p14471 vibration testing apparatus ii -...

P14471 Vibration Testing Apparatus II Detailed Design Review

12/10/2013

Brett Billings

Jacob Gardner

Nick Greco

Ron Jimbo

Claire Kobal

Ryan Selig

Ashley Waldron

1

Agenda Project Summary

Selected Design

Preliminary Analysis

Frame

Motor

Electrical / Control System

Safety

Improvements from P13471

Test Plan

BOM

Project Plan

Concerns/Issues

Appendix

2

Project Summary

3

Problem Statement

Update company’s vibration test apparatus Meet UL 844 Standard

Continue progress started by Team 13471

Done: the eccentric drive mechanism

Still needs:

Frame

Motor

Control system

4

House of Quality Engineering Metrics

Customer Requirements

Cus

tom

er W

eigh

ts

Dis

plac

emen

t of

lum

inai

re

Vib

rati

on o

f lu

min

aire

Dur

atio

n of

vib

rati

on t

est

Low

sou

nd

Mac

hine

won

't o

pera

te if

mov

ing

part

s ar

e ex

pose

d

Com

plet

ely

stop

mac

hine

wit

h

Em

erge

ncy

Stop

Min

imiz

e pi

nch

poin

ts

Min

imiz

e nu

mbe

r of

ope

rato

rs

Vol

tage

of

mot

or

Mou

nt p

enda

nt c

onfi

gura

tion

Mou

nt s

tanc

hion

con

figu

rati

on

Mou

nt y

oke

conf

igur

atio

n

Mou

nt t

runn

ion

conf

igur

atio

n V

isua

lly

disp

lay

sett

ings

and

sta

tus

of

test

Ope

rati

on d

ocum

enta

tion

Step

s re

quir

ed f

or S

et-u

p

Isol

ate

mot

or f

rom

oil

spi

lls

Mai

nten

ance

doc

umen

tati

on

Max

wei

ght

of m

ount

ed l

umin

aire

Tot

al m

ater

ials

cos

t

Tim

e to

Set

up

Mac

hine

foo

tpri

nt

Adherence to UL844 testing standard 5 5 5 5

Apparatus is safe 5 3 5 5 3 3 1

Motor must be compatible with available voltage 5 5 3 3

Ability to test multiple configurations 3 5 5 5 5 1 1 1

Easy to use 3 5 1 3 3 1 3

Easy to maintain 2 3 1 5 3

Visually display test information/feedback to

operator 3 3 3 3 5 1 1 1 1

Ability to test a range of luminaire weights 4 5 5 5 5 1 1 1 5

Cost under $4000 3 5

Long service life 4 1 1 5 3 1

Similar dimensions to existing machine 1 5

Technical Targets (Specifications)

1/32

in.

2000

cyc

les/

min

35 h

ours

< 8

5 dB

A

yes

< 1

0 se

cond

s

< 3

≤ 2

< 2

40 V

AC

Yes

Yes

Yes

Yes

Yes

80%

via

sur

vey

(eas

y to

foll

ow)

< 1

0 st

eps

Yes

80%

via

sur

vey

(eas

y to

foll

ow)

