p14471 vibration testing apparatus ii integration demo 4/15/2014

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P14471 Vibration Testing Apparatus II Integration Demo 4/15/2014. Brett Billings Jacob Gardner Nick Greco Ron Jimbo Claire Kobal Ryan Selig Ashley Waldron. Agenda. Demo Items BoM & Budget Issues Project Plan Appendix. Demo Items. Mount 18 lb luminaire to 3/4'' conduit - PowerPoint PPT Presentation

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Systems Design Review

P14471 Vibration Testing Apparatus IIIntegration Demo4/15/2014Brett BillingsJacob Gardner Nick Greco Ron JimboClaire KobalRyan SeligAshley Waldron1

1AgendaDemo ItemsBoM & BudgetIssuesProject PlanAppendix

2

2Demo Items3Mount 18 lb luminaire to 3/4'' conduitAdjust displacementTurn on VFD & motor, 500 RPMDisplay RPM & elapsed time on LCDEnd with E-Stop

3BoM / Budget4Current costs:

Remaining costs:VFD enclosure - $80Shipping to Syracuse - $600Travel Expenses - $240Expected final cost: $3,400https://edge.rit.edu/edge/P14471/public/WorkingDocuments/Detailed%20Design/BOM_rev6_tracking.pdf

4Issues5

Reinforce motor mount

Vibration noise at certain frequencies

Decide on Control Panel layout

Shipping apparatus to Syracuse

Ryan

5Project Plan6

6Questions?77Appendix8Brett8Room Layout9

Ask CCH where they would like the display to be?9Selected DesignInterchangeable ConduitsMotor with V-beltVFDDigital Dial GaugeEncoderLCD, MicrocontrollerPolycarbonate GuardsE-stopPaint for Rust Protection

10

Brett10

11Engineering RequirementsNumberRequirementRaw ScoreUnitsIdeal Measure1Displacement of luminaire69in1/322Vibration of luminaire69cycles/min20003Duration of vibration test69hours354Isolate motor from oil spills45BinaryYes5Maintenance Documentation44Survey (easy to follow)80%6Mount pendant configuration35BinaryYes7Operation Documentation33Survey (easy to follow)80%8Machine won't operate if crankshaft enclosure is open25BinaryYes9Completely stop machine with Emergency Stop25seconds< 1010Maximum voltage of Motor25V AC24011Minimize number of operators21people212Max weight of mounted luminaire20lbs> 15013Visually display settings and status of test18BinaryYes14Steps to set up16steps< 1015Setup Time16seconds< 12016Low Sound15dBA< 85 17Minimize pinch points15Count< 318Total materials cost15$< 4,00019Mount stanchion configuration7BinaryYes20Mount yoke configuration7BinaryYes21Mount trunnion configuration7BinaryYes22Machine footprint5in2< 34X481212House of QualityEngineering MetricsCustomer RequirementsCustomer WeightsDisplacement of luminaireVibration of luminaireDuration of vibration testLow soundMachine won't operate if moving parts are exposed Completely stop machine with Emergency StopMinimize pinch pointsMinimize number of operatorsVoltage of motorMount pendant configurationMount stanchion configurationMount yoke configurationMount trunnion configurationVisually display settings and status of testOperation documentationSteps required for Set-upIsolate motor from oil spillsMaintenance documentationMax weight of mounted luminaireTotal materials costTime to Set upMachine footprintAdherence to UL844 testing standard5555Apparatus is safe5355331Motor must be compatible with available voltage5533Ability to test multiple configurations35555111Easy to use3513313Easy to maintain23153Visually display test information/feedback to operator333351111Ability to test a range of luminaire weights455551115Cost under $400035Long service life411531Similar dimensions to existing machine15Technical Targets (Specifications)1/32 in.2000 cycles/min35 hours< 85 dBAyes< 10 seconds< 3 2< 240 V ACYesYesYesYesYes80% via survey (easy to follow)< 10 stepsYes80% via survey (easy to follow)> 150 lbs< $4000< 120 seconds< 34X48 in2Raw score6969691525251521253577718331645442015165Relative Weight11%11%11%2%4%4%2%3%4%6%1%1%1%3%5%3%7%7%3%2%3%1%13Crux of MSDI13Safety ChecklistER # 8 Machine GuardingER # 9 Emergency StopER # 16 Low Sound

