1. 1 P14471 Vibration Testing Apparatus II Final Review 5/13/2014 Brett Billings Jacob Gardner Nick Greco Ron “Sparky” Jimbo Claire Kobal Ryan Selig Ashley Waldron

2. Agenda 2 Revisit of Requirements Build Test Issues Lessons Learned Project Management Appendix

3. 3 Revisit of Requirements

4. Customer Requirements 4

5. Engineering Requirements 5 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

6. House of Quality 6

7. UL844 7 2000 RPM 1/32’’ displacement 35 hours

8. 8 Build

9. Frame Assembly 9 Steel was assembled and welded in shop All welded joints were annealed to relieve hardness caused by the heat during welding C-channel was machined to fit on top of frame and to hold flange assembly Baseplate for crankshaft mechanism was modified and mounted to frame

10. Crankshaft Modifications 10 Modifications to improve adjustment: Added access holes to connecting rod Replaced 3/8-24 set screw with a 3/16-100 set Re-machined T-block for bushing Replaced springs with weaker ones Access hole added to rear guard

11. Additional Work 11 Dial Gauge Added magnetic back plate Created alignment block to ensure gauge is perpendicular to box (cosine error) Top guard was re-machined in order to ensure adequate overhang for bolts Painted steel frame to resist rusting

12. Belt Guard Mount There was a misunderstanding in the machine shop and half of our original belt guard was thrown away A new, rectangular guard was fabricated Elongated holes were drilled in the L- brackets to allow for vertical adjustment Issue: Seems like there might be a lot of vibration. Never tested with machine on. 12

13. Encoder Mount Original design: Attach mount to bottom of belt guard Issue: Belt guard adjustment requires encoder to be adjusted as well Final design: Metal arm extending horizontally from L-bracket with rubber pad to prevent excess movement 13

14. Control of Motor Variable Frequency Drive added to control motor frequency VFD spec’d based on: Remote start/stop Remote ramp up or ramp down the speed of the motor External faults that could be used as an E-Stop 14

15. Feedback from Apparatus Closed loop control system RPM read by rotary encoder and sent to MCU Raw feedback from the encoder is processed and displayed on LCD Encoder needs to have high enough resolution to keep the error within 1% of 2000 RPM 15

16. Microcontroller: Programming 16 Microcontroller Unit (MCU) is a product of Texas Instruments (TI) under the MSP430 family MSP430G2452 – Main program and LCD communication MSP430G2553 – VFD switching logic TI Launchpad board used to reprogram MCU

17. Microcontroller: Interfacing 17 Supply voltage is 3.3 V DC from voltage regulator unit MSP430G2452 – Drives control and logic for the test LCD (10 pin connections) Feedback from Encoder Output A (1024 PPR) Control switch to manually pause/resume test (10 k Ω pull-up) Primitive serial data to MSP430G2553 (2 pin connections) MSP430G2553 – Directly controls VFD through switches Toggles transistors (switches) used to send digital data to VFD Additional control switch to power on and off both MCUs and LCD

18. Display Unit 18 20x4 HD44780 (Hitachi) Liquid Crystal Display (LCD) with LED backlighting Implements ASCII printable characters Character display: 4 rows, 20 columns Commands entered as parallel data Data [7..0]; Register Select; Enable Write mode; fixed contrast and lighting

19. Microcontroller: Logic/Implementation 19 Initialization Wait for about a second for display to power on before writing Set internal clock frequency to 16 MHz Varying clock speed essentially varies all delays and timing involved Configure input and output pins Write static items to display Initialize integer variables Configure and enable Timer and Edge Triggered interrupts Interrupt handlers Timer A: Increments a time-keeping variable Edge 1: Increments frequency counter from Encoder output Edge 2: Toggles a pause variable from pause/resume control switch

20. Microcontroller: Logic/Implementation 20 Display routines Send Command Simple routine to send commands in form of parallel data Command specified as binary string e.g.: SendCommand("1101010010"); sets character position to the start of line four Enable automatically set low and then high to send the full command Write Character Converts inputted character to binary equivalent and sends the command Direct ASCII compatibility due to HD44780 controller Write String Writes a sequence of characters; e.g.: WriteString(“Hello world!”);

