High Torque Test Stand

05413 Aditya - Oriana - Don - Jesse - Ron - Dana - Geoff

Lightnin SPX

2

Team Members

Aditya Sanghi, IE - Project Leader

Dana Harris, IE Ron Mendolera, EE Jesse Warner, EE

Dr. William Scarbrough, Project Coordinator

Geoff Cusano, ME Oriana Starr, ME Don Strong, ME

Dr. Alan Nye, Project Mentor

3

Project Overview

Sponsor: Lightnin SPX Manufacture pumps, mixers, etc. Gear reducer production moved to

Rochester, NY from Wytheville, VA Evaluate final assembly & testing processes Identify & solve inefficiencies

4

700/800 Series Overview Sizes Configurations Hollow & Solid shafts Weight Assembly process

Mixer

Gear Reducer

5

Assembly Stand

Side

Front

6

Assembly Rotation

Rotated 90° - front

Rotated 90° - back

7

Spin Test & Assembly Area

8

Torque Stand

Side

Front

9

Project Mission Statement Identify and eliminate process inefficiencies

Redesign & relocate the torque test stand Propose process flow improvements Adhere to constraints

time, cost, footprint & height Avoid hazardous workstations

10

Initial Improvement Ideas Obvious

Reduce long travel distance to torque test Fork truck

Reduce travel time between stands Crane Fork truck

“Homerun” 3-in-1 stand Assembly, spin test, torque test

11

Time Studies - Plan Identified largest areas for improvement

1) Torque test stand setup: 135 min

2) Spin Test Stand setup: 25 min

3) Walk time during large assembly: 20 min

4) Transportation to torque test : 12 min

Justify discontinuing development of 3-in-1 concept

Torque test stand setup: examine further

12

Eliminate 3-in-1 Concept Impossible to meet yearly production volume

497 min. of build time per reducer, only 1 stand Projected costs were prohibitive Much more risk

Brand new, unique design If the all-in-one stand breaks down, entire process halted

Customer visits interrupt production Can only build one unit at a time

13

Input from Lightnin

Meeting with Management: December 2004 100% torque testing – Warranty issues Remove waste Relocate torque stand – reclaim dock

Ultimately: accomplish torque AND spin test in the time it currently takes just to spin

This would further encourage 100% torque testing

14

Final Improvement Ideas Perform spin test on torque stand

Eliminate spin test stand & transport time Reduce setup time for torque stand

Adjustable input motor Universalized couplers with splines Oil tanks with heater Simplified operator controls

Reunite small & large assembly areas

15

Final Design Concept Current large assembly

area Use current assembly stand Redesign the torque test

stand Reduce height & footprint Torque AND spin test

capacity Make the process more

efficient Standardize controls: direct

labor NOT technician

16

CURRENT Torque Test Stand Setup Align shafts: motor output to reducer input

Manually adjust reducer height Spacer plates

Adjust distance: motor output to reducer input Bolt input shaft

Couple the reducer’s output shaft to the slave unit Measure, bolt

Heat the oils Cannot begin until setup is complete

Manually adjust air pressure regulator for torque control

17

NEW Torque Test Stand Setup

Align shafts: motor output to reducer input Automatically adjust input motor height Universal mounting plate Scissor lift with elevation control

Adjust distance: motor output to reducer input Rail, keyed couples

Couple the reducer’s output shaft to the slave unit Splined couples

Heat the oils Can begin before the reducer is craned onto the stand Automatic electronic control

Adjust air pressure regulator for torque control Automatic electronic control

18

Inline Input Motor

Same arrangement as current Components

25 HP motor 40:1 Reducer Clutch 60 HP motor Torque Sensor

Existing Mount

19

Horizontal Movement Function

Allow input motor assembly to slide accommodate 8 different input configurations

Rails Specs

Weight Capacity Moment Capacity

Actuator Specs

Overcome Friction Forces

UNI-LIFT

M1

Linear Actuator

SKF

Profile Rail

Guides

20

Vertical Movement Function

Allow input motor assembly to adjust to 8 different input heights

Hydraulic Lift Specs

Weight Capacity Transverse Load Capacity 3’ X 7’ Platform Mounting Substructure

LK Goodwin

Tandem Hydraulic Lift

21

Input Couple Function

Connects Input Motor to Input Shaft of Testing Reducer

Improvements Two Keyways reduces

alignment. No Bolting reduces

setup time.

22

Output Couple Function

Connect output shaft of tested reducer to slave

Design Time Savings

Indexing No Height Adjustments

Specs Universal Female

Female Spline

700 Series Spline800 Series Spline

23

Coupling Analysis Stress Analysis

782/882 Coupling Tmax = 310,000 in-lb

ShaftHollowStressSheardD

TrK

)(32

44

ShafSolidStressShearD

TrK

4

2

StrengthShearss ysy 577.