> 1

50 l

bs

< $

4000

< 1

20 s

econ

ds

< 3

4X48

in2

Raw score

69

69

69

15

25

25

15

21

25

35 7 7 7 18

33

16

45

44

20

15

16 5

Relative

Weight

11%

11%

11%

2%

4%

4%

2%

3%

4%

6%

1%

1%

1%

3%

5%

3%

7%

7%

3%

2%

3%

1%

6

Engineering Requirements Number Requirement

Raw

Score Units

Ideal

Measure 1 Displacement of luminaire 69 in 1/32

2 Vibration of luminaire 69 cycles/min 2000

3 Duration of vibration test 69 hours 35

4 Isolate motor from oil spills 45 Binary Yes

5 Maintenance Documentation 44 Survey (easy to follow) 80%

6 Mount pendant configuration 35 Binary Yes

7 Operation Documentation 33 Survey (easy to follow) 80%

8 Machine won't operate if crankshaft enclosure is open 25 Binary Yes

9 Completely stop machine with Emergency Stop 25 seconds < 10

10 Maximum voltage of Motor 25 V AC 240

11 Minimize number of operators 21 people 2

12 Max weight of mounted luminaire 20 lbs > 150

13 Visually display settings and status of test 18 Binary Yes

14 Steps to set up 16 steps < 10

15 Setup Time 16 seconds < 120

16 Low Sound 15 dBA < 85

17 Minimize pinch points 15 Count < 3

18 Total materials cost 15 $ < 4,000

19 Mount stanchion configuration 7 Binary Yes

20 Mount yoke configuration 7 Binary Yes

21 Mount trunnion configuration 7 Binary Yes

22 Machine footprint 5 in2 < 34X48

7

Selected Design

8

Selected Design

Interchangeable Conduits

Motor with V-belt

VFD

Digital Dial Gauge

Encoder

LCD, Microcontroller

Polycarbonate Guards

E-stop

Paint for Rust Protection

9

Preliminary Analysis

10

Maintaining Displacement ER #1: Displacement must be 1/32’’

Clamping force: Provided by 2 x A574 screws - 5/8’’-11 M = torque on screws = 168.9 M ft-1

Frictional force: 2 possible locations: = 33.8 M ft-1 (worst case)

Maximum force applied: 1.68 ft-lbs. (motor) at 1/32’’ = 645 lbs.

Required screw torque: = 38 ft-lbs. (Safety factor of 2) Max recommended A574 torque = 220 ft-lbs

*Detailed calculations in Appendix

1 2

11

Engineering Analysis: Forces

ER # 12 – Maximum Luminaire Weight

Force on collar/conduit = 1641.3N (368.979lbf)

Force from connecting rod = 2822.68N (634.564lbf)

Calculated friction forces

Worst case = 297.68N (66.921 lbf)

Torque on connecting rod = 2.13667Nm (1.575 lbft)

Torque on block = 2.399Nm (1.769 lb ft)

Torque on crankshaft = 2.399Nm(1.769 lb ft)

*Refer to Appendix

12

Engineering Analysis: Fatigue

Conduit

σa =15456.9psi so σm =0psi

σa < 0.5*σ0

Therefore Infinite Life

Factor of Safety

σar =15,5229psi < 0.5*σ0

Infinite life

C-Channel

Max stress = 7181.27psi = σa

σa < 0.5*σ0

Infinite Life

Refer to appendix

σ0 =35,000psi; σu =58,000psi

13

Engineering Analysis: Fatigue/Buckling

Extension Rod:

Buckling:

Pcr = 4576.61lbf

368.9 lbf < 4576.61lbf

No buckling

Fatigue:

σa =469.698psi

σa < 0.5*σ0

Infinite Life

Threaded Connector

Buckling:

Pcr = 13800.8lbf

368.9 lbf < 13800.8lbf

No buckling

Fatigue:

σa =2855.26psi

σa < 0.5*σ0

Infinite Life

• Refer to appendix

σ0 =35,000psi; σu =58,000psi

14

Frame

15

Final Frame Design

16

Frame Halve Views

Front and Back Views of

Full Assembly

Front and Back

Views of Crankshaft

17

Analysis Overview ER # 2, 3 – Vibration of Luminaire, Test Duration

ER # 12 – Maximum Luminaire Weight

ER # 22 – Machine Footprint

Tested both modal and harmonic response of frame using ANSYS Workbench

Simplified system to incorporate the respective weights of each system but not the complexity (bolt holes, threads, etc.)

Initially tested using a displacement of 0.015625” at the collar. This yielded:

𝜎𝑉𝑀 = 3749.2 𝑝𝑠𝑖 and 𝛿𝑥 = 0.017024 𝑖𝑛

Tested using lower displacements and achieved a good result with a displacement of 0.0144” at the collar. This yielded:

𝜎𝑉𝑀 = 3455.3 𝑝𝑠𝑖 and 𝛿𝑥 = 0.015689 𝑖𝑛

18

Frame Analysis at 0.015625 in.