21. Microcontroller: Logic/Implementation 21 Main algorithm (simplified) Test paused (or stopped) Signal VFD to stop motor Hold state, including timer and latest status message on display Test resumed (or started) Signal VFD to start motor and set to default speed (~2000 RPM) Resume state For each passing second… Update time both internally and on display Count up to a specific frequency from encoder signal Use specific frequency and time passed to accurately calculate RPM RPM within 1% of target: normal operation; else within 5%: ramp motor speed up or down through VFD; else outside 5%: pause test Pause test if no encoder signal detected or 35 hours elapsed

22. 22 Test

23. Current Testing Status 23

24. Encoder Testing Initial testing done independent of apparatus with a DC motor to evaluate following components: Output signal’s amplitude Output frequency Power and control connections Allowed encoder to be integrated with apparatus and connected to MCU to display speed on LCD 24

25. VFD Control Testing The VFD control signals were also tested independently on a proto-board for isolation purposes The VFD was programed for the motor used as well as for the digital outputs needed for the control signal To remotely control the VFD power transistors were used as switches The control of these switches would be coming from the MCU 25

26. Safety Test 26 Failed at RIT – 6 of 14 items are “No” Labeling, lockouts, 2 nd E-stop Will pass at CCH in Syracuse Ordered additional lockout & lock

27. Setup Test 27 Did not meet original engineering metrics Target: 2 minutes, 10 steps Actual: 16 minutes, 14 steps Should have used previous team as benchmark Drastic improvement vs 49 minutes & 31 steps Can be done with one person though

28. Setup Test 28 Standard Work for CCH – steps, time, visual aids Method to reach displacement in 2 adjustments Use of dial gauge Quick reference table 1 turn =.019’’ Reliable to +/- 3%

29. 29 Issues

30. Luminaire Vibration 30 Luminaire vibrates more than machine Extra conduit was threaded Set screw was tightened CCH not able to help by email/phone Resolution: Try plumber’s tape Consult CCH in Syracuse during final testing

31. Motor Mount Excess vibration in motor mount at 1/3 speed Mount was reinforced with t-shaped brace Top View 31

32. Electrical VFD damaged during initial testing Root cause analysis performed VFD replaced by CCH All future wiring done by licensed electrician 32

33. Electrical 33 Encoder mounting Coupler needed to be modified Coupler broke right before shipping Enclosures Shipped apparatus without LCD stuff Control changes from CCH at demo

34. 34 Lessons Learned

35. Experience Gained 35 Combined structural mechanics with vibration Required learning more in-depth features of structural mechanics & natural frequency Required learning of ANSYS Workbench to analyze the stress at the operating frequency and the natural frequency of the frame Electrical component selection & wiring

36. Lessons Learned 36 Review the previous MSD team’s work more thoroughly before starting Verify existing parts match CAD models Communicate effectively between both team members and others helping with the project Weigh the risks of using free help vs. hired professionals

37. Lessons Learned 37 Iterative design process Escalate issues when you can’t solve them yourself Compromise on differences of opinions between team members Work together to meet internal deadlines Clearly define team member roles e.g. Document owners

38. 38 Project Management

39. Budget 39 Original Budget = $4,000.00 Current Costs = $2,978.88 Parts = $2,540.33 S/H = $198.55 Expected Travel = $240.00 Items saved on: CCH donated VFD & replacement ($290x2) CCH paid for shipping ($600) No welding fees ($400) No electrician fees ($200) https://edge.rit.edu/edge/P14471/public/WorkingDocuments/Detailed%20Design/BOM_rev6_tracking.pdf

40. Risk Analysis 40

41. What’s Left? Remaining work: Finalize technical paper Travel to Syracuse for final testing – Test Plan B’s Fix issues detected during testing Solve excessive luminaire vibration Deliver maintenance & operation documentation If we don’t finish by 5/22: Enough work for a Phase III? Work for a Co-op? 41

42. Questions? 42

43. 43 Appendix

44. Room Layout 44

45. Selected Design 45 Interchangeable Conduits Motor with V-belt VFD Digital Dial Gauge Encoder LCD, Microcontroller Polycarbonate Guards E-stop Paint for Rust Protection

46. Test Plans 46 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

47. Full Risk Analysis 47 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

48. VFD Damage Incident 48 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