14Test Plans15Refer to Excel documenthttps://edge.rit.edu/edge/P14471/public/WorkingDocuments/MSDII_Build%20Test%20Documentation/P14471 Test Plans_Rev2.xlsxor EDGEhttps://edge.rit.edu/edge/P14471/public/Build%2C%20Test%2C%20Document

Maintaining DisplacementER #1: Displacement must be 1/32Clamping force:Provided by 2 x A574 screws - 5/8-11 M = torque on screws= 168.9 M ft-1Frictional 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 Appendix1216Bolt TorqueGuide17

Setup ImprovementsER # 11 Minimize number of operatorsER # 14 Steps to set upER # 15 Setup time

18Explain this is a bitch18Setup Improvements

Finer set screwBefore:11 threads per inch1 turn = 290% of displacement!After:100 threads per inch1 turn = 33% of displacement

Changes required:Machine new set screw plateRequires threaded bushing for set screw19Why are we doing this?19Set Up ImprovementsSet screwAccount for excess space between conduit and collarFlange Dimensioned to be placed in same location every timeBlocks on the C channel

FlangeCollar crankshaft connectionCollar set screws

ER # 11 Minimize number of operatorsER # 6, 19-21 Mount 4 configuration typesER # 13, 14 Setup time, number of steps 2020Full Risk Analysis21See EDGEhttps://edge.rit.edu/edge/P14471/public/ProjectManagement/Risk%20Analysis.pdfVFD Damage Incident22See EDGEhttps://edge.rit.edu/edge/P14471/public/WorkingDocuments/VFD%20Damage%20Incident/VFD%20Damage%20Incident.pdfBoM & Other Fees14471 Luminaire Vibration Test Aparatus IIBill of Materials

