hardinge universal turret 05412- senior design project
DESCRIPTION
Hardinge Universal Turret 05412- Senior Design Project. Project Sponsor: Hardinge Inc. Team Members. Matt Buonanno - ME. Owen Brown - ME. Brian Heeran - ISE. Steven Paul - ME. Brice Wert - ME. Eric Newcomb - ME. Robert Yarbrough - ME. Scope Introduction. Turret Indexing Cutting - PowerPoint PPT PresentationTRANSCRIPT
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Team Members
Brian Heeran - ISE
Brice Wert - ME
Robert Yarbrough - ME
Owen Brown - MEMatt Buonanno - ME
Eric Newcomb - ME
Steven Paul - ME
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Project Scope
Design a simple turret index model
Benchmarking
Torque Motor Integration
Design
Analysis
Prototyping
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Accomplishments
1. Needs Assessment & Benchmarking2. Concept Development3. Design Objectives4. Feasibility Assessments5. Preliminary Design6. Hardinge Review
ID
1
2
3
4
5
6
12/10 1/4
1/4 1/18
1/14 1/21
1/21 1/28
1/28 2/11
2/11 2/18
W S T F M T S W S T F M T S W S T F M T S W S T F M T SDec 5, '04 Dec 12, '04 Dec 19, '04 Dec 26, '04 Jan 2, '05 Jan 9, '05 Jan 16, '05 Jan 23, '05 Jan 30, '05 Feb 6, '05 Feb 13, '05 Feb 20, '05 Feb 27, '05
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Long Term Objectives
Complete project on time meeting technological/performance requirements.
Expanding relations between Hardinge Inc. and RIT
Gather data to establish the feasibility of future torque motor applications.
Demonstrate competitive advantage through the use of Torque Motor.
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Benchmarking
Goals Determine current state of industry Evaluate feasibility of new design
Turret Selection Chosen to represent cross-section of
manufacturer’s offerings Chosen to maintain data compatibility
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Benchmarking Cont.
CriterionPrimary Characteristics
Index TimeIndex Motor TypeNumber of Tooling StationsTurret OperationMax TorqueTotal Turret Weight
Secondary CharacteristicsTooling SystemLive Tooling CapabilityTurret Operating PressureEtc…
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Benchmarking Cont.Indexing Time - Station to Station
Quest 42Quest 51/65Quest 51/65
TT 65Talent 6/45, 8/52Talent 10/78, 8/52A
RedlineYellowline
BTP-50BTP-63
BTP-125BTS-63
BTS-80BTS-100
SM-BR 12/30SM-BR 16/30
SM-BR 20/30SM-BR 25/30
SM-12SM-16
SM-20SM-25
SMA-16SMA-20
SMA-25LS-200
LS-120LS-160
LS-120SVLS-160SV
LS-240SV
BTP-80BTP-100
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1 1.2
Time (s)
Hardinge
Sauter
Pragati
Duplomatic
Loshin
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Benchmarking Cont.
Models Offered vs. Tooling Stations
0
5
10
15
20
25
30
35
8 10 12 16 24
Tooling Stations
Mo
del
s O
ffer
ed
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Benchmarking Cont.
Benchmarking Conclusions New turret design should be designed around a 12
station turret Need to strive to attain an indexing time of less than
0.15 seconds
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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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Torque Motor Technology
Reduced Cost Improved Reliability High Accuracy &
Repeatability High Efficiency
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Torque Motor Benefits
Characteristic: Short compact design Gear unit / belt drives
eliminated Hollow shaft design Few mechanical
components No torsional backlash Increased rigidity
Customer Benefit: Simple integration into the
machine Easy to service (no gear box oil) Improved efficiency Flexible mounting concepts Advantage in mounting and
logistics Improved repeatability Improved control characteristics Low noise system Increased dynamic performance
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Torque Motor Availability Options
4 different rotor models available off the shelf from ETEL, Inc. Selected model based upon:
Project Torque Requirements. Length Heat Generation Cost
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Design Objectives
Technological Attributes Designs must include
the use of a torque motor.
Design shall have as few parts as possible.
Design must include current top plate locking mechanism used by Hardinge in their Quest series turret.
Performance Attributes Designs must equal or
exceed current industry leader performance attributes such as index time, repeatability, and static stiffness.
Designs must result in increased reliability.
Designs shall incorporate adequate cooling of the torque motor.
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Concept Development
Project Scope Redefinition Locking Mechanism Cooling Common Tooling Live Tooling
6 Conceptual Designs Developed
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Design Concerns
Heat generation and removal Thermal Deflection Sealing the motor Bearings Static Stiffness Controller Interface Component ordering lead time
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Technical Assessment
Requirements 1 2 3 4 5 6
Torque Motor 52 64 48 52 56 52
Fewest Parts -30 9 -24 -3 -6 3
Locking Mechanism -9 24 6 15 15 15
Off-shelf Use -4 56 32 24 40 40
Hollow Cavity -2 16 16 -2 12 16
Tooling Load -6 -5 -3 -6 -5 -5
Housing 20 22 20 22 20 18
Control Compatibility -3 -2 -3 -2 -3 -2
18 184 92 100 129 137
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Preliminary Design
Top Plate
Assembly
Top Plate Interface
Housing
Bearings
Support
Structure
Coupler Torque Motor
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System Dynamics
The response of the motor to a command to index the turret between station one and two.
Shown with no tooling on top plate.
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Finite Element Stress Analysis Output from finite element software based on indexing load of 700 N-m torque.
Max Von Mises Stress found to be 22.7 MPa.
Yield strength of steel 285 MPa.
Factor of safety of 10.4.
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Finite Element Stress Analysis Output from finite element software based on indexing load of 700 N-m torque.
Max Von Mises Stress found to be 19 MPa.
Yield strength of steel 285 MPa.
Factor of safety of 15.8.
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Future Plan
1. Detailed Design2. Pilot Builds3. Iterative Problem Solving4. Testing & Analysis5. Hardinge Review
ID
1
2
3
4
5
3/7 3/21
3/21 4/5
4/5 4/20
4/20 5/5
5/5 5/13
S T F M T S W S T F M T S W S T F M T S W S T F M TFeb 27, '05 Mar 6, '05 Mar 13, '05 Mar 20, '05 Mar 27, '05 Apr 3, '05 Apr 10, '05 Apr 17, '05 Apr 24, '05 May 1, '05 May 8, '05 May 15, '05