Shaft Replacement Standard Operating Procedure

Disconnect EMAs X Axis EMA Y Axis Tools Needed: Snap Ring Pliers, Computer, EMA Software Step 1: Remove pin ring from EMA clevis and load cell If using new joint: Just retract EMA with the software. Y Axis Tools Needed: 7/8 wrench, Computer, EMA Software Step 1: Remove pin from EMA clevis and load cell Step 2: Retract EMA using the software

Moving EMAs Flip Breaker to turn on power to EMA controllers Plug in cables to EMA-1 Open Moog GUI Go to motion tab and change position Click download pointing arrow in top left to download setup to the controller Open NI MAX Reset the USB-6216 DAQ device Set analog channel output to zero along with its minimum

Moving EMAs 2 Plug in serial cable to EMA-2 (Repeat previous slide steps) Open Moog GUI and select “Use current model” (883-045) Go to motion tab and change position Click download pointing arrow in top left to download setup to the controller Open NI MAX Reset the USB-6216 DAQ device Set analog channel output to zero along with its minimum

Outlet Flow Inlet Removal Tools Needed: Adjustable wrench, bucket Step1: Using adjustable wrench, unscrew oil inlet hose, pour excess oil into bucket. Step 2: Remove oil inlet adapter from bearing housing using the adjustable wrench

LVDT and The Tools needed: 3/8 allen key, 3/4 wrench Step 1: Removal thermocouple from housing by hand. Step 2: Remove LVDT’s from LVDT fixture Step 3: Using the 3/8 Allen key and 3/4 wrench, unscrew the LVDT fixture from the rig

Oil Outlet Removal Tools needed: 7/8 wrench, bucket Step 1: Using the adjustable wrench, unscrew all outlet hoses, pour excess oil into bucket

Remove the Encoder Tools needed: 3/32 Allen key, flathead screwdriver Step 1: Using the flathead screwdriver, unscrew the encoder from the table Step 2: Using the Allen key, unscrew the setscrews in the encoder, releasing it from the journal

Remove the V-Belt and the Pulley Tools needed: 5/32 Allen key Step 1: Remove v-belt safety cover from top of table Step 2: Using the Allen key, unscrew the setscrew holding the V-belt pulley to the journal Step 3: Pull back on the pulley to stretch the V-belt and simultaneously pull off the journal Step 4: Set belt and pulley off to the side

Remove Pillow Bearing Tops Tools needed: 9/16 Socket, Ratchet Step 1: Using the socket and ratchet, loosen pillow block bearing bolts Step 2: Finish unscrewing the bolts by hand

Remove Load Cells Tools Needed: Adjustable wrench Step 1: Using the adjustable wrench, loosen load cell, unscrew the rest by hand to avoid tangling the wires. Step 2: Preferably with a partner, pick up and rotate housing so Y-load cell is now rotated 90 degrees. Step 3: Using wrench, remove the Y-load cell

Remove Journal From Housing Tools needed: 3/16 Allen key Step 1: Using Allen key, loosen set screws Step 2: Remove busing insert by pulling it away from the housing Step 3: Slowly remove the journal from the bearing housing.

Replace Journal Shaft

Installing the Journal ********** Tools needed: Oil Step 1: Lubricate the journal shaft Step 2: Check to make sure you are installing from the CORRECT SIDE. Step 3: Insert shaft until it comes close to the other side. You should be able to support it from the other side Step 4: Holding the journal shaft from both ends, twist it until you feel that it is centered with the journal bearing and push it the rest of the way into the housing.

Installing the Bushing Insert Tools needed: Oil and 3/16 Allen Key Step 1: Lubricate the journal and bearing insert. Step 2: Check orientation of flat spots in the journal and orient the insert accordingly. Step 3: Use the Allen key to tighten set screws, fixing the bearing insert to the journal.

Install Load Cells Tools Needed: Adjustable wrench Step 1: Locate the correct orientation for installment Step 2: Hand tighten the X-load cell Step 3: With help, rotate the housing to access the Y-load cell, and using the wrench, tighten the Y-mount Step 4: Ensure the load cells are in the correct orientation for connection to EMAs

Reinstall Oil Hoses Tools needed: 7/8 wrench, adjustable wrench, bucket Step 1: Install oil inlet adapter Step 2: Screw on oil inlet hose first Step 3: Screw on both outlet hoses last

Install Sensors and V-Belt Tools needed: 5/32, 3/32, 3/8 Allen key, 3/4 wrench and flat head Step 1: Place thermocouple in oil outlet adapter Step 2: Place encoder on journal Using the flat head screwdriver, screw in until washing has firmly pressed bracket to the sheet metal Using the 3/32 Allen key, tighten the set screws Step 3: Place pulley on the journal Locate the flat of the journal Orient V-belt pulley so set screw is in line with the journal’s flat Using the 5/32 Allen key, tighten set screw Step 4: replace LVDTs Place mount so bottom tip is against the table top Use 3/8 Allen key and the 3/4 wrench to tighten the mount against the table Place the LVDTs back in the slots but them from touching the housing until after the EMAs are hooked up. Tighten LVDTs down with 4-40 screws

Connect EMAs to the Housing Tools needed: Computer, EMA software Step 1: Flip the breaker to turn on the power to the EMA controllers Step 2: Plug in serial cable to EMA-1 Step 3: Open up Moog GUI and select “use current model” (883-045) Reset fault Step 5: Open NI MAX Reset the USB-6216 DAQ device. Open test panel Set analog output channel zero min to 0 and the max to 10V Divide the starting position by max length and multiply by 10 Use this voltage to move EMA to original position Adjust voltage incrementally until the rod end and clevis line up Step 6: Unplug power chord to EMA Step 7: Place pin and replace snap ring

Connect the EMAs to the Housing Step 1: Plug in serial cable to EMA-2 Step 2: Open up Moog GUI and select “use current model” (883-045) Rest fault Step 3: Plug in the EMA power cord Reset the USB-6216 DAQ device Step 4: Open the NI MAX Reset the USB-6216 DAQ device. Open test panel Set analog output channel zero min to 0 and the max to 10V Divide the starting position by max length and multiply by 10 Use this voltage to move EMA to original position Adjust voltage incrementally until the rod end and clevis line up Step 5: Unplug power cord to EMA Step 6: Place pin and hand tighten nut

Connect EMAs to the Housing Step 1: Plug in serial cable to the EMA-1 Step 2: Open up MOOG GUI and select “Use Current Model” (883-045) Reset fault Go to motion tab and change to open loop force Click downward pointing arrow in top left to download setup to the controller Step 3: Plug in serial cable to the EMA-2 Step 4: Open up MOOG GUI and select “Use Current Model” (883-045)