EstimatedActualBoM Costs$2,376.18$2,345.77Other Costs$1,677.62$168.85Total Cost$4,053.80$2,514.62TrackingItem Part DescriptionSupplierPart # Req.QtyPriceper UnitUnitOrderQtyTotalPriceLeadTimeConfirmedDeliveryNotesInvoiceActual Total Price3 phase Power CordsFLEX CORD 20ft 10AWG 4-COND TYPE 300 VOLTSAutomationDirectSJE00W-10-4BK201$39.00single1$39.001/27/145089093$39.005V Power Supply25 W, Single Output, Metal Case, Chassis Mount, Ac-Dc Power SupplyDigiKey102-1928-ND1$27.50single1$27.507 Days1/27/14Currently only two in stock should it be sold new shippment doesnt arrive until Jan 22 201438399125$27.42A-Belt for V-DriveDodge P/N A33- 9.5" center shaft to center shaftAutoZone173401$5.99single1$5.990 Days1/27/14Store #2922$5.99Adjustment Screw Block6061 Aluminum, 4'' x 12'' x 1/2"McMaster Carr8975K4291$19.05single1$19.057 days1/27/140114NGRECO$19.05Adjustment Slider1018 Steel, 4'' x 4'' x 1-1/2''MODIFY EXISTING - TEAMN/A1$0.00N/A10.00 daysN/AAdd 2 holes for Ubolt lockN/A0.0Belt GuardN/AMODIFY EXISTING - TEAMN/A1$0.00N/A10.00 daysN/AWeld Belt Guard Shut & Add New LatchN/A0.0Belt Guard Latches4 Draw latchesAmazona13031300ux03171$5.22double2$10.442 days3/19/14$10.44Bolts for Flange1/2"-13 Black Oxide Steel Machine Shop4$0.00single40.0N/AN/A0.0Bolts for Motor Mount/Belt Guard Mount 5/16"-18, 3 1" Long, Fully ThreadedMcMaster Carr92620A58312$9.77Qty 501$9.777 Days1/27/140114NGRECO$10.07Bolts for Stop Plate1/4 - 20 Black Oxide SteelMachine Shop2$0.00single20.0N/AN/A0.0Concrete anchorVibration-Resistant stud anchor for concrete, 3/4" Diam. 6" lengthMcMaster Carr94475A3146$7.30single6$43.802 days3/13/140313CKobalConduit2" NPT Steel ConduitMODIFY EXISTING - SEND OUTN/A1$100.00N/A1$100.007 daysSend OutCut to 26.5" and rethread bottomN/AConduit1 inch EMT conduit (10 ft)Lowes1$6.99single1$6.99none3/17/14$7.55Conduit1'' NPT Threaded PipeDebbie SupplyN/A1$9.99single1$9.99none4/8/14Cost for threadingConnecting RodLow-Carbon Steel, 3" x 8'' x 1/2''MODIFY EXISTING - TEAMN/A1$0.00N/A10.00 daysN/AAdd 2 access holes for wrench, and 2 holes for Ubolt lockN/A0.0Coupling (for encoder)COUPLING 8mm TO 0.375in ALUM ALLOY FOR TRD-N/NA & TRDA-20/25 SERIES ENCODERSAutomationDirectMCGL20-8-9521$27.50single1$27.503 Days1/27/145089093$27.50Dial GaugeMitutoyo Absolute 0.0005"-.5 Digital Dial GaugeWares Direct504-543-6831$162.42single1$162.427 Days1/27/14WD-250773$163.93Driven BushingDodge 1610 1" Inner Diameter Bushing (DODGE P/N 117159)MRO Supply1194491$10.95single1$10.952 Days1/27/14S1194783$10.95Driven SheaveDodge 6.55" Outer Diameter, A-belt, 1-Groove Sheave (DODGE P/N 118204)MRO Supply1353161$31.08single1$31.082 Days1/27/14S1194783$31.08Driver Bushing Dodge 1210 .625" Inner Diameter Bushing (DODGE P/N 117078)MRO Supply1170781$9.85single1$9.852 Dayslisted incorrect DODGE PN - corrected, to be reordered 3/17S1202528$19.62Driver Bushing Dodge 117078 BushingMRO Supply1184641$9.85singel1$9.857 days3/18/14Replacement for incorrect bushingDriver Sheave Dodge 1610, 3.75" Outer Diameter, A-belt, 1-Groove Sheave (DODGE P/N 118190)MRO Supply1353131$19.24single1$19.242 Days1/27/14S1194783$19.24Electric boxPolycarbonate Enclosure with Metal Snap Latch Hinged Clear Cover-14x12x6Solutions DirectAMP1426CCLF1$74.11single1$74.11Need to OrderElectrical Components16 pin headersDigiKey952-1861-ND1$0.48pack1$0.487 days3/31/14EncoderENCODER 1024 PPR 8mm SOLID PUSH- PULL 5-30VDC 2m (6.5ft) CBL MED DUTYAutomationDirectTRD-N1024-RZWD1$135.00single1$135.003 Days1/27/145089093$135.00Encoder Extention 6 Conductor Wire ~ (6) 14 GaugeAll Battery Sales & Service C5596$1.75single6$10.501/27/1443479$7.32E-Stop ButtonE-StopCorrosion-ResistantEnclosure Switch Pull toReset,SPST-NC,PlasticMcMaster Carr6785K221$44.60single2$89.207 days1/27/140114NGRECO$91.70EyeboltSteel Eyebolt w/ shoulder for lifiting, 1/2"-13 Threaded size, 1-1/2" long threadMcMaster Carr3014T4912$4.94single2$9.882 days3/13/140313CKobalFrame materialsMechanical/Structural Steel Square Tube 2"X2"X1/4" X20",21.65", 25", Klein Steel4$15.14single1$15.141/27/14505923$15.14Frame materialsS3x7.5 A36 Steel 61.5" longKlein Steel4$86.66single4$346.641/27/14Added 103.62, to balance invoice505923$450.26Frame materialsMechanical/structural Steel Square Tube 2"X2"X1/4"X26.563"Klein Steel2$15.78single2$31.561/28/14Separate Order60434$26.00Frame materialsASTM A36 Hot Rolled Steel Square Bar 2" x20",21.65", 25" Klein Steel2$41.16single1$41.161/27/14505923$41.16Frame materialsASTM A36 Hot Rolled Steel Plate 1/2" x 24"X24"Klein