BackgroundCooper Crouse-Hinds Industries is a leader in the manufacturing of luminaires, an encased lighting system, for hazardous locations. These luminaires are placed in environments in which they are subject to harsh vibration disturbances. Luminaires must meet the testing standards set in UL 844, which include vibration RPM and displacement, apparatus setup, and test duration. The company is currently using an outdated testing apparatus and would like to incorporate improvements into the new design. This project is a continuation of P13471 which started the process and has already built the eccentric drive mechanism. The goal of P14471 was to finish the test apparatus by adding the frame, motor, and control system.

Left to right: Luminaire; CCH’s current apparatus; The eccentric drive mechanism

Acknowledgements

Joe Manahan – Cooper Crouse-HindsKevin Wolfe – Cooper Crouse-HindsMike Zona – MSD Team GuideDr. Varela – RIT Faculty AdviserJan Maneti – RIT Sr. Mechanical TechnicianRob Kraynik – RIT Sr. Mechanical TechnicianRyan Crittenden – RIT Sr. ElectricianLarry Meyer – RIT Electrician

Conclusions•All engineering metrics met during preliminary testing at RIT•Final testing to occur at Cooper Crouse-Hinds in Syracuse, NY

•What would we do differently?•Review the previous MSD team’s work more thoroughly before planning•Verify existing parts match CAD models

•Lessons Learned:•To effectively communicate between both team members and others helping with the project.•To compromise on differences of opinions between team members•To work together to meet internal deadlines•To clearly define team member roles•To effectively troubleshoot unforeseen complications

Luminaire Vibration Test Apparatus IIP14471

Design Specifications and Process•The House of Quality Matrix links the Engineering Requirements to the Customer Requirements, using a 1-3-5 priority scale (5 = highest).

•Design process:1. Functional decomposition identified the different functions2. A morph table was used to brainstorm options for each3. Pugh charts were used to select the best option for each

Final Design The final concept is made up of a painted steel frame, a vertical 3 phase 240 VAC motor, a drive belt system with a belt guard, an encoder, a dial gage, an LCD screen, and an emergency stop button. These components fulfill the requirements found in the House of Quality Matrix.

•Setup improvements from the P13471 Design:•Access holes added to eliminate unnecessary disassembly•Finer set screw for better more precise adjustment•Quick change conduit system•Reduced setup time by 67%

Image of the bolt access holes

Brett BillingsIndustrial and Systems Engineer

Nicholas GrecoMechanical Engineer

Ashley WaldronMechanical Engineer

Claire KobalMechanical Engineer

Ronald JimboElectrical Engineer

Ryan SeligElectrical Engineer

Jacob GardnerMechanical Engineer

Image of the hex wrench access hole for the set screw

Set ups made for various sizes

CAD model of final assembly for MSDI Final assembly for MSDII

Top 5 requirements:

•Displacement = 1/32”• Vibration = 2000 RPM• Duration = 35 hrs• Safety• Ease of Use