Multidisciplinary Engineering Senior Design

Hardinge Universal TurretProject 05412 2005 Critical Design Review

May 13, 2005

Project Sponsor: Hardinge Inc.

Team Members: Brian Heeran (Team Leader)

Owen BrownMatt BuonannoEric NewcombSteven PaulBrice Wert

Robert Yarbrough

Kate Gleason College of EngineeringRochester Institute of Technology

Team Mentor: Dr. James Taylor

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Background Information

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Senior Design 2 - Plan

• Detailed Design (3/7 – 3/28)• Iterative Problem Solving (3/29 – 4/8)• Component Fabrication (4/12 – 4/29)• Prototype Assembly (4/27 – 5/11)• Hardinge Review (5/13)

ID Task Name

1 Detailed Design2 Iterative Problem Solving3 Component Fabrication4 Prototype Assembly5 Hardinge Review

3/7 3/283/29 4/8

4/12 4/294/27 5/12

5/13 5/13

M F T S W S T M F T S W S T M F T S W S T M F T S W S T MFeb 27, '05 Mar 13, '05 Mar 27, '05 Apr 10, '05 Apr 24, '05 May 8, '05 May 22, '05 Jun 5, '05 Jun 19, '05

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Project Intent

• Sustain Hardinge Inc. as an industry leader in turret manufacturing.– New technology

• Improved reliability and flexibility of future designs.– Fewer parts– Versatile motor

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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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Project Overview

• Project Scope:– Establish the feasibility of Torque Motor

Integration.– Design a Turret Index Model capable of being

manufactured.– Design for adequate cooling of the Torque

Motor.

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Desired Outcomes• Technical

– Include the use of a torque motor.

– Design with as few parts as possible.

– Included current top plate locking mechanism used by Hardinge in their Quest series turret.

• Performance– Equal or exceed current

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

– Demonstrate increased reliability of assembly.

– Incorporate adequate cooling of the torque motor.

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Final Design

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Analysis of Design• Output from finite element

software based on an indexing load of 633 N-m Torque. – Max Von Mises Stress

found to be 47.3 MPa.– Yield Strength of

1018- CD steel 370 MPa.

– Factor of Safety of 7.8.

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Development of Machining Experience

• Standard Stock Sizes & Availability• Bearing Lead Time & Availability• Availability of Fasteners & Taps

– English & Metric• SHCS• Flat Head w/ Chamfer• Hex Head

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Assembly Components

• Side Walls (2x)– Supports Torque

Motor and Stator-Up Plate by securing it to the Base Plate

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Assembly Components

• Stator-Up Plate– Affixes Torque motor

and Side Walls to Base Plate

– Main Drive shaft assembly passage

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Assembly Components

• House Front– Supports part of

locking coupler, exposure to CNC Environment

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Assembly Components

• Interface Plate– Connects Top Plate

to Main Drive Shaft

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Assembly Components

• Main Drive Shaft– Shaft feature changes

for manufacturability– Location and company

with more aggressive machining capabilities than RIT

– Final determination: Hardinge Inc.

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Assembly Components

• Hydraulic Block– Supports Variable

Axial Guide and locking coupler while including potential expandability features for Hardinge Inc.

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Assembly Components

• Variable Axial Guide– Locates within

Hydraulic Block– Provides bearing

surface, bearing retaining attributes and centricity control for Main Drive Shaft

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Assembly Components

• Bearing Block (Upper & Lower)– Second major

bearing surface in line with Variable Axial Guide

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Final Assembly

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Torque Motor Implementation

• Powering– Etel Inc. high voltage motor driver

• Encoding– Sick/Stegmann incremental encoder

• Thermal Overload Protection– Analog and Digital sensors within Stator,

providing temperature feedback

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Torque Motor Cooling

• Max power produced: 1000 W (approx)• Cooling options

– Ventilation slots• Simple, inexpensive• Slots placed in base and top of housing

– Small AC powered fans• Fans mounted on top of housing

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Torque Motor Cooling

• Further Options– Custom heat pipes

• Expensive• Decreased reliability

– Cooling sleeve• Extremely Expensive• Electron Channel Technology

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Outcomes• Desired

– Preparation for pilot builds.

• Detailed Drawings• Machining• Cooling• Torque Motor Integration

• Actual – Completed prototype

assembly.– Further completed

formal documentation for use by project sponsor for future builds and testing.

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Recommendations for Project Sponsor

• Develop detailed testing procedures for:– Cooling– Variable Tool load Conditions– Worst Case Scenarios– Stiffness

• Investigate inverse torque motor operation (switching stator & rotor orientation).

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Conclusions

• The project culminated with:– An assembled prototype.– Investigated cooling options.– Project poised for future investigations.

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Acknowledgements

• Special Thanks to:– Dr. James Taylor (Faculty Mentor)– Dr. Jacquie Mozrall (Faculty Coordinator)– Mr. John Bonzo (ISE Facilities Manager)– Mr. Dave Hathaway (ME Facilities Manager)– Mr. Rob Kraynik (Senior Mechanical Technician)– Mr. Steve Kosciol (Senior Mechanical Technician)

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Questions