team 14 john armitage douglas devoto brian polkowski marykate wioncek southco vibration fatigue...
TRANSCRIPT
TEAM 14John Armitage
Douglas DeVoto
Brian Polkowski
Marykate Wioncek
SOUTHCOVibration Fatigue Tester
SouthcoGlobal manufacturer
of access hardware solutionsFasteners, latches,
hinges, handles, etc.
Industries served:Computers,
electronics, automotive, aerospace, marine, etc.
Project GoalDesign and build a
vibration fatigue testerSimulate off-
highway service environment
Test compression latches
Business Benefit
Quality assuranceProvide quality test
data to customerAids in proper latch
selectionProduct
improvementAccurate data on
failure conditions
Customers/Wants
Top 3 Wants:- Accurate Data- Adaptable to Different Kinds
of Latches- Adjustable Forces and Hz
Current State/Future StateOutsourced to testing company
Used linear actuators (not designed for high speed testing)
BenchmarkingExisting vibration testers
Shaker tablesInstron machines
Other benchmarkingActuatorsHammer drills
2 secondary springs
Roller followerAlignment rodsCam Follower
Bracket
Subsystem: Secondary Spring System
Subsystem: FrameSafety Shield
Polycarbonate80/20
Machine Base Base Plate FrameMotor MountAlumilite Covers
Prototype Testing ProcedureUsed dummy latch with built in force sensorAdjusted to 100lb preloadRan machine with calibrated sensors at
several speeds up to 3600 rpm to verify that the prototype achieved 3000N of force
Latch Testing ProcedureBolt latch plate to baseAdjust spanner nut to
apply the appropriate initial loadConfirm correct load
using labview softwareTurn on motor and
change to correct speed
Record number of cycles to failure
Validation of Metrics
Goal Results
Adjustable to 60Hz √
Adjustable initial load up to 100lb √
Adjustable Dynamic load up to 3000N √
± 5% of desired load √
Additional Test ResultsMeasurement of Decibels
OSHA standards state that a worker can be exposed to 90 dB for an 8 hour work day.
Hearing Equipment is required in Southco testing facilityrpm dB
600 74.81200 79.81800 82.82400 84.33000 84.83600 88.1
Project CostsMechanical Components Cost
Motor $4,000 Springs $170 Machine Table $1,300 Drive Belt $250 Linear Bearings $400 Roller Follower $200 Pillow Blocks $300 Cam Bushing $200 Raw Material $1,700
$8,520
Software Components CostForce Sensor $400 Accelerometer $365 Controllers $4000
$4,765
Total Costs CostMechanical Components $8,520 Software Components $4,765Machinist Time $6,500 Engineering Time $50,000
$69,785
Cost AnalysisFinal cost of testing
mechanism to Southco $15000
Cost of latch testingPrevious testing - $625
per latchCurrent testing – Cost
of LatchSave on shipping costsFaster data acquisition
Implementation PlanHand off of Prototype to Southco
Representatives: 12/4Plans:
Move Prototype to Southco facilityBegin testing of latches as soon as possibleProduce machines for other Southco facilities
AcknowledgementsThank you to our Southco Sponsors:
Ratnesh DwivediRon MagidsonMark DiAntonioJesus AlbillosAl Frattarola
Thank you to our Advisor:Mr. Nate Cloud
Special Thanks to:Ed Cicutti
Resonance
w=sqrt(K/m) m kg k N/m w rad/s f hertzf=w/2Pi 4 400000 316.2278 50.32921
2 400000 447.2136 71.176254 700000 418.33 66.579292 700000 591.608 94.157331 437000 661.0598 105.2109
437N/mm 1 700000 836.66 133.15862500lb/in
Cam Torquespring force no preload follower displacment mm cam offset mm secondary k initial secondary force
2555.1778 2.776160148 1.388080074 1038 1380
theta v m/s a m/s^2 x mm k N/mm m F w T N*m T lbsf*ft Thp F of f Tf N*m Tf lbsf*ft Tf hp T total hp
0 0 197.266 0 920.4 6 3008.418 376.98 0 0 0 30.08418 2.292415 1.690798 1.158963 1.158963
5 0.045582453 196.5153433 0.121094405 3241.066 0.391893 0.289045 0.198127 32.41066 2.469692 1.821551 1.248588 1.446715
10 0.090817997 194.2690862 0.2419583 3464.288 0.834579 0.615554 0.421933 34.64288 2.639787 1.947007 1.334582 1.756516
15 0.135362361 190.544324 0.362361613 3677.737 1.320567 0.974 0.667631 36.77737 2.802436 2.06697 1.416811 2.084443
