Hardinge Universal Turret Senior Design Project Project Sponsor: Hardinge Inc.

2 of 28 Team Members Brian Heeran - ISE Brice Wert - ME Robert Yarbrough - ME Owen Brown - ME Matt Buonanno - ME Eric Newcomb - ME Steven Paul - ME

3 of 28 Scope Introduction Turret Indexing Cutting Movement

4 of 28 Project Scope  Design a simple turret index model  Benchmarking  Torque Motor Integration  Design  Analysis  Prototyping

5 of 28 Accomplishments 1. Needs Assessment & Benchmarking 2. Concept Development 3. Design Objectives 4. Feasibility Assessments 5. Preliminary Design 6. Hardinge Review

6 of 28 Long Term Objectives Complete project on time meeting technological/performance requirements. Expanding relations between Hardinge Inc. and RIT Gather data to establish the feasibility of future torque motor applications. Demonstrate competitive advantage through the use of Torque Motor.

7 of 28 Benchmarking Goals Determine current state of industry Evaluate feasibility of new design Turret Selection Chosen to represent cross-section of manufacturer’s offerings Chosen to maintain data compatibility

8 of 28 Benchmarking Cont. Criterion Primary Characteristics Index Time Index Motor Type Number of Tooling Stations Turret Operation Max Torque Total Turret Weight Secondary Characteristics Tooling System Live Tooling Capability Turret Operating Pressure Etc…

9 of 28 Benchmarking Cont.

10 of 28 Benchmarking Cont.

11 of 28 Benchmarking Cont. Benchmarking Conclusions New turret design should be designed around a 12 station turret Need to strive to attain an indexing time of less than 0.15 seconds

12 of 28 Traditional Motors vs. Torque Motors Direct drive with torque motor Motor 1FW3.. Gear box Customer machine Traditional drive with motor and gear box  Large outside diameter allows for more poles, and windings thus allowing for higher torques.  Large diameter means higher torque can be generated with the same power input.

13 of 28 Torque Motor Technology Reduced Cost Improved Reliability High Accuracy & Repeatability High Efficiency

14 of 28 Torque Motor Benefits Characteristic: Short compact design Gear unit / belt drives eliminated Hollow shaft design Few mechanical components No torsional backlash Increased rigidity Customer Benefit : Simple integration into the machine Easy to service (no gear box oil) Improved efficiency Flexible mounting concepts Advantage in mounting and logistics Improved repeatability Improved control characteristics Low noise system Increased dynamic performance

15 of 28 Torque Motor Availability Options 4 different rotor models available off the shelf from ETEL, Inc. Selected model based upon: Project Torque Requirements. Length Heat Generation Cost

16 of 28 Design Objectives Technological Attributes  Designs must include the use of a torque motor.  Design shall have as few parts as possible.  Design must include current top plate locking mechanism used by Hardinge in their Quest series turret. Performance Attributes  Designs must equal or exceed current industry leader performance attributes such as index time, repeatability, and static stiffness.  Designs must result in increased reliability.  Designs shall incorporate adequate cooling of the torque motor.

17 of 28 Concept Development Project Scope Redefinition Locking Mechanism Cooling Common Tooling Live Tooling 6 Conceptual Designs Developed

18 of 28 Alternative Concepts

19 of 28 Alternative Concepts Cont.

20 of 28 Design Concerns Heat generation and removal Thermal Deflection Sealing the motor Bearings Static Stiffness Controller Interface Component ordering lead time

21 of 28 Technical Assessment Requirements Torque Motor Fewest Parts Locking Mechanism Off-shelf Use Hollow Cavity Tooling Load Housing Control Compatibility

22 of 28 Preliminary Design Top Plate Assembly Top Plate Interface Housing Bearings Support Structure Coupler Torque Motor

23 of 28 Preliminary Design - Assembly

24 of 28 System Dynamics  The response of the motor to a command to index the turret between station one and two.  Shown with no tooling on top plate.

25 of 28 Finite Element Stress Analysis  Output from finite element software based on indexing load of 700 N-m torque.  Max Von Mises Stress found to be 22.7 MPa.  Yield strength of steel 285 MPa.  Factor of safety of 10.4.

26 of 28 Finite Element Stress Analysis  Output from finite element software based on indexing load of 700 N-m torque.  Max Von Mises Stress found to be 19 MPa.  Yield strength of steel 285 MPa.  Factor of safety of 15.8.

27 of 28 Future Plan 1. Detailed Design 2. Pilot Builds 3. Iterative Problem Solving 4. Testing & Analysis 5. Hardinge Review

28 of 28 References “Torque Motors Do the Trick” Holzknecht, Arthur, ETEL Inc. Schaumburg, Ill., “Siemens Torque Motors” Siemens AG 2004, “ Rexroth IndraDyn T Synchron- Torquemotor” Bosch Rexroth AG,