Automated Port Connection Alignment System

Ray Schroeder

ET 494 Senior Design II

Fall 2014

September 1, 2014

Abstract.

With the advent of electro-hydraulic applications, computer automated test stands used in quality control have seen advances in complexity and technology to keep up with ever changing demands. One component these machines are employed to test is fluid gear motors. Gear motor test stands were developed specifically for quality control in the fluid power industry where the primary function and use is in the detection of manufacturing defects in hydraulic gear motors. Defects are identified by automated testing of the gear motors, after assembly, according to manufacturer specifications and “passed” or “failed” according to those predetermined conditions. The machines are completely computer controlled throughout testing thus limiting human error and human involvement with the exception of loading and unloading test units, hydraulically connecting the test unit, closing the shielding prior to testing, entering test unit manufacturing data, and starting the test cycle. To reduce downtime between tests and eliminate complications in hydraulically connecting the gear motor test unit to the test stand, automated connection of the gear motors ports to the stand are recommended.

automated port connection system

proposal

Located at the front of the machine, the test area contains upper and lower transparent shielding, the Test Fixture, the gear motor test unit, and all required port connections necessary to couple the gear motor hydraulically. Currently, a manual method of connecting the high pressure hydraulic hose to the test unit is employed, which can be cumbersome and time consuming considering the rigidity of these hoses due to their high pressure rating and size, complicating the alignment of the hydraulic hose end fittings to thread onto the SAE/JIC fittings installed in the motor. An Automated Port Connection Alignment system to automatically align port connectors to the gear motors ports on the test stand would eliminate this manual labor segment of the test procedure, decreasing downtime between tests, and allowing an increase in the number of test units to be output daily.

automated port connection alignment system

proposal - continued

Hydraulic hose to motor Port Connector Couplings (PCC) to directly couple the test unit motor to the test stand will not be offered, the scope of this project will only provide the vertical and horizontal linear motion systems capable of aligning the PCC mechanism to the motors ports. For system design and functional real world computer motion simulation, the Port Connector Coupling (PCC) will be FOR REFERENCE ONLY and represented by a “Red” colored block in all documentation.

The extent of the project will consist of using currently available technology in linear motion systems and the full function of each subsystem, both horizontal and vertical, collectively will be mechanically simulated using Solidworks Simulation 2013 design software, to show real world operation.

METHOD

The test unit motor is mounted into the test fixture and secured with the already present automated test unit clamps. Once secured, the test area shields will be closed, to provide protection from all moving devices and high pressure hydraulic lines. Upon start of the test, the horizontal portion of the Automated Port Connection Alignment System is actuated, extending outwards to align with the ports on the test unit motor. Alignment is accomplished via a mechanical stop at its retracted position to be used as a “home”/”zero” position for the horizontal system. The actuator of the horizontal system is controlled by the LABVIEW software that operates the entire test stand. Position of the horizontal system in relation to the test unit ports will be acquired during system installation using LABVIEW manually by the programmer during initial setup. With the horizontal system aligned with the test unit ports, vertical actuation is then performed to lower the FOR REFERENCE ONLY port connector assembly to connect the test stand to the test units ports. Testing of the motor is then executed as normal. At the completion or the fail of a test, the vertical system will retract and raise the FOR REFERENCE ONLY port connectors up away from the motor to hydraulically decouple the test unit from the test stand, subsequentially the horizontal portion of the system will retract inward to its original starting position, thus allowing access for removal of the test unit motor.

OBJECTIVES

The project goals will consist of using available technology in linear motion systems and three dimensional models to fully simulate each function of the system using Solidworks 2013/2014 software to show real world operation. The software simulation will consist of several sequences;

1) The test gear motor is inserted into the tooling fixture.

2) The gear motor is clamped to the tooling face.

3) The horizontal subsystem, powered by the stepper motor, translates rotational torque to the precision ball screw via gear belt to traverse and align the vertical subsystem assembly with the gear motor ports.

4) The vertical subsystem actuates the cylinders and lowers the port connectors downward to engage the test gear motor’s ports to finalize preparation for testing.

5) For simulation, the testing sequence length will be substantially shortened to a duration of only 3 seconds, at its completion both systems will retract in the reverse.

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COMPLETION TIMELINE

Fall 2014 semester, ET494;

All simulations using Solidworks 2013/2014 software:

9/28/14 - Simulate gear motor test unit insertion and clamping.

10/12/14 - Simulate horizontal and vertical subsystem actuation.

10/26/14 - Simulate unclamping and removal of gear motor test unit.

12/5/14 - Simulation of all system operations in sequence for class presentation.

PROJECTIONS

No Southeastern Louisiana University resource will be used for any part or portion of this project. Intellectual property created, made, or originated by Ray Schroeder shall be the sole and exclusive property of Ray Schroeder, except as he may voluntarily choose to transfer such property, in full, or in part.

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Automated Port Connection Alignment System

Ray Schroeder

ET 493 Senior Design I

Spring 2014

ray.schroeder@selu.edu