Steel1$113.22single1$113.221/27/14505923$113.22Frame materialsASTM 36 Hot Rolled Steel Plate 3/8" x 8"X240"Klein Steel1$51.36single1$51.361/27/14505923$51.36Frame materialsASTM A36 Hot Rolled Steel C Channel 10" X30# 48"long Klein Steel1$168.70single1$168.701/27/14505923$168.70Key for Driven Side1/4" X 1/4" X 12" Long McMaster Carr98535A1501$3.70single1$3.707 Days1/27/140114NGRECO$3.70Key For Driver Side3/16" X 3/16" X 12" Long McMaster Carr98535A1401$2.74single1$2.747 Days1/27/140114NGRECO$2.77LCD DisplayDOT MATRIX LCD DISPLAY, 128X64Newark82T46491$17.28single1$17.281/27/141/14/14 8.56 AM$17.28LCD DisplayLCD 20x4HD44780.BizDU2004ABB6NTDW1$11.99single1$11.997 days3/31/14Replacement for broken LCDLockout DeviceChoose-A-Color PadlockMcMaster Carr13305A151$15.55single1$15.557 days1/27/140114NGRECO$15.55MCU and LCD Power CablesTwo conductor cablesLocal Hardware store2$2.00QTY 22$4.00Need to OrderRon CheckMotor Baldor M3545, 1HP, 3450RPM, 3PH, 60HZ (BALDOR P/N M3545)Volland Electric Eqpt CorpM35451$235.00single1$235.003-4 Days1/27/14PSI268905$235.00Mount for Belt Guard / Motor1/8" Thick, 2" Wide, 6' Long Steel RodMcMaster Carr6511K5112$23.34single2$46.687 days1/27/140114NGRECO$46.68Nuts for Flange1/2" 18-8 Stainless Steel Machine Shop4$0.00single40.0N/AN/A0.0Nuts for Motor Mount/ B.G.M5/16"-18 Hex NutMcMaster Carr94804A03010$6.71Qty 501$6.717 Days1/27/140114NGRECO$6.71Polycarbonate Guard (Rear)Impact-Resistant Polycarbonate Sheet, Clear, 8" x 13" x 1/4''MODIFY EXISTING - TEAMN/A1$0.00N/A10.00 daysN/AAdd access hole for hex keyN/A0.0Polycarbonate Guard (Top)Impact-Resistant Polycarbonate Sheet, Clear, 24" x 24"x 1/4''McMaster Carr8574K551$45.04single1$45.047 days1/27/140114NGRECO$45.04Safety Sign"Do not operatore without guards", Self-Adhesive, 3.5'' x 5''Grainger3TU811$2.43single1$2.437 days1/27/149338656334$2.34Safety Sign"Electrical Hazard", Self-Adhesive, 7'' x 10''Grainger38K5631$10.36single1$10.3610 days1/27/149340860734$9.98Screws for Motor/Belt Guard Mount5/16"-18, 1 1/2", Fully Threaded Socket Head ScrewMcMaster Carr91251A5875$12.09Qty 501$12.097 Days1/27/140114NGRECO$12.09Set Screwalloy steel extended point set screw 1/2"-13 thread 1-1/2"LGMcMaster Carr92505A7232$7.355 pack1$7.352 days3/13/140313CKobalSet Screw18-8StainlessSteel,3/16"-100Thread,1-1/2"LengthMcMaster Carr98625A2301$9.15single1$9.157 days1/27/140114NGRECO$9.15Set ScrewFine adjustment set screw 18-8 stainless steel 3/16"-100 thread 1-1/2LGMcMaster Carr98625A2301$9.15single1$9.153/13/140313CKobalSet Screw Bushing5/8"Long Brass Bushing for3/16"-100ThreadFine-AdjustmentSet ScrewMcMaster Carr98625A3401$6.88single1$6.887 days1/27/140114NGRECO$6.88Set Screw KeyCushion Grip LoopedT-HandleHex Key 5/64"Hex,6"Blade LengthMcMaster Carr5419A291$2.41single1$2.417 days1/27/14Wrong size (too small)0114NGRECO$2.41Set Screw KeyCushion Grip LoopedT-HandleHex Key 3/32"Hex,6"Blade LengthMcMaster Carr5419A311$1.92single1$1.927 days3/13/14Correct size - 3/32''0313CKobalSpray PaintRust Protection Paint Advance Auto PartsRTA920310$6.69Single 10$66.900 Days 1/27/14Pick-up from Store, only have 7/106846401434791$46.83Stop Plates/ Flange8"x8"x0.5" A 36 Steel PlateMcMaster Carr6544K351$51.79single1$51.797 Days1/27/140114NGRECO$51.79Terminals16 - 14 Gauge Hook Terminal (Vinyl) All Battery Sales & Service 201201 bag$7.09single1$7.091/27/1443479$7.09Threaded RodASTM A193 Grade B7 Alloy Steel Threaded Rod, 1/2"-13 Threaded, 1'L Black oxide finishMcMaster Carr94210A0121$4.47single1$4.472 days3/13/140313CKobalTI LaunchPadMSP-EXP430G2 - MSP430 LaunchPad Value Line Development kitTexas InstrumentsMSP-EXP430G21$9.99single1$9.993 Days1/27/14316588$9.99U-boltType 304 Stainless Steel U-Bolt 1/4"-20 x 1-3/8" L Thread, for 1-3/4" ODMcMaster Carr8896T1061$3.24single1$3.247 days1/27/14Not sure if it's the way to go now0114NGRECO$3.24Variable Frequency DriveDRIVE, ADJUSTABLE FREQUENCY, 3P 230V IN/3P 230V OUT, 4.8A, 1.5HP, FS2, W/O EMCEatonMMX32AA4D8N0-01$290.21single00.01/30/14Donated by EatonN/A0.0Voltage RegulatorStep supply voltage down from 5V to 3.3VDigiKeyBP5233A331$14.30single1$14.300 days1/27/1438399125$8.84Washers for Flange1/2" 18-8 Stainless Steel Large OD Flat WasherMachine Shop4$0.00single40.0N/AN/A0.0Washers for Motor Mount/ B.G.M5/16" Inner Diameter, 18-8 Stainless Steel, Flat Washers McMaster Carr93852A10310$5.60Qty 251$5.607 Days1/27/140114NGRECO$5.60Welding Squaresmagnetic quick clampsMcMaster Carr5021A442$66.00single2$132.001/27/14CAUTION: magnetic0114NGRECO$132.00