StressShearAllowablessyall 75.

780/880 2.125 3.175 10620 1.05 5.20 1.2 9271 3.8781/881 2.250 3.300 14160 1 5.20 1.2 10892 3.2782/882 2.750 4.000 21500 1.2 5.20 1.2 11342 3.1783/883 3.500 4.900 18010 1.3 5.20 1.2 6107 5.7

(psi)

T (in - lb)

ID (in)

Unit F.S.Kd2 Kt

3 Km4OD

(in)

24

Fatigue Analysis

Fatigue Failure Analysis:

Surface Factor Size FactorMachined Surface

a 2.7 Kb 0.75 For d > 2" In Torsion

b -0.265Ka 0.81

Load Factor Stress ConcentrationFor Torsion

Kc 0.577 Ke 1Stress Concentrations taken into account in Stress Anylysis

Sut 95 kpsi Minimum Tensile Strength

Se' 47.88 kpsi Endurance Limit =.504Sut

Se 16.73625 kpsi 780/880 9 12 4a 436.7913 781/881 11 6 2b -0.2361 782/882 11 5 2

783/883 6 72 241. Number of Cycles in millions of cycles

# of Test in life

load (kpsi)

N1 Unit

Se

Sa ut

29.0 )

9.0log(

3

1 2

Se

Sb ut

KaKbKcKeSeSe '

b

aN

1

25

Spline Development 30

o Flat root profile

Size restriction 6/12 Pitch

Analysis

Ss1 2035.0 20000 psi 9.83

Sh1 2918.0 20000 psi 6.85

Sp1 5239.7 20000 psi 3.82

Sc2 301.6 1500 psi 4.97

St3 7049.1 22000 psi 3.12

Shear Stress under root of external tooth of solid shaft

Shear Stress under root of external tooth of hollow shaft

Shear Stress at Pitch Diameter of Tooth

Compressive Stress on side of Spline

Factor of Safety

DescriptionStress Calculated Allowable*

Bursting Stress on Spline

fre

as KD

TKS

3

16

fhre

areh KDD

KTDS

44

16

fe

map tKDNL

KTKS

4

fe

amc hKDNL

KTKS

9

2

LDt

TS

wtan

1

1000000

212.0656.1 222

2riDDrpm

S oi

YLD

TS

e23

4

f

mat K

SSSKKS 231

26

Overall Structure Function

Support loads Set height for slave and

new couplers Universal mounting plate Actuator mount

Design Two tier design Footprint: 9’ x 19’ Clearance

27

Stand Analysis Member Analysis

Critical members Size Recommendations Mount Requirements

Actuator Assembly Universal Plate

Loads Weights Output Torque

28

Controls

Oil temperatures Elevation of input motor Torque

29

Oil Temperature Control Heat oils up to operating

temperature before test unit is place on stand

Tanks are insulated and temperature-controlled

80-gallon tank for lube oil 50-gallon tank for brake

transmission oil

30

Elevation Control

Eliminates the need to make manual height adjustments with spacer plates.

Uses a programmed PLC with a position sensor in the feedback loop to control the hydraulic pump motor.

31

Elevation Control AlgorithmSelect Model:

1) 750/8802) 781/8813) 782/8824) 783/883

Select Reduction:A) DoubleB) Triple

D/A ConversionInput: Output: 1A 0V 1B 3.363V 2A .457V 2B 4.521V 3A 1.219V 3B 5.903V 4A 2.474V 4B 7.838V

X

CompareY, X

Open Relay

Close Relay

Hydraulic Pump Motor

Position Sensor

(20mV/mm)

Position

YY >= X

Y < X

Model Reduction

Height relative to 780/880 double reduction (mm)

Position sensor output voltage at this height (V)

780/880 Double 0.00 0.000780/880 Triple 168.00 3.363781/881 Double 22.86 0.457781/881 Triple 226.06 4.521782/882 Double 60.96 1.219782/882 Triple 295.15 5.903783/883 Double 123.70 2.474783/883 Triple 391.90 7.838

D/A Conversion Table

Position Sensor

32

Eliminates the need to make manual adjustments of air pressure regulator to control brake pressure which determines torque.

Uses a programmed PLC with a torque sensor in the feedback loop to control an electronic air pressure regulator.

Torque Control

33

Torque Control Algorithm

No ChangeInitialize to

0V (3 psi)

Voltage Source

V1

Compare V1, 5.3V (~65 psi)

Start/Stop Process

Operator Personnel

X

Applied Torque

Pneumatic-Controlled Brake

Voltage-Controlled Air Pressure Regulator (85.5 mV/psi)

Compare Y, X

Increase 85mV

Decrease 85mV

Digital Input of Desired Torque.