20 0.178876535 185.3694045 0.482075151 3881.135 1.841593 1.35829 0.931044 38.81135 2.957425 2.181284 1.495168 2.426212
25 0.221029351 178.7837119 0.600871031 4074.27 2.388809 1.761895 1.207697 40.7427 3.104594 2.289831 1.569572 2.777268
30 0.2615 170.8373673 0.718523118 4257.002 2.952958 2.17799 1.49291 42.57002 3.243836 2.39253 1.639967 3.132877
35 0.299980476 161.5908472 0.834807457 4429.254 3.524563 2.599584 1.781893 44.29254 3.375092 2.48934 1.706326 3.488219
40 0.33617792 151.1145231 0.949502692 4591.015 4.094111 3.019661 2.069836 45.91015 3.498354 2.580253 1.768643 3.838479
45 0.369816847 139.4881263 1.062390494 4742.337 4.652225 3.431305 2.351999 47.42337 3.61366 2.665299 1.826938 4.178936
50 0.400641244 126.8001406 1.173255976 4883.328 5.189831 3.827822 2.623793 48.83328 3.721096 2.744539 1.881253 4.505046
55 0.428416519 113.1471293 1.281888098 5014.155 5.698304 4.202853 2.880859 50.14155 3.820786 2.818067 1.931653 4.812512
60 0.452931286 98.633 1.388080074 5135.036 6.169607 4.550468 3.119133 51.35036 3.912898 2.886005 1.978221 5.097354
65 0.473998973 83.36821402 1.49162976 5246.239 6.596403 4.865257 3.334906 52.46239 3.997634 2.948503 2.021061 5.355967
70 0.491459241 67.46894559 1.592340044 5348.075 6.972149 5.142393 3.524869 53.48075 4.075233 3.005737 2.060292 5.585161
75 0.505179207 51.05619775 1.690019219 5440.893 7.291172 5.377692 3.686156 54.40893 4.14596 3.057903 2.096049 5.782205
80 0.515054455 34.25488142 1.784481345 5525.08 7.548721 5.567651 3.816364 55.2508 4.210111 3.105218 2.128482 5.944845
85 0.521009827 17.19286475 1.875546611 5601.05 7.741 5.709468 3.913573 56.0105 4.268 3.147915 2.157748 6.071321
90 0.523 1.2084E-14 1.963041666 5669.243 7.865176 5.801056 3.976352 56.69243 4.319963 3.186241 2.184019 6.160371
95 0.521009827 -17.19286475 2.04679996 5730.118 7.91938 5.841034 4.003755 57.30118 4.36635 3.220454 2.207471 6.211226
100 0.515054455 -34.25488142 2.126662054 5784.148 7.902677 5.828715 3.995311 57.84148 4.407521 3.25082 2.228285 6.223596
105 0.505179207 -51.05619775 2.202475926 5831.814 7.815033 5.764072 3.951001 58.31814 4.443842 3.27761 2.246648 6.197649
110 0.491459241 -67.46894559 2.27409726 5873.601 7.657264 5.647707 3.871239 58.73601 4.475684 3.301095 2.262746 6.133985
115 0.473998973 -83.36821402 2.341389721 5909.991 7.430976 5.480806 3.756836 59.09991 4.503413 3.321547 2.276765 6.033601
120 0.452931286 -98.633 2.404225213 5941.459 7.138502 5.265089 3.608972 59.41459 4.527392 3.339232 2.288887 5.897859
125 0.428416519 -113.1471293 2.462484126 5968.468 6.782828 5.002757 3.429155 59.68468 4.547973 3.354412 2.299293 5.728448
130 0.400641244 -126.8001406 2.51605556 5991.465 6.36752 4.696442 3.219191 59.91465 4.565496 3.367337 2.308152 5.527342
135 0.369816847 -139.4881263 2.564837539 6010.871 5.896656 4.34915 2.981139 60.10871 4.580284 3.378244 2.315628 5.296767
140 0.33617792 -151.1145231 2.608737205 6027.086 5.37475 3.964212 2.717281 60.27086 4.59264 3.387357 2.321874 5.039156
145 0.299980476 -161.5908472 2.647670991 6040.476 4.806687 3.54523 2.430089 60.40476 4.602843 3.394882 2.327033 4.757122
150 0.2615 -170.8373673 2.681564785 6051.374 4.197661 3.096036 2.122188 60.51374 4.611147 3.401007 2.331231 4.453419
155 0.221029351 -178.7837119 2.710354067 6060.077 3.553119 2.620646 1.79633 60.60077 4.617779 3.405899 2.334584 4.130914
160 0.178876535 -185.3694045 2.733984037 6066.84 2.878708 2.123226 1.455372 60.6684 4.622932 3.409699 2.337189 3.792561
165 0.135362361 -190.544324 2.752409713 6071.875 2.180231 1.608056 1.102247 60.71875 4.626769 3.412529 2.339129 3.441376
165 0.135362361 -190.544324 2.752409713 6071.875 2.180231 1.608056 1.102247 60.71875 4.626769 3.412529 2.339129 3.441376
170 0.090817997 -194.2690862 2.76559602 6075.351 1.463609 1.079502 0.739948 60.75351 4.629417 3.414483 2.340468 3.080416
175 0.045582453 -196.5153433 2.773517858 6077.388 0.734846 0.541995 0.371512 60.77388 4.630969 3.415627 2.341253 2.712764
180 6.40753E-17 -197.266 2.776160148 6078.058 1.03E-15 7.62E-16 5.22E-16 60.78058 4.63148 3.416004 2.341511 2.341511