Displacement

19

Frame Analysis at 0.0144 in.

Displacement

20

Motor

21

Motor Selection

Maximum Load= 150 lbs

Torque Necessary= 1.68 ft-lbs

We will be running the motor at full load torque to allow for a longer life.

𝐺𝑒𝑎𝑟 𝑅𝑎𝑡𝑖𝑜 =𝑖𝑛𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑

𝑜𝑢𝑡𝑝𝑢𝑡 𝑠𝑝𝑒𝑒𝑑=

3500

2000= 1.75

With the v-drive offset, the motor can produce less torque than needed by the crankshaft system.

ER #2 – Vibration of Luminaire

ER #10 – Max Motor Voltage

ER #12 – Maximum Luminaire Weight

22

Motor Performance Data:

Baldor M3545

Updated cost from Volland Electric

Equipment Corp: $237.51

*This is a saving of almost $235.00 from

the original estimate

We chose a 1 HP motor with

a full-load torque of 1.5 LB-FT

23

V-Drive Selection

All information was gathered from the Dodge catalog

For the given gear ratio of 1.75, Type A, 1-Groove

Driver Datum Diameter: 3.4”

Outer Diameter= 3.4”+.37”= Approx. 3.75”

Driven Datum Diameter: 6.2”

Outer Diameter= 6.2”+.37”= Approx. 6.55”

Driver Taper Lock Bushing (1210), .5” Shaft Diameter

Driven Taper Lock Bushing (1610), 1” Shaft Diameter

Distance from center shaft to center shaft using donated belt guard: 9.5”

*Unable to locate actual Dodge belt. A very similar belt will be purchased through AutoZone.


ER #4 – Isolate Motor from Oil Spills

24

Motor Mount to Frame

25

Encoder Placement

The current shaft has to be machined down to a smaller size at the very

end to add a coupling for the encoder.

*Encoder to be discussed further in electrical systems 26

Electrical / Control System

27

Component Placement at CCH

28

Flow Diagram

29

Power Connection Schematic

30

Power Supply

VGS-25-5

25 Watt 5V AC-DC converter

5A max delivered current

3.1 x 1.11 x 2.03 inches

*Refer to appendix for power calculations 31

Encoder TRD-N1024-RZWD


ER #13 – Display System Status

Resolution: 1024 Pulses Per Revolution (PPR)

Max frequency: 100 kHz

Max RPM detection: 100 kHz / 1024 PPR * 60 = 5859

RPM

32

33

ER # 10 – Max voltage of Motor

Enclosure

AMP1426CCLF

Polycarbonate enclosure with metal

snap latch

14 x 12 x 6 inches

34

Control System Pseudo Code Initial delay to allow sufficient startup time for motor

Repeat (loop) the following until Timer_A value reads 35 hrs

Wait for appropriate delay time to avoid overworking MCU CPU

Use Timer_A capture from pin 11 of MCU to retrieve digital encoder signal

Read and store timer value upon rising edge of signal into var "A"

Read and store timer value upon next rising edge into var "B"

Period = B - A

Frequency = 1 / Period

Resolution = 1024

Speed of vibration in RPM = Frequency / Resolution * 60

; Dimensions = (rev / min) = (pulses/sec) / (pulses/rev) * (60 sec/min)

Send RPM and elapsed time (also from Timer_A) to LCD display via pinouts

if RPM exists above safety threshold (2000 RPM + threshold)

exit loop with error code set high

Update VFD with new RPM information to step up or down accordingly

Send signal to alert VFD to bring motor to a complete stop

if error code set high

Write "Test Ended Abruptly: High RPM" to LCD display

else

Write "Test Completed Successfully" to LCD display

35

Launchpad and Display Encasing

ER # 3 – Duration of Vibration Test

ER #13 – Display System Status

36

Safety

37

Polycarbonate Guards ER # 8 – Crankshaft Enclosure is Guarded

ER # 17 – Minimize Pinch Points

Top and rear guard Clear, Polycarbonate ½’’ Excellent impact resistance Warning labels Replace existing top guard