Enter

D/A Conversion (250 uV/in. lb)

0 V

Torque Sensor250 uA/in.lb

Y

Y = X

Y > X

Y < X

V1 < 5.3

V1 > 5.3

Stop

Start

Electronic Air Pressure Regulator

Torque Sensor

34

Electronic Database

Eliminates the need to search through hard copies for previous test data.

Visual basic used to create a user-friendly Microsoft Access database

35

Old vs. New Process Comparison Estimated time saved: over 1.5 hours!

TaskOld

EquipmentTimes (min)

New Equipment

Times (min)

Time Saved (min)

Height Spacer plates 16 Adjustable lift 0.50 7.50

DistanceFlanged input shaft

10 Rail & couple 6.25 11.75

CoupleFlanged couples

21 Spline 0.33 20.67

Oil After setup 60 During setup 0.50 59.50

107 7.58 99.42

36

Final Layout Options

Two locations Current large assembly “Back bay” area

Options1) Just replace spin stand with torque stand

2) Move ALL final assembly operations to the back bay area

37

Layout Option 1

Easiest to implement, less change Rearrange assembly stand Still have wasted transport time from having

small & large assembly separated

38

Current Large Assembly

39

Redesigned Large Assembly

40

Layout Option 2 Requires greater willingness to change Move all to back bay, reunites small & large

assembly areas, eliminates wasted transportation time

Slight downtime, but current production volumes/build times indicate that it could be done during off-times without delaying shipments

More room to work, both for reducer assembly, and the areas near current large assembly

Flow

41

Back Bay Layout

42

Simulation Results of simulation, given the new design Greatly reduced torque test time, not enough

to accomplish ultimate goal Still takes 20-30 minutes longer to do torque &

spin vs. just spin May still be worthwhile to implement the

design Reclaim dock, improve flow, save time Future Lean activities may make up the remaining

time Standardization, kaizen, etc.

43

Cost of Implementation BOM

Cost to Build the stand - $10,000 Sum total = 35,368

44

Incremental Revenue/Savings Incremental Revenues

Revenue by selling extra torque testing as a service (20 units @ $2k/unit)

Revenue by marketing selling extra units due to improved reliability (10@$30k)

Incremental Savings Warranty Costs saved due to the 100% testing

(25k in Yr2 and 50k thereafter) Labor Savings (3 hrs @$75/hr /torque tested unit) Moving from the shipping dock ($10/sq ft)

45

Final Recommendations Build stand Lean, kaizen, process improvements

activities

“It is very difficult early on to turn the flywheel of improvement, especially from a dead stop, or worse yet a negative rotation.” Good to Great by Jim Collins

46

Acknowledgments

SPX Process Equipment, Lightnin Division Dave Engel, Lightnin SPX Al Aponte, Lightnin SPX Jeff Flint, Lightnin SPX Production staff at Lightnin Dr. Hany Ghoneim, ME Department Dr. Elizabeth DeBartolo, ME Department Bob Thomas, Rochester Gear

Questions

?

48

Initial Concept Development Transportation

Rail system, wheels, rotary arm, trolley, etc. Slave unit

Pump, two gears, electric generator, etc. Attachment of test unit to stand

Clamps, magnets, pins, bolts, etc.

49

Needs Assessment

Order Qualifiers & Winners Cost to build SHALL NOT exceed $200,000 Return On Investment Labor savings Design software to be compatible with Autodesk

Inventor Utilize existing equipment

Scope

50

Simulation Model 780 781 782 783

Current Value added time 221.97 223.83 230.3 222.85

Non Value added 26.91 27.23 40.27 40.84 Other 25.47 25.92 43.08 40.52 Transfer 6.47 6.49 5.66 5.27 Wait 384.32 400.74 427.22 398.36

Total 665.15 684.23 746.54 707.86

780 781 782 783

Proposed Value added time 297.49 297.57 304.19 303.29

Option 1 Non Value added 33.98 33.99 28.95 29.1 Other 0 0 4 3.97 Transfer 12.03 11.97 14.04 13.81 Wait 452.3 464.8 469.68 503.56 Total 795.81 808.33 820.86 853.73

780 781 782 783

Proposed Value added time 297.29 297.49 303.63 304.5

Option 2 Non Value added 34.03 34.03 29.04 28.91 Other 0 0 0 0 Transfer 11.02 11.01 10.97 10.98 Wait 442.61 460.97 473.1 473.68

Total 784.96 803.51 816.75 818.07

Compare total times across all options

0100200

300400500600

700800900

780 781 782 783

Reducer Type

To

ta T

ime

(Min

)Current

Option 1

Option 2

51

Slave & Braking

Reuse current slave, Replacements small enough didn’t meet spec Reduce cost of project

Current brake Works well Reduce cost

52

Process Flow

AssemblyStand

TorqueTest

SpinTest

Shipping100% 80%

20%

Distance ~ 500 ft

53

Initial Concept Development Level 0: Station Setup Options

Three Stations

Two Stations

One Station