1. P14471 Vibration Testing Apparatus II Integration Demo 4/15/2014 Brett Billings Jacob Gardner Nick Greco Ron Jimbo Claire Kobal Ryan Selig Ashley Waldron 1

2. Agenda Demo Items BoM & Budget Issues Project Plan Appendix 2

3. Demo Items 3 Mount 18 lb luminaire to 3/4'' conduit Adjust displacement Turn on VFD & motor, 500 RPM Display RPM & elapsed time on LCD End with E-Stop

4. BoM / Budget 4 Current costs: Remaining costs: VFD enclosure - $80 Shipping to Syracuse - $600 Travel Expenses - $240 Expected final cost: $3,400 https://edge.rit.edu/edge/P14471/public/WorkingDocuments/Detailed%20Design/BOM_rev6_tracking.pdf

5. Issues 5 Reinforce motor mount Vibration noise at certain frequencies Decide on Control Panel layout Shipping apparatus to Syracuse Ryan

6. Project Plan 6

7. Questions? 7

8. Appendix 8

9. Room Layout 9

10. Selected Design Interchangeable Conduits Motor with V-belt VFD Digital Dial Gauge Encoder LCD, Microcontroller Polycarbonate Guards E-stop Paint for Rust Protection 10

11. 11

12. Engineering Requirements NumberRequirement Raw Score Units Ideal Measure 1 Displacement of luminaire69in1/32 2 Vibration of luminaire69cycles/min2000 3 Duration of vibration test69hours35 4 Isolate motor from oil spills45BinaryYes 5 Maintenance Documentation44Survey (easy to follow)80% 6 Mount pendant configuration35BinaryYes 7 Operation Documentation33Survey (easy to follow)80% 8 Machine won't operate if crankshaft enclosure is open25BinaryYes 9 Completely stop machine with Emergency Stop25seconds< 10 10 Maximum voltage of Motor25V AC240 11 Minimize number of operators21people2 12 Max weight of mounted luminaire20lbs> 150 13 Visually display settings and status of test18BinaryYes 14 Steps to set up16steps< 10 15 Setup Time16seconds< 120 16 Low Sound15dBA< 85 17 Minimize pinch points15Count< 3 18 Total materials cost15$< 4,000 19 Mount stanchion configuration7BinaryYes 20 Mount yoke configuration7BinaryYes 21 Mount trunnion configuration7BinaryYes 22 Machine footprint5in 2 < 34X48 12

13. House of Quality Engineering Metrics Customer Requirements Customer Weights Displacement of luminaire Vibration of luminaire Duration of vibration test Low sound Machine won't operate if moving parts are exposed Completely stop machine with Emergency Stop Minimize pinch points Minimize number of operators Voltage of motor Mount pendant configuration Mount stanchion configuration Mount yoke configuration Mount trunnion configuration Visually display settings and status of test Operation documentation Steps required for Set-up Isolate motor from oil spills Maintenance documentation Max weight of mounted luminaire Total materials cost Time to Set up Machine footprint Adherence to UL844 testing standard5555 Apparatus is safe5 3553 3 1 Motor must be compatible with available voltage5 5 33 Ability to test multiple configurations3555 5111 Easy to use3 5 133 1 3 Easy to maintain2 3 1 53 Visually display test information/feedback to operator3333 511 1 1 Ability to test a range of luminaire weights4555 5111 5 Cost under $40003 5 Long service life4 1153 1 Similar dimensions to existing machine1 5 Technical Targets (Specifications) 1/32 in. 2000 cycles/min 35 hours < 85 dBA yes < 10 seconds < 3 ≤ 2 < 240 V AC Yes 80% via survey (easy to follow) < 10 steps Yes 80% via survey (easy to follow) > 150 lbs < $4000 < 120 seconds < 34X48 in 2 Raw score 69 1525 15212535 777 1833164544201516 5 Relative Weight 11% 2%4% 2%3%4%6%1% 3%5%3%7% 3%2%3%1% 13

14. Safety Checklist ER # 8 – Machine Guarding ER # 9 – Emergency Stop ER # 16 – Low Sound 14

15. Test Plans 15 Refer to Excel document https://edge.rit.edu/edge/P14471/public/WorkingDocuments/MSDII_B uild%20Test%20Documentation/P14471 Test Plans_Rev2.xlsx https://edge.rit.edu/edge/P14471/public/WorkingDocuments/MSDII_B uild%20Test%20Documentation/P14471 Test Plans_Rev2.xlsx or EDGE https://edge.rit.edu/edge/P14471/public/Build%2C%20Test%2C%20Do cument https://edge.rit.edu/edge/P14471/public/Build%2C%20Test%2C%20Do cument

16. Maintaining Displacement ER #1: Displacement must be 1/32’’ Clamping force: Provided by 2 x A574 screws - 5/8’’-11 M = torque on screws = 168.9 M ft -1 Frictional force: 2 possible locations: = 33.8 M ft -1 (worst case) Maximum force applied: 1.68 ft-lbs. (motor) at 1/32’’ = 645 lbs. Required screw torque: = 38 ft-lbs. (Safety factor of 2) Max recommended A574 torque = 220 ft-lbs *Detailed calculations in Appendix 1 1 2 2 16

17. Bolt Torque Guide 17

18. Setup Improvements ER # 11 – Minimize number of operators ER # 14 – Steps to set up ER # 15 – Setup time 18

19. Setup Improvements Finer set screw Before: 11 threads per inch 1 turn = 290% of displacement! After: 100 threads per inch 1 turn = 33% of displacement Changes required: Machine new set screw plate Requires threaded bushing for set screw 19

20. Set Up Improvements Set screw Account for excess space between conduit and collar Flange Dimensioned to be placed in same location every time Blocks on the C channel Flange Collar – crankshaft connection Collar – set screws ER # 11 – Minimize number of operators ER # 6, 19-21 – Mount 4 configuration types ER # 13, 14 – Setup time, number of steps 20

21. Full Risk Analysis 21 See EDGE https://edge.rit.edu/edge/P14471/public/ProjectManageme nt/Risk%20Analysis.pdf https://edge.rit.edu/edge/P14471/public/ProjectManageme nt/Risk%20Analysis.pdf

22. VFD Damage Incident 22 See EDGE https://edge.rit.edu/edge/P14471/public/WorkingDocumen ts/VFD%20Damage%20Incident/VFD%20Damage%20Incide nt.pdf https://edge.rit.edu/edge/P14471/public/WorkingDocumen ts/VFD%20Damage%20Incident/VFD%20Damage%20Incide nt.pdf