Total >$2,376.18

Other CostsDescriptionEstimated CostActual CostShipping Costs -OrderingEstimated 10% of material cost$237.62$168.85(see Invoice Records)Shipping Costs - ApparatusSend apparatus to Cooper Crouse Hinds$600.00TBDTravel3 trips x 2 cars, per trip x car = $30 gas + $10 tolls$240.00TBDElectrician FeesWiring all components$200.000.0(donated by RIT electrician)Welding FeesFrame Assembly - need certified welder$400.000.0(done at RIT for no cost)

Total >$1,677.62$168.85

Invoice RecordsSupplierInvoiceDateDescriptionBase CostS/HTaxTotal CostAdvance Auto Parts68464014347911/14/14Paint$46.830.00.0$46.83All Battery Sales and Service434791/14/14Bee Wire, Terminals$14.41$11.280.0$25.69AmazonN/A3/19/14Belt Guard Latches$10.440.00.0$10.44Auto ZoneStore #29221/14/14V-Belt$5.990.00.0$5.99Automation Direct50890931/14/14Encoder, Coupling, Cable$201.500.00.0$201.50Debbie SupplyN/A4/8/14NPT Conduit$9.990.00.0$9.99Digi-Key383991251/14/14Power Supply, Regulator$36.26$4.78$2.90$43.94Digi-KeyN/A3/31/1416 pin headers$0.480.00.0$0.48Grainger93386563341/14/14Danger Sign$2.340.00.0$2.34Grainger93408607341/15/14Danger Sign$9.980.00.0$9.98HD44780BizN/A3/31/14LCD$11.990.00.0$11.99Klein Steel5059231/14/14Various Frame Materials$839.840.00.0$839.84Klein Steel604341/28/142'' Square Tube x 2$26.000.00.0$26.00LowesN/A3/17/141'' EMT Conduit$7.550.00.0$7.55McMaster-Carr0114NGRECO1/14/14Various$464.43$27.170.0$491.60McMaster-Carr0313CKOBAL3/13/14Various$76.57$6.560.0$83.13McMaster-CarrN/AN/ASet screw, springs, bushing$70.000.00.0$70.00MRO SupplyS11947831/14/14Belt Drive Items$72.22$45.480.0$117.70MRO SupplyS12025283/18/14Belt Drive Items$9.85$9.770.0$19.62Newark1/14/14 8.56 AM1/14/14LCD$17.28$9.080.0$26.36Texas Instruments3165881/14/14MCU$9.990.00.0$9.99Volland Electric Equipment CorporationPSI2689051/20/14Motor$235.00$22.850.0$257.85Wares DirectWD-2507731/14/14Dial Gauge$163.93$31.880.0$195.81Totals$2,342.87$168.85$2.90$2,514.62