 3 System to not run near resonate frequency Does not shake itself apart
CN15 1 Minimize noise of system Under 85 decibels(OCIA standard for requiring
ear protection)
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PUGH Matrix: Rotational to Linear Motion Mechanism
February 21, 2013 UL Vibration Test Apparatus 29
# Evaluation Criteria Crankshaft Eccentric Shaft Scotch Yoke Cam & Follower1 Robustness s + + -2 Cost + - + s3 Design Simplicity s + s s4 Adjustability s - + s5 Component Wear s s - -6 Ease of Lubrication - + - -7 Part Replacement s - + +8 Accuracy/Tolerance Stack-up + + + -9 Ease of Maintenance s s + s10 Ease of Manufacture + - + s11 In-house Manufacture + - + s12 Ease of Assembly s s s s13 Noise/Vibration + + - s14 Safety s + s s
4 1 5 -3
Rotational to Linear Conversion
Sum
PUGH Matrix: Slider Mechanism
February 21, 2013 UL Vibration Test Apparatus 30
# Evaluation Criteria Pillow Block Bearings Viscous Fluid Layer Roller Bearings w/wheels Linear Bearings on rails1 Robustness + + S +2 Cost S + S S3 Design Simplicity S S - S4 Component Wear + - S +5 Ease of Lubrication + + S +6 Containment of Lubricant S - S +7 Part Replacement + - + +8 Ease of Maintenance + S + +9 Ease of Manufacture + + S +
10 In-house Manufacture S S S S11 Ease of Assembly S S S S12 Noise/Vibration S - S S
6 0 1 7
Slider Mechanism
Sum
PUGH Matrix: Displacement Adjustment Mechanism
February 21, 2013 UL Vibration Test Apparatus 31
# Evaluation Criteria Screw Linear Actuator Pivot Cam slider w/ tightening bolt1 Robustness - + -2 Cost - + +3 Design Simplicity - + +4 Part Replacement - + S5 Accuracy of Adjustment + - -6 Ease of Manufacture - S +7 In-house Manufacture - + +8 Ease of Assembly - + +9 User Friendly + S S
-5 5 3
Displacement Adjustment Mechanism
Sum
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Risk Assessment
February 21, 2013 UL Vibration Test Apparatus 33