Hardinge Universal Turret 05412- Senior Design Project

Project Sponsor: Hardinge Inc.

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Team Members

Brian Heeran - ISE

Brice Wert - ME

Robert Yarbrough - ME

Owen Brown - MEMatt Buonanno - ME

Eric Newcomb - ME

Steven Paul - ME

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Scope Introduction

Turret Indexing Cutting Movement

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Project Scope

Design a simple turret index model

Benchmarking

Torque Motor Integration

Design

Analysis

Prototyping

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Accomplishments

1. Needs Assessment & Benchmarking2. Concept Development3. Design Objectives4. Feasibility Assessments5. Preliminary Design6. Hardinge Review

ID

1

2

3

4

5

6

12/10 1/4

1/4 1/18

1/14 1/21

1/21 1/28

1/28 2/11

2/11 2/18

W S T F M T S W S T F M T S W S T F M T S W S T F M T SDec 5, '04 Dec 12, '04 Dec 19, '04 Dec 26, '04 Jan 2, '05 Jan 9, '05 Jan 16, '05 Jan 23, '05 Jan 30, '05 Feb 6, '05 Feb 13, '05 Feb 20, '05 Feb 27, '05

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Long Term Objectives

Complete project on time meeting technological/performance requirements.

Expanding relations between Hardinge Inc. and RIT

Gather data to establish the feasibility of future torque motor applications.

Demonstrate competitive advantage through the use of Torque Motor.

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Benchmarking

Goals Determine current state of industry Evaluate feasibility of new design

Turret Selection Chosen to represent cross-section of

manufacturer’s offerings Chosen to maintain data compatibility

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Benchmarking Cont.

CriterionPrimary Characteristics

Index TimeIndex Motor TypeNumber of Tooling StationsTurret OperationMax TorqueTotal Turret Weight

Secondary CharacteristicsTooling SystemLive Tooling CapabilityTurret Operating PressureEtc…

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Benchmarking Cont.Indexing Time - Station to Station

Quest 42Quest 51/65Quest 51/65

TT 65Talent 6/45, 8/52Talent 10/78, 8/52A

RedlineYellowline

BTP-50BTP-63

BTP-125BTS-63

BTS-80BTS-100

SM-BR 12/30SM-BR 16/30

SM-BR 20/30SM-BR 25/30

SM-12SM-16

SM-20SM-25

SMA-16SMA-20

SMA-25LS-200

LS-120LS-160

LS-120SVLS-160SV

LS-240SV

BTP-80BTP-100

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2

Time (s)

Hardinge

Sauter

Pragati

Duplomatic

Loshin

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Benchmarking Cont.

Models Offered vs. Tooling Stations

0

5

10

15

20

25

30

35

8 10 12 16 24

Tooling Stations

Mo

del

s O

ffer

ed

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Benchmarking Cont.

Benchmarking Conclusions New turret design should be designed around a 12

station turret Need to strive to attain an indexing time of less than

0.15 seconds

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Traditional Motors vs. Torque Motors

Direct drive with torque motor

Motor

1FW3..

Gear box

Customer machine

Customer machine

Traditional drive with motor and gear box

Large outside diameter allows for more poles, and windings thus allowing for higher torques.Large diameter means higher torque can be generated with the same power input.

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Torque Motor Technology

Reduced Cost Improved Reliability High Accuracy &

Repeatability High Efficiency

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Torque Motor Benefits

Characteristic: Short compact design Gear unit / belt drives

eliminated Hollow shaft design Few mechanical

components No torsional backlash Increased rigidity

Customer Benefit: Simple integration into the

machine Easy to service (no gear box oil) Improved efficiency Flexible mounting concepts Advantage in mounting and

logistics Improved repeatability Improved control characteristics Low noise system Increased dynamic performance

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Torque Motor Availability Options

4 different rotor models available off the shelf from ETEL, Inc. Selected model based upon:

Project Torque Requirements. Length Heat Generation Cost

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Design Objectives

Technological Attributes Designs must include

the use of a torque motor.

Design shall have as few parts as possible.

Design must include current top plate locking mechanism used by Hardinge in their Quest series turret.

Performance Attributes Designs must equal or

exceed current industry leader performance attributes such as index time, repeatability, and static stiffness.

Designs must result in increased reliability.

Designs shall incorporate adequate cooling of the torque motor.

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Concept Development

Project Scope Redefinition Locking Mechanism Cooling Common Tooling Live Tooling

6 Conceptual Designs Developed

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Alternative Concepts

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Alternative ConceptsCont.

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Design Concerns

Heat generation and removal Thermal Deflection Sealing the motor Bearings Static Stiffness Controller Interface Component ordering lead time

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Technical Assessment

Requirements 1 2 3 4 5 6

Torque Motor 52 64 48 52 56 52

Fewest Parts -30 9 -24 -3 -6 3

Locking Mechanism -9 24 6 15 15 15

Off-shelf Use -4 56 32 24 40 40

Hollow Cavity -2 16 16 -2 12 16

Tooling Load -6 -5 -3 -6 -5 -5

Housing 20 22 20 22 20 18

Control Compatibility -3 -2 -3 -2 -3 -2

  18 184 92 100 129 137

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Preliminary Design

Top Plate

Assembly

Top Plate Interface

Housing

Bearings

Support

Structure

Coupler Torque Motor

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Preliminary Design - Assembly

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System Dynamics

The response of the motor to a command to index the turret between station one and two.

Shown with no tooling on top plate.

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Finite Element Stress Analysis Output from finite element software based on indexing load of 700 N-m torque.

Max Von Mises Stress found to be 22.7 MPa.

Yield strength of steel 285 MPa.

Factor of safety of 10.4.

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Finite Element Stress Analysis Output from finite element software based on indexing load of 700 N-m torque.

Max Von Mises Stress found to be 19 MPa.

Yield strength of steel 285 MPa.

Factor of safety of 15.8.

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Future Plan

1. Detailed Design2. Pilot Builds3. Iterative Problem Solving4. Testing & Analysis5. Hardinge Review

ID

1

2

3

4

5

3/7 3/21

3/21 4/5

4/5 4/20

4/20 5/5

5/5 5/13

S T F M T S W S T F M T S W S T F M T S W S T F M TFeb 27, '05 Mar 6, '05 Mar 13, '05 Mar 20, '05 Mar 27, '05 Apr 3, '05 Apr 10, '05 Apr 17, '05 Apr 24, '05 May 1, '05 May 8, '05 May 15, '05

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References

“Torque Motors Do the Trick” Holzknecht, Arthur, ETEL Inc. Schaumburg, Ill., 2004.

“Siemens Torque Motors” Siemens AG 2004, www.ad.siemens.de.

“298798 Rexroth IndraDyn T Synchron-Torquemotor” Bosch Rexroth AG, 2004 . www.boschrexroth.com.