SANDIA M.A.S.T.Miniature Automated Shock Tester

Design ChallengeSandia National Labs requires their equipment to be tested under shock conditions of 1 to 200 g’s, and within a time constraint of 1 to 10 milliseconds. Our device simulates these conditions and records the data for subsequent analysis. Commercial shock testers are far too large and are not cost effective for our client.

Hickory Base•Strong and durable •Gives a classy touch to the product

Linear Motor and Track•From Baldor Motion•Provides 16.5 [lb] continuous force•220 [lbf] peak value

Shock ResponsesThrough preliminary testing and experimental math modeling, shock pulses were obtained that matched the client’s specs. By varying the material used to dampen out the response, various pulses were obtained.

Mechanical SystemsAn arm mounted to the linear motor provides the force transmitted to the drop table through two steel rods. This impacts a visco-elastic damper with a specific stiffness. Special bushings press fit into the drop table alleviate tolerance issues and resonance.

Electronic/Control SystemsThe linear motor is controlled though a commercial motor controller that uses hall effect and linear encoder feedback to track the motor's position. The impact waveform is monitored though a piezoelectric accelerometer using LabView as the user interface.

Motor Controller•Provides 3 phase power to the linear motor

Hold-Down Fixture•Mounts test sample to the table•Variable Configurations

Special Thanks To:•Project Sponsor: Sandia National Laboratories•Project Advisor: Dr. Steven Beyerlein•Graduate Student Mentor: Kysen Palmer•The graduate students of Idaho Engineering Works

Control Housing•Provides stability to the structure•Houses motor controller and other electronics

Fernando De La Garza, Mike Brewster, Cameron Hjeltness, Travis Nebeker, Nicholai Olson

Visco-Elastic Damping Materials•Dampens shocks to specific amplitudes•Interchangeable with other stoppers •Client can easilly fabricate on site

Drop Table•Solid aluminum table to mitigate resonance

Linear Encoder•Detects table position to within 15 microns