final design review

Final Design Review: Integrated Designs

Team 14: Solution Analyst: Edgar LozanoSafety Officer: Bernie GabrielChief Financial Officer: Nicholas BalabanDesign Engineer: Josh McHugh

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Mission Statement

Integrated Designs aims to create a functional and viable solution to Cal Weld’s Position welder by incorporating a system to engage and disengage the turntable. Our project plans to assist the welders for a more comfortable and efficient way of working to provide their consumers with quality products.

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About Universal Calweld

● Serving the industry for over 30 years located in Fremont, California

● Builds high purity assemblies and integrated systems for high technology industries

● Provides manufacturing and engineering service to a variety of industries

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Project BackgroundSponsor: Greg Rozema

Faculty Advisor: Ala Qattawi

● Turntables need an integrated clutch

● Allows welders to freely rotate a part or assembly

● High frequency motors interfere with welding equipment

4http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf

Problem Description

● Industry standards ○ High surface polish of 5-10 Ra○ Weld integrity of leaking gas at no greater than 10–9 cm3/s

● Turning the motor on and off causes electromagnetic interference with the TIG welding equipment

● Motor must be on in order to rotate the component being welded○ No free rotation

● Integrated Clutch will solve these issues

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Current System Layout

CobraTurn Digital Turntable Framework

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http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf

Constraints/Requirements

● Integrated clutch must fit within the given housing assembly

● Turntable must run correctly with maximum 10RPMs and 300lb max load

● Must be able to rotate freely with the integrated clutch

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Constraints/Requirements

● Must not interfere with turntable gas lines

● Must use reliable steels to prevent frequent maintenance

● Design has to be cost effective

8http://www.mkproducts.com/support/Manuals/091-0677D_CobraTurn_DigTurntable_Lores.pdf

Solution Implementation

● Clutch will be implemented above the worm gear○ Sharing the same shaft

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● The shifter fork assembly will be on a shaft parallel to the clutch

Modifications to the Current System

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Design System- Dog Clutch

● Dog Clutch will have set of teeth to mate with the worm gear

● C-clip will be used to keep worm gear in place

● Dog clutch will be connected to the turntable shaft through splines

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Design System- Lever

Engaging and Disengaging Dog Clutch:● Shifter fork is fixed to an external

shaft○ Locks in place using a detent ball

and spring mechanism

● Shifter fork → Dog Clutch

○ Actuates the dog clutch to engage the worm gear driven by the motor

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Implemented System Design

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Equipment List

● Dog Clutch● Modified Worm Gear● Shifter Fork● Shaft for Fork● Plate for Lever Assembly● Detent ball/Spring● C-clips● Machined Splines● Bolt for lever plate

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Design System Cost Analysis

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● Cost of dog clutch and modified worm gear: $1950

Full Implementation

● Assuming Cal Weld Purchases enough materials for 50 prototype assemblies, it will cost a total of $7,335 to implement our design.

● Assembly time: one hour per turntable, assuming all parts are made

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Stress Analysis

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Pressure on Fork Shift: 10 N/m2

Prototype Description

● Lever assembly will use a pin instead of J-B Weld to hold the shifter fork

● Both the worm gear and dog clutch will be made of 440 stainless steel

● C-clip will be placed on top of the worm gear

● Components are to scale except the turntable shaft and housing assembly

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Prototype Simulation

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Prototype Rationale

● Prototype provides:○ Visual representation for our final design○ Technical understanding of our problem

● Simulating manufacturability○ Machining○ Purchasing

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Measures Taken

● Quality: Stainless steel tested to shown positive for desired application

● Reliability: Analysis of tolerances, stresses, and lifetime (AGMA Equations)○ Proper lubrication to prevent grooves from getting worn out

● Safety: Depth of splines and machine shop protocols○ Dog clutch lever designed to eliminate any concerns

● Changed shape of grooves on worm gear

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Project Deliverables

● Prototype dog clutch lever design (3D Printed model)

● CAD Drawings including dimensions

● Mechanical Installation Guide● List of Components needed to

create the design● Final Report

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Future Recommendations

● Keep all tolerances to about ±0.5mm

● Maintain proper lubrication

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http://www.sprint-uk.com/

Questions?

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http://gph.is/1gSo4RG

final design review

Documents