1. Fatigue Life Testing Platform for Electroformed Bellows EEEE Jadon Weinel Hector Vargas Customer: NiCoForm, Inc.Advisor: Dr. E. Debartolo EMEM Richard Kraynik Zachary Eastman James Haschmann © 2003-2004, Team 04035 February, 2004

2. Outline IntroductionGoals Preliminary Design RedesignFabrication –Mechanical –Electrical Software Flow Conclusion

3. Goals Design, fabricate and debug a fatigue life testing platform for electroformed bellows Deliver a technical data package that allows the sponsor to reproduce the platform

4. What Is a Bellows? Bellows are dynamic components requiring a combination of strength, elasticity and long cycle life. Consisting of stacked circular convolutions, bellows can facilitate axial, angular, and/or defected motion. Common uses: Hermetically sealed vibration dampeners Aligned and Offset axis torque couplings Pressure sensors activators Springs

5. Test Procedure Concept Place bellows into test platform Input desired data –Frequency –Displacement Start test –Pressurize bellows Run test Test ends when the PLC detects a loss of pressure in the system which indicates a failure in the bellows integrity.

6. Preliminary Design Base Tester Top Support Rods Solenoid Pressure Switch Isolator Feet Bellows Adapters Actuator Flange Bellows Adapter Flange

7. Redesign Minor cosmetic changes to the base Actuator flange Development of optical feedback system Addition of centering spider diaphragm Relocated the solenoid and pressure switch Top bellows adapter Tester top

8. Final Test Platform Design

9. Exploded View Feet Base Actuator and actuator collar Hose fitting Support rod Slide Upper bellows adapter Lower bellows adapter Spider diaphragm Spider collar Spacer

10. Test Platform Design Details O-rings seat in the recesses. One prevents the upper bellows adapter from falling. The other provides a seal between the bellows adapter and the slide. Here, the spider diaphragm and major components attached to the base can be seen.

11. Fabrication Conventional Methods –Grinding –Milling –Turning –Wire Electrical Discharge Machining Materials –304 Stainless Steel Base, Slide, Support Rods, Coil Collar –Brass Bellows Adapters, Spider Collar

12. Optical Feedback System OPTEK 830L Series Circuit to drive the LED in the OPTEK 830L Series optical chopper and also condition the return signal brought back by the optical detector to provide feedback to the BEI Inc. motion controller. OPTEK Inc. 831L55 transmissive photo transistor package. Works with above circuit to provide position feedback of the motion of the actuator.

13. Electronics Cabinet Closed – Position for normal operation and storage when not in use. Open – For maintenance purposes and reprogramming of the PLC and Motion Controller.

14. Software Flow

15. Conclusion/Outcomes Completed Items Mechanical Components Electronics Cabinet Wiring of Electronics Cabinet Low Frequency Actuator Motion Critical Design Review Package To Be Completed Before Demonstration Receive Spider From Vendor Test Motion of Voice Coil at Higher Frequencies Install Optical Sensor

16. Questions or Comments! Visit: www.NiCoForm.com