Move mounting holes away from edge

Increases strength, but slight overhang

Modify rear guard Add access hole to decrease setup time

38

Belt Guard

ER # 17 – Minimize Pinch Points

Protects operator from 2000 RPM belt

Donated

Modifications required:

Convert to “split” type

Weld existing halves together

Cut guard in half in other direction

Change existing mounting brackets

39

Lock Out, E-stop

ER # 8 – Crankshaft Enclosure is Guarded

Lock out during maintenance

On electrical box, after power is isolated

Lock out procedure to be written in MSDII

ER # 9 – Completely Stop Machine with E-Stop

E-stop

Located on machine

Manually cuts power immediately

40

Engineering Analysis: Sound

ER # 16 – Low Sound

Hearing Protection / Engineering Intervention To be determined in MSD II with Test Plan

Based on sound “dosage”

Dosage Calculation: L = dBA Sound Level

T = 8 hour exposure limit

C = actual exposure hours D = 100 * (C1/T1 + C2/T2 + C3/T3 +…)

D > 50% requires hearing protection

D > 80% requires engineering intervention

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736

http://www.industrialnoisecontrol.com/comparative-noise-examples.htm

http://www.coopersafety.com/noisereduction.aspx

Maximum 8 Hour Exposure:

dbA hours Comparison

40 8192 Library

50 2048 Conversation at home

60 512 Conversation at restaurant

70 128 Radio or TV

80 32 Average Factory

85 16 Hearing protection required

90 8 Blender

100 2 Motorcycle

110 0.5 Live Rock Music = Pain Threshold

120 0.125 Thunderclap

130 0.03125

140 0.0078125

150 0.001953125 Jet Take-Off (25m) = Eardrum Rupture

41

https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9736






http://www.coopersafety.com/noisereduction.aspx

Safety Checklist ER # 8 – Machine Guarding

ER # 9 – Emergency Stop

ER # 16 – Low Sound

Item Safety Item Yes No N/A Owner Due Date

1 Is lockout/tagout procedure posted?

2 Can all energy sources be locked out? (electrical, air, hydraulic, water, etc.)

3 Are all electrical devices labeled with voltage and power source?

4 Are all machine controls labeled?

5 Are all machine hazards adequate guarded to prevent bodily contact? (motion, heat, light, ejection, etc.)

6 Do machine interlocks/light curtains inhibit motion?

7 Are E-Stops located at all operator stations?

8 Are utilities routed to avoid trip hazards?

9 Have any potential waste materials been identified? Do they have a disposal procedure?

10 Is there adequate egress from area?

11 Is a fire extinguisher located within 75 ft?

12 Is there adequate access for all operations? (maintenance, setups, operation, etc.)

13 Is machine designed to minimize overhead and extended reaching, pulling, bending, and twisting?

14 Is all required training complete and documented? (LOTO, maintenance, setup, operation, etc.)

42

Improvements from P13471

43

Setup Improvements ER # 11 – Minimize number of operators

ER # 14 – Steps to set up

ER # 15 – Setup time

44

Setup Improvements Current setup procedure:

1. Measure displacement with dial gauge

2. Lockout machine

3. Remove top guard (8 screws)

4. Remove rear guard (4 screws)

5. Remove collars (2)

6. Remove connecting rod (plate)

7. Loosen locking bolts (2)

8. Adjust set screw

9. Perform 2-7 in reverse

10. Repeat 1-9 until 1/32’’ reached ~ 5x

Approximately 60 minutes to setup

10 minutes

2x

45

Setup Improvements

Displacement adjustment without removing rear guard,

collars, or connecting rod (plate)

Also, U-bolt prevents block from rotating

Changes required:

Add 2 access holes to connecting rod (plate)

Add 4 holes total for u-bolt

Add 1 access hole to rear guard

Doesn’t impact safety, .2’’

46

Stress and Deformation Analysis of

Connecting Rod

47

Maximum Stress Situation: Fixed support on flat edge, 900 lbs added in either tension

or compression along edge with cut-out.

