critical design review- integrated designs
TRANSCRIPT
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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
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Project Background
Cobra Digital Turntable Framework
http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf 7
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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
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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
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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
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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
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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.
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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
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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
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Simulation
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Pressure on Fork Shift: 10 N/m2
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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
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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
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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