drop testing apparatus team members: deatly butler mark clouse chris dux kris honas shaun scott drew...

Drop Testing Apparatus

Team Members: Deatly ButlerMark ClouseChris DuxKris HonasShaun ScottDrew Stephens

Client: Itron, Inc. Brian Priest

Technical Advisors: Steve Beyerlein

Mike Severance

Presentation OverviewCustomer NeedsMechanical Components Table Drop Design Orientation Devices Height Adjustment

Electrical Components Data Acquisition CPU Interface Software Camera

CostsRecommended DesignWork RemainingQuestions?

Needs

Repeatable Impacts ( 45 +/- 5 deg)

Adjustable Drop Height (18-60 inches)

Portable (Wheels)

Short Setup time (<1 min)

Video Data Acquisition (automatically named and stored)

Mechanical Components

Table Drop Design

Orientation Devices

Height Adjustment

Table Drop Design Using Pneumatics

Fast Acceleration

Simple

Inexpensive

Non Electrical

Long Life

Table Drop Design #1Frontside Pneumatic

PROSOne Pneumatic

Four Linear Bearings

CONSTable Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects

No Initial Vertical Motion

Table Drop Design #1Frontside Pneumatic

Table Drop Design #2Backside Pneumatic

PROSOne Pneumatic DeviceFour Linear BearingsPneumatic Does Not Interfere With Table Space

CONSTable Only Rotates – Could Potentially Cause Slight Rotation On Dropped ObjectsNo Initial Vertical Motion

Table Drop Design #2Backside Pneumatic

Table Drop Design #3Double Pneumatic

PROSVertical Pneumatic Prevents Rotation on Test Device

CONSMore Linear BearingsMore Pneumatic CylindersIncreased Chance of System Malfunction

Table Drop Design #3Double Pneumatic

Orientation DevicesCradle Block Design

PROSSimple Block Design

Inexpensive

Simple Operation

Minimal Setup Time

Easily Removable

CONSWorks Best for Smaller Devices

Additional Testing Required to Confirm Functionality

Orientation Device Design #1Edge Testing

Orientation Device Design #2Corner Testing

Orientation Device Design #2Corner Testing

Height Adjustment Design #1

Manual Hand Crank

ProsSmooth Adjustment For Any HeightAble To Raise And Lower Heavier Loads.

ConsSlow AdjustmentInvolved Manufacturing ProcessIncreased Cost

Height Adjustment Design #1Manual Hand Crank

Height Adjustment Design #2

Pin and Collar ProsQuick Adjustment

Predetermined Standard Heights

Secure Locking Mechanism

ConsOperator Must Be Able To Support Weight Of Table And Mechanism

Height Adjustment Design #2Pin and Collar

Electrical Components

Data Acquisition

CPU

Interface

Software

Camera

Importing to a PC

Video for each test will be imported to a PC by using GPIB interface.

Instrument controlled by Labview.

Automatically will name and store video clips for each test.

CPUZero Footprint PC - $500 (w/o monitor)

LCD PC - $1000

GPIB Interface

General Purpose Interface Bus

Standard interface between instruments and controllers from various vendors.

8-bit parallel communication.

5 bus management lines (ATN, EOI, IFC, REN, & SRQ)

3 handshaking lines.

8 ground lines.

LabVIEW Software

Uses VI’s

(Virtual Instrumentation)

Imitates physical instruments.

Cheaper than Hardware.

Modular Program design.

Will be used with GPIB to control the video.

Video Camera

Handheld will fall in about 0.5 seconds

Video below 200 fps may be able to capture enough images

Acquisition (fps)

Distance between images

192 ½ inch

96 1 inch

48 2 inches

Camera Option #1Machine Vision System

• Pros High Speed Acquisition

(>10000 fps)

• Cons Small Picture Area

(1.5” x 1.25”) Designed as an Automatic

Inspection Sensor Doesn’t capture video

Camera Option #2High Speed Video Camera

• Pros Easily interfaced and controlled

with LabVIEW software Could be tested with lower

quality cameras• Cons

High Cost Low Acquisition Speeds

(< 500 fps)

Mechanical Costs

Pneumatic Cylinder (1-3) $50eaShafts (1-2) $40eaRaw Materials Sheet Metal $70 Metal Tubing $20 Misc. Hardware $60

Linear Bearings (2-6) $60eaSpur Gear and Rack $200Valves and Fittings $100Compressor (Optional) $300Total ~$1400

Electrical Costs

Computer ~$1500

GPIB $300

Misc. $200

Camera ~$800

Recommended Design

Single Pneumatic Operation (Back Side)

Track Mounted Block Orientation Device

Pin and Collar Height Adjustment

LCD PC or Laptop

GPIB Interface

LabVIEW Software

Work RemainingSpring 2006

Detail Design: (Jan. 9th 2006 – Feb. 1st 2006) - Order parts. - Assess Drawing package. - Complete drawing package.

Fabrication: (Feb 2nd 2006 – March 20th 2006) - Build product.

Validation: (March 21st 2006 – April 20th 2006) - Debug and fix product. - Validate performance of product. - Draft final project report.

Delivery: (April 21st 2006 – May 9th 2006) - Archive project documentation. - Deliver product. - Write final report.

Our Questions for ItronWill ~200 fps be enough for the video?

Computer?

Camera?

GPIB?

Labview license?

Questions?