Equivalent Stress Max (Left): 4117.4 psi

Compare to yield of structural steel: ~36,000 psi

Maximum Deformation (Right): .00045 inches

Setup Improvements

Finer set screw

Before:

11 threads per inch

1 turn = 290% of displacement!

After:

100 threads per inch

1 turn = 33% of displacement

Changes required:

Machine new set screw plate

Requires threaded bushing for set screw

48

Set Up Improvements

• Set screw

• Account for excess space

between conduit and collar

• Flange

• Dimensioned to be

placed in same location

every time

• Blocks on the C channel

Flange

Collar –

crankshaft

connection

Collar – set

screws

ER # 11 – Minimize number of operators

ER # 6, 19-21 – Mount 4 configuration types

ER # 13, 14 – Setup time, number of steps

49

Test Plan

50

Test Plan

Displacement Test

Date Completed: ______________________

Performed By: _______________________________

Engr. Spec.

# Specification (description)

Unit of

Measure

Marginal

Value Tolerance Comments/Status

1 The total displacement of the

Luminaire must be 1/32" inches 1/32 +/- 2%

1,2 The adjustment screws must be

tightened to the proper torque ft-lbs >=38 -

51

Test Plan

Vibration Test

Date Completed: ______________________

Performed By: _______________________________

Engr. Spec.


Unit of

Measure

Marginal


2 Vibration of Luminaire must be

2000 rpm rpm 2000 +/- 2%

13 Vibration measurement is sent

back to the display binary Yes -

12 Apparatus will sufficiently vibrate

a large weight luminaire lb >=150 -

3 Vibrates for 35 hours hours >=35 -

10 Motor power is sufficient to fully

run the test hp >=1 -

52

Test Plan

Dimensional Test

Date Completed: ______________________

Performed By: _______________________________

Engr. Spec. # Specification (description) Unit of Measure

Marginal

Value Comments/Status

11 Conduits fit the frame binary Yes

22 Footprint difference compared to old

apparatus ft^2 <=2

53

Test Plan

Configuration Test

Date Completed: ______________________

Performed By: _______________________________

Engr. Spec. # Specification (description) Unit of Measure

Marginal


6 Apparatus works while pendant mounted binary Yes

19 Apparatus works while stanchion

mounted binary Yes

20 Apparatus works while yoke mounted binary Yes

21 Apparatus works while trunnion

mounted binary Yes

54

Test Plan

Ease of Use Test

Date Completed: ______________________

Performed By: _______________________________

Engr. Spec.


Unit of

Measure

Marginal


13 Display shows rpms and

running time binary Yes

14,15 Closed loop feedback keeps

rpms in check rpm 2000

+/- 2%

11,14,15 Survey given says apparatus is

easy to operate % >=80

4 Motor is isolated from oil spills binary Yes

5 Survey given says apparatus is

easy to maintain % >80

55

Test Plan

Safety Test

Date Completed: ______________________

Performed By: _______________________________

Engr.

Spec. #

Specification

(description)

Unit of

Measure

Marginal


8 Machine will not run during

LOTO binary Yes

17 Pinch points are covered # exposed 0

16 Noise is below 85 decibels dB <=85

9 Emergency Stop cuts all power

to the apparatus binary Yes

7 Complete Safety Checklist # fail 0 56

Bill of Materials

57

Bill of Materials ER # 18 – Total cost <= $4,000

Total Overall Price:

$2,564.59 58

Project Planning

59

Engineering Requirements to be

addressed in MSDII

60

ER # 5 – Maintenance Documentation

ER # 7 – Operation Documentation

Completed Action Items from DDRs

Update CAD drawings for machine shop

Perform additional vibration simulations

Perform additional torque analysis

Check VFD effect on motor poles

Check voltage, current, and load requirements

61

Risk Assessment

*Highest risk items only, refer to Appendix for full list

ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due

1Displacement is not equal

to 1/32in

Apparatus doesn't meet

UL844Poor design 3 2 6 Make it adjustable Brett DONE

1Displacement is not equal

to 1/32in


UL844Disp. changes during test 3 2 6

Calculate torque required on bolts so

displacement won't slip.Brett DONE

2Vibration is not 2000

cycles per min


UL844Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE

2Vibration is not 2000

cycles per min


UL844RPM changes during test 3 2 6

Design closed loop feedback and VFD to

adjust RPMRyan DONE

8 Pinch points existOperator injury could

occurExistence of pinch point 2 3 6 Guard all pinch points Brett DONE

12 Frame falls apart Test fails, costly to fixVibration is same as natural

frequency3 2 6

Perform ANSYS Analysis, add supports to

change natural frequencyNick DONE

12 Frame falls apart Test fails, costly to fix Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE

12 Frame falls apart Test fails, costly to fix Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE

12 Frame falls apart Test fails, costly to fix Improper construction 3 2 6 Use certified welder Nick MSDII

16Electrical shock from

apparatus

Operator injury could

occurImproper wiring 3 2 6 Use certified electrician Ron MSDII

15Project deadline is not

metCustomer is dissatisfied Correction of mistakes 3 2 6 Participate in milestone design reviews ALL Ongoing

Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe

Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely

62

MSD II Schedule

63

MSD II Schedule

64

Concerns/Issues

Where to place display?

Modifying apparatus once shipped to CCH for testing?

65

Questions?

66

Appendix

67

Full Risk Analysis ID Risk Effect Cause Severity Likelihood Score Action Item Owner Due

Poor design 3 2 6 Make it adjustable Brett DONE

Disp. changes during test 3 2 6 Calculate torque required on bolts so displacement won't slip. Brett DONE

Poor calibration 2 1 2 Define calibration procedure and schedule Jake MSDII

Crankshaft slipping 3 2 6 Evaluate previous team's design Nick DONE

RPM changes during test 3 2 6 Design closed loop feedback and VFD to adjust RPM Ryan DONE

Belt slips 2 2 4 Use v-belt and belt guard (for oil drip) Ashley DONE

Motor inefficiencies 3 1 3 Accept Risk --- DONE

Belt is too loose 1 2 2 Design motor mount to be adjustable Ashley DONE

Frame misalignment 2 1 2 Write procedure to verify conduit is 100% vertical Claire MSDII

3 Motor burns out Costly to replace, test fails Motor burns out 3 1 3 Calculate required torque and RPM, select appropriate motor Ron DONE

Crankshaft improperly lubricated 3 1 3 Define maintenance procedure and schedule Ron MSDII

Motor is too loud 2 1 2 Add motor enclosure, sound damping, hearing protection Brett MSDII

Vibration of frame 2 1 2 Add sound damping, add hearing protection Brett MSDII

Luminaire breaks and rattles 2 1 2 Accept Risk - test will be ended early --- DONE

Operators don't wear earplugs 1 2 2 Accept Risk - exposure duration is still low --- DONE

Fixed guard not in place 3 1 3 Place warning labels on apparatus Brett MSDII

Machine not properly guarded 3 1 3 Install polycarbonate guard and belt guard Brett MSDII

Energy source not isolated 3 2 3 Install location to lockout machine Brett MSDII

Lockout not observed 3 1 3 Accept Risk --- DONE

Button is broken 3 1 3 Define maintenance schedule Ryan MSDII

Electrical failure 3 1 3 Use certified electrician Ron MSDII

8 Pinch points exist Operator injury could occur Existence of pinch point 2 3 6 Guard all pinch points Brett DONE

Setup requires awkward positioning 2 2 4 Design conduit to be assembled first, then attached all at once Claire DONE

Luminaire is too heavy 2 1 2 Specify use of lift assist or 2nd operator, Design for use Brett MSDII

10 Can't mount all configurations typesCustomer is not able to test some

configurationsProject scope 2 2 4 Use current fixtures Claire DONE

11 Oil spill on motor connection Motor failure/smoke Leakage 1 2 2 Offset motor so oil can't drip on it Ashley DONE

Vibration is same as natural frequency 3 2 6 Perform ANSYS Analysis, add supports to change natural frequency Nick DONE

Improper construction 3 2 6 Use certified welder Nick MSDII

Poor material selection 3 2 6 Perform ANSYS Stress Analysis Nick DONE

Luminaire is too heavy 3 2 6 Perform ANSYS Stress Analysis Nick DONE

13 Project runs over budget

Customer is dissatisfied,

engineering requirements must be

sacrificed

Unforeseeable expenses 2 2 4 Proper budgeting/compare prices/buy standard sizes Nick Ongoing

14 Apparatus is larger than existing one Customer is dissatisfied New holes must be drilled in concrete floor 1 2 2 Accept Risk --- ---

Correction of mistakes 3 2 6 Participate in milestone design reviews ALL Ongoing

Delay in Tool Shop 2 2 4 Schedule machine time 1 week in advance with Tool Shop Ashley MSDII

Materials are delivered late 2 2 4 Order during Winter Break Nick 1/17/2014

16 Electrical shock from apparatus Operator injury could occur Improper wiring 3 2 6 Use certified electrician Ron MSDII

17 RPM can't be measured accurately Apparatus doesn't meet UL844 Tachometer vibrates too much 3 1 3 Add damping Jake MSDII

18 Unable to integrate measurement devices with displayMachine is just as difficult to setup

and monitor as beforeLack of knowledge 2 2 4 Research integration requirements and prepare LabView backup Ryan 12/20/2013

19 Can't get items (Motor, VFD, etc.) from Eaton in available timeNeed to purchase items instead,

increased cost of projectLead time is too long 2 2 4

Request items by specified date from CCH and ask for delivery date. Have

backup supplier prepared.Ron DONE

Severity Scale: 1 = Minor, 2 = Noticeable, 3 = Severe

Likelihood Scale: 1 = Improbable, 2 = Possible, 3 = Very Likely

1

2

Machine is too loud4

Operator injury could occurMachine operates when moving parts exposed5

Hearing conservation or

engineering intervention is

required

Apparatus doesn't meet UL844Vibration is not 2000 cycles per min

Apparatus doesn't meet UL844Displacement is not equal to 1/32in

Operator injury could occurMachine starts during maintenance6

Operator injury could occurEmergency stop doesn't work7

Customer is dissatisfied, Students

receive poor course grade, RIT's

reputation is negatively impacted

Project deadline is not met15

Operator injury could occurApparatus is not ergonomically safe to setup9

12 Frame falls apart Test fails, costly to fix

68

Engineering Analysis: Displacement

69

Engineering Analysis: Displacement

70

Engineering Analysis: Forces

71

Engineering Analysis: Fatigue

72

Engineering Analysis: Machine Guarding General Industry (29 CFR 1910)

1910.211(d)(44)

"Pinch point" means any point other than the point of

operation at which it is possible for a part of the body to

be caught between the moving parts of a press or

auxiliary equipment, or between moving and stationary

parts of a press or auxiliary equipment or between the

material and moving part or parts of the press or

auxiliary equipment.

1910.212(a)(1)

Types of guarding. One or more methods of machine guarding shall be provided to protect the

operator and other employees in the machine area from hazards such as those created by point

of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding

methods are-barrier guards, two-hand tripping devices, electronic safety devices, etc.

