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Pneumatic Test Bed Pneumatic Test Bed A Major Qualifying Project Report Submitted to the faculty of WORCESTER POLYTECHNIC INSTITUTE In partial fulfillment of the requirements for the Degree of Bachelor of Science By __________________ Richard MacKendrick [email protected] ___________________ Syed Kazim Naqvi [email protected] ___________________ Brendan White [email protected] Date of Submission: 22nd April 2010 Approved: Professor Eben C. Cobb [email protected] Abstract To enhance the learning experience of students in WPI’s mechatronics class, a pneumatic piston-spring assembly was designed and fabricated. Mathematical and bond graph analysis was performed to obtain theoretical metrics for the device’s operation. These theoretical metrics were compared with experimental results using sensors and data acquisition methods. The theoretical and experimental values were determined to have an acceptable deviation and can be reproduced by future students for the purpose of demonstrating the limits of theoretical metrics. ii Table of Contents ABSTRACT ......................................................................................................................................................................II TABLE OF CONTENTS ....................................................................................................................................................III TABLE OF TABLES ...................................................................................................................................................... VIII EXECUTIVE SUMMARY .................................................................................................................................................. 1 1 INTRODUCTION .................................................................................................................................................... 6 2 BACKGROUND RESEARCH .................................................................................................................................... 7 2.1 EQUIPMENT ..................................................................................................................................................... 7 2.1.1 Pneumatic Cylinders................................................................................................................................. 7 2.1.2 Solenoid Valve .......................................................................................................................................... 8 2.1.3 Pressure Regulators ................................................................................................................................. 9 2.1.4 Pressure Transducer ................................................................................................................................. 9 2.1.5 Force Transducer...................................................................................................................................... 9 2.1.6 Springs ................................................................................................................................................... 10 2.1.7 Pneumatic Tubing .................................................................................................................................. 11 2.1.8 Compressed Air Dryer and Filter ............................................................................................................ 11 2.2 BOND GRAPH INTRODUCTION............................................................................................................................ 12 3 GOALS AND OBJECTIVES .................................................................................................................................... 13 4 TASK SPECIFICATIONS ........................................................................................................................................ 14 4.1 PERFORMANCE SPECIFICATIONS.......................................................................................................................... 14 4.2 DESIGN SPECIFICATIONS .................................................................................................................................... 14 5 METHODOLOGY.................................................................................................................................................. 15 ST 5.1 1 ITERATION – VEX CONSTRUCTION.................................................................................................................. 15 5.1.1 Design limitations .................................................................................................................................. 16 ND 5.2 2 ITERATION ................................................................................................................................................ 17 5.2.1 Linear slider replacement....................................................................................................................... 17 5.2.2 Potentiometer vs. accelerometer dilemma ............................................................................................ 18 5.2.3 Mounting brackets and guide rod.......................................................................................................... 18 6 FINAL DESIGN SELECTION................................................................................................................................... 19 6.1 SYSTEM SCHEMATIC ......................................................................................................................................... 19 iii 6.2 DESIGN COMPLIANCE AND ACCURACY .................................................................................................................. 21 6.2.1 Tolerance Issues ..................................................................................................................................... 21 6.2.2 Alignment of piston-spring assembly ..................................................................................................... 21 6.2.3 Linear Slider ........................................................................................................................................... 22 6.2.4 Spring considerations ............................................................................................................................. 23 6.3 FINAL ASSEMBLY ............................................................................................................................................. 24 6.4 CIRCUITRY FOR SENSOR OUTPUT ........................................................................................................................ 25 6.5 DATA GATHERING ........................................................................................................................................... 27 6.5.1 DAQ Interface Design Decision .............................................................................................................. 27 6.5.2 Programming Logic ................................................................................................................................ 28 6.5.3 Accelerometer calculations .................................................................................................................... 30 6.5.4 Front Panel ............................................................................................................................................. 31 6.6 THE FINAL PRODUCT ........................................................................................................................................ 32 7 RESULTS AND ANALYSIS ..................................................................................................................................... 34 7.1 MATHEMATICAL SYSTEM OF EQUATIONