1. Multidisciplinary Engineering Senior Design Hardinge Universal Turret Project 05412 2005 Critical Design Review May 13, 2005 Project Sponsor: Hardinge Inc. Team Members: Brian Heeran (Team Leader) Owen Brown Matt Buonanno Eric Newcomb Steven Paul Brice Wert Robert Yarbrough Kate Gleason College of Engineering Rochester Institute of Technology Team Mentor: Dr. James Taylor

2. Slide 2 of 27 Background Information

3. Slide 3 of 27 Senior Design 2 - Plan Detailed Design (3/7 – 3/28) Iterative Problem Solving (3/29 – 4/8) Component Fabrication (4/12 – 4/29) Prototype Assembly (4/27 – 5/11) Hardinge Review (5/13)

4. Slide 4 of 27 Project Intent Sustain Hardinge Inc. as an industry leader in turret manufacturing. –New technology Improved reliability and flexibility of future designs. –Fewer parts –Versatile motor

5. Slide 5 of 27 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.

6. Slide 6 of 27 Project Overview Project Scope: –Establish the feasibility of Torque Motor Integration. –Design a Turret Index Model capable of being manufactured. –Design for adequate cooling of the Torque Motor.

7. Slide 7 of 27 Desired Outcomes Technical –Include the use of a torque motor. –Design with as few parts as possible. –Included current top plate locking mechanism used by Hardinge in their Quest series turret. Performance –Equal or exceed current industry leader performance attributes such as index time, repeatability, and static stiffness. –Demonstrate increased reliability of assembly. –Incorporate adequate cooling of the torque motor.

8. Slide 8 of 27 Final Design

9. Slide 9 of 27 Analysis of Design Output from finite element software based on an indexing load of 633 N-m Torque. –Max Von Mises Stress found to be 47.3 MPa. –Yield Strength of 1018- CD steel 370 MPa. –Factor of Safety of 7.8.

10. Slide 10 of 27 Development of Machining Experience Standard Stock Sizes & Availability Bearing Lead Time & Availability Availability of Fasteners & Taps –English & Metric SHCS Flat Head w/ Chamfer Hex Head

11. Slide 11 of 27 Assembly Components Side Walls (2x) –Supports Torque Motor and Stator-Up Plate by securing it to the Base Plate

12. Slide 12 of 27 Assembly Components Stator-Up Plate –Affixes Torque motor and Side Walls to Base Plate –Main Drive shaft assembly passage

13. Slide 13 of 27 Assembly Components House Front –Supports part of locking coupler, exposure to CNC Environment

14. Slide 14 of 27 Assembly Components Interface Plate –Connects Top Plate to Main Drive Shaft

15. Slide 15 of 27 Assembly Components Main Drive Shaft –Shaft feature changes for manufacturability –Location and company with more aggressive machining capabilities than RIT –Final determination: Hardinge Inc.

16. Slide 16 of 27 Assembly Components Hydraulic Block –Supports Variable Axial Guide and locking coupler while including potential expandability features for Hardinge Inc.

17. Slide 17 of 27 Assembly Components Variable Axial Guide –Locates within Hydraulic Block –Provides bearing surface, bearing retaining attributes and centricity control for Main Drive Shaft

18. Slide 18 of 27 Assembly Components Bearing Block (Upper & Lower) –Second major bearing surface in line with Variable Axial Guide

19. Slide 19 of 27 Final Assembly

20. Slide 20 of 27 Torque Motor Implementation Powering –Etel Inc. high voltage motor driver Encoding –Sick/Stegmann incremental encoder Thermal Overload Protection –Analog and Digital sensors within Stator, providing temperature feedback

21. Slide 21 of 27 Torque Motor Cooling Max power produced: 1000 W (approx) Cooling options –Ventilation slots Simple, inexpensive Slots placed in base and top of housing –Small AC powered fans Fans mounted on top of housing

22. Slide 22 of 27 Torque Motor Cooling Further Options –Custom heat pipes Expensive Decreased reliability –Cooling sleeve Extremely Expensive Electron Channel Technology

23. Slide 23 of 27 Outcomes Desired –Preparation for pilot builds. Detailed Drawings Machining Cooling Torque Motor Integration Actual –Completed prototype assembly. –Further completed formal documentation for use by project sponsor for future builds and testing.

24. Slide 24 of 27 Recommendations for Project Sponsor Develop detailed testing procedures for: –Cooling –Variable Tool load Conditions –Worst Case Scenarios –Stiffness Investigate inverse torque motor operation (switching stator & rotor orientation).

25. Slide 25 of 27 Conclusions The project culminated with: –An assembled prototype. –Investigated cooling options. –Project poised for future investigations.

26. Slide 26 of 27 Acknowledgements Special Thanks to: –Dr. James Taylor (Faculty Mentor) –Dr. Jacquie Mozrall (Faculty Coordinator) –Mr. John Bonzo (ISE Facilities Manager) –Mr. Dave Hathaway (ME Facilities Manager) –Mr. Rob Kraynik (Senior Mechanical Technician) –Mr. Steve Kosciol (Senior Mechanical Technician)

27. Slide 27 of 27 Questions