Plus specifics for Electrical Markings, Lubrication Access, Belts, and more

73

https://www.osha.gov/pls/oshaweb/owastand.display_standard_group?p_toc_level=1&p_part_number=1910

https://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1910_0212&src_anchor_name=1910.212(a)(1)



Power Calculations

74

Bolt Torque

Guide

75

Morph

Table

76

Attach Luminaire

Measure Vibration Displacement

Measure Vibration Frequency

Measure Elapsed Time

Display Feedback

Protect Operator - Hearing

Protect Operator - Moving Parts

Rust Protection

Move Crankshaft

Architecture

Central System

Power supply Motor system

Sensors

Display/user

interface

Luminaire

connection

Crankshaft

connection

Safety features

77

Alternatives Considered:

Design Element:

Evaluation Criteria Paint Electroplate Anode Stainless

Technical difficulty - - +

Cost - 0 -

Durability + 0 +

Maintenance + - +

Time required - + -

Total + +2 +1 +3

Total - -3 -2 -2

Net 0 -1 -1 +1

Rust Protection

DATUM

DATUM

Design Element:

Evaluation Criteria Screws Pins Socket Magnet

Setup time required + - +

Durability - 0 -

Cost - + -

Compatibility with luminaires 0 - -

Total + +1 +1 +1

Total - -2 -2 -3

Net 0 -1 -1 -2

Attach Luminaire

DATUM

DATUM

Design Element:

Evaluation Criteria Vertical Direct Speed Reducer Vertical w/ Belt Horiz. w/ 90°

Rotational capabilities - + -

Motor life + + +

Technical difficulty - - -

Safe to operate 0 - 0

Cost - + -

Maintenance - - -

Lubrication isolation + + +

Total + +2 +4 +2

Total - -4 -3 -4

Net 0 -2 +1 -2

DATUM

DATUM

Move Crankshaft

Consider Systems Level

Consider Systems Level

78

Design Element:

Evaluation Criteria Dial Gauge Laser Electrical Contact Magnify Ruler

Connection difficulty + - -

Cost - - 0


Accuracy + + -

Durability + 0 -

Dual purpose + + -

Total + +4 +2 +1

Total - -2 -3 -4

Net 0 +2 -1 -3

Measure Vibration

Displacement

DATUM

DATUM


Design Element:

Evaluation Criteria Stopwatch Software Egg Timer Hourglass

Technical difficulty - + +

Cost - 0 0

Durability + 0 -

Accuracy + - -

Expandability + - -

Total + +3 +1 +1

Total - -2 -2 -3

Net 0 +1 -1 -2

Measure Elapsed

Time

DATUM

DATUM

Design Element:

Evaluation Criteria Tachometer Laser Electrical Contact Pedometer

Cost - - +


Accuracy + 0 -

Connection difficulty + 0 -

Dual purpose + + 0

Durability + 0 0

Total + +4 +1 +2

Total - -2 -2 -2

Net 0 +2 -1 0

DATUM

DATUM

Measure Vibration

Frequency

79

Design Element:

Evaluation Criteria Seven Segment LED iPhone Dial

Expandability + + -

Cost - - +

Technical difficulty 0 - +

Ease of data relay 0 - -

Lifespan 0 - +

Display accuracy 0 0 -

Total + +1 +1 +3

Total - -1 -4 -3

Net 0 0 -3 0

Display Feedback

DATUM

DATUM


80

Design Element:

Evaluation Criteria Guard Plate Robot Enclosure Light Curtain

Safety + 0 -

Cost - - -

Interference with apparatus - - +

Technical difficulty - + -

Durability - 0 -

Dual purpose 0 + 0

Total + +1 +2 +1

Total - -4 -2 -4

Net 0 -3 0 -3

Protect Operator -

Moving Parts

DATUM

DATUM

Design Element:

Evaluation Criteria Damping Pads Earplugs Damp. Enclosure

Area of effect - 0

Cost + -

Safety 0 0

Interference with apparatus + -

Durability 0 0

Technical difficulty + -

Dual purpose 0 +

Total + +3 +1

Total - -1 -3

Net 0 +2 -2

DATUM

DATUM

Protect Operator -

Sound


Consider Systems Level Consider Systems Level

81

VFD internal circuitry

82

p14471 vibration testing apparatus ii -...

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