Team K-TRON

Team Members:Ryan Vroom

Geoff CunninghamTrevor McClenathan

Brendan Tighe

Outline• Project definition• Overview of design process

> Important decisions made with rationale

• Concept selection> Concept chosen with validation

• Implementation plan• Final remarks

Project Scope

» Design a testing apparatus to produce external vibration to the SFTII load cell under specific loading

Metrics:• Apply mass of 120 kg in 6

increments• Frequency range: Achieve 120 Hz

(112 Hz “magic number”) and as low as possible

• Acceleration range: 0.05 g – 0.3 g• Max displacement of 1 mm

SFTII

Adding Value to Sponsor’s Business

• Exact modeling can increase load cell accuracy-Filtering out environmental noise

• Allow K-TRON to remain as the “World’s number one feeder company”

Subsystem Design

Load Cell Testing Apparatus

Actuator Application of Mass Frame Design

Include Flexures/Adaptable to both

Load Cells0-120 kg

Upper Frequency Range >112 Hz/

Achieve Range of GForces/Repeatable

Benchmarking: ActuatorBose Electro-Magnetic Linear Drive:• Cost: ~ $35,000.00!• Production time ~ 3 years

Parker Linear Actuator:•Can only work up to 100 Hz •Requires load relieving•Expensive: Actuator/Controller combo costs ~$11,000.00

Benchmarking: Actuator

BEI Kimco Voice-Coil Linear Actuator:

• Max load of 13.5 kg

Piezomechanik Piezoelectric Actuator:•Will need a very powerful controller (1000V output) to work•Actuator/Controller combo= $13,880

Benchmarking: Chosen Actuator

• After checking calculations, determined lower voltage actuator could be used

d=amplitude

a=gravitational force

Results Determined:

» Low end frequency at low g force – 27 Hz at 0.05 g’s

» Low end frequency at high g force – 68 Hz at 0.3 g’s

daf

4

1

Benchmarking: Chosen Actuator

Piezomechanik Piezoelectric Actuator, PSt 150/7/40 VS12:

• Lower voltage requirement 150 volts• 40 µm displacement• Max. load of 1000 N must use 100

kg instead of 120 kg• Actuator: $699.00• Controller: + $4990.00

$5689.00

Actuator: Cost Analysis

Actuator Cost Analysis

     

Concept Description Cost

1 Electro-Magnetic Linear Drive $35,000

2 Parker Linear Actuator $11,000

3 BEI Kimco Voice-Coil $900

4Piezomechanik Piezoelectric

System (1000 V) $13,880

5Piezomechanik Piezoelectric

System (150 V)

$5,689

Benchmarking: Load Application

Machined steel:• Cost of material greater than $115 per

20 kg mass• High machining timeMachined lead:• Toxic issues• Cost of material greater than $140 per

20 kg mass• High machining time45 lb weights:• High resultant moment

25 lb. cast plates:• Small, circular shape reduces unwanted

moment forces during testing• Pre-bored center hole reduces

machining time• Low cost of $13.99 per 11.3 kg

Benchmarking: Chosen Loading Application

Benchmarking: Chosen Loading Application

• Weight selection determined center rod:– 1.25 in. acme threaded rod-rod diameter

ideal for existing hole and cost– Acme threaded collar to minimize movement

of weights during testing – Analysis of rod under worst case scenario,

assume cantilevered beam w/ distributed load

» Safety factor of 5.7

• Center hole diameter of weights, 2-1/32 in.– Machine aluminum inserts that are press-

fitted - provide slip fit between rod and plate

Loading Design: Cost AnalysisMass Loading

Parts:      

# Description Cost Ea. ($) Cost ($)

12 25 lb. weight 13.99 167.88

1 Acme Threaded Collar 19.78 19.78

13 ft. Acme Threaded

Rod 40.43 40.43

12 Weight Inserts 0 (scrap) 0

    Total Cost ($) 228.09

Machining:    

Time (hrs.) Cost per hour Cost ($)

~20 free 0

Overall Cost excluding shipping ($) 228.09

Exploded System Design

1) Base Plate2) Steel Supports3) Steel Struts4) Support Blocks5) Flexure6) Flexure Connector7) Weight Post8) Rod Connecting screw9) Load Cell10) Actuator Connecting Screw11) Actuator12) Actuator Stabilizer

12

3

4

56

7

98

11

10

12

4

Completed System Design

Frame Design: Steel Support Tubing

Main structural parts made of 1008 steel• 24” x 24” x 1” base plate• 1” x 1” square tubing• Support blocks

– All steel parts welded to increase rigidity

1008 steel properties:• Elastic Modulus ~ 29,000 ksi• Tensile strength ~ 49.3 ksi• Yield Strength ~ 41.3 ksi

Base plate

Square tubing

Support block

Frame Design: Finite Element Analysis

•Steel square tube with 80 N shear load at tip

•Maximum deformation of 9.42e-4 in.

•Factor of Safety > 9.6

Frame Design: Flexure

Flexures connect threaded rod to steel supports• Reduces lateral motion of the rod• All applied stresses are tensile

Frame Design: Finite Element Analysis

•Stainless steel flexure device with 45 N tensile load applied at right cutout

•Maximum deformation of 4.26e -3 in.

•Factor of Safety > 8.7

Frame Design: Actuator Support

After speaking with Dr. Sun on possible failure:• Actuator support will be bolted to base plate

using the four pre-existing screw holes• The support will keep Actuator from buckling

under high loads

ActuatorActuator support

Frame Design: Load Cell/Actuator Connector

•Steel bolt body with 1000 N compression load applied at center gives factor of safety > 4.17

•Effective loading difference on face is 471N

•Maximum deformation of 1.5e -5 in.

Frame Design: Cost Analysis

Frame System Cost Analysis

Parts:      

# Description Cost Ea. ($) Cost ($)

1 Steel Plate 421.63  421.63

1Steel Square

Tube 19.43 19.43

2 Flexures 0 (in house) 0

1Alum. 6” x 6”

Block 0 (scrap) 0

1Alum. Flexure

Connector 0 (scrap) 0

5 M8 Bolts 0 (in house) 0

8 M4 Bolts 0 (in house) 0

    Total Cost ($) 441.06

Machining:

Time (hrs.) Cost per hour Cost ($)

~20 free 0

Overall Cost Analysis

Mass Loading Cost

All Supplies $228.09

Frame System Cost Total System Cost

All Supplies $441.06 $6,358.1

5

Actuator System Cost

All Supplies $5,689.00

Implementation Plan• Test the as-built apparatus to

complete validation of design (in process)

• Manufacture SFTIII adaptation mount

• We will hand-off the project to K-Tron so they can test their load cells

Acknowledgements

• Thank you to our sponsor at K-Tron:– Tim Baer– Jim Foley

• Thanks to our advisor:– Dr. Keefe

• Special thanks to:– Steve Beard

QuestionsExploded View

Frame Design: Finite Element Analysis

•Steel SFTIII adapter support with 720 N applied load at attached face

•Maximum deformation of 2.447e-4 in.

•Factor of Safety > 100 with full load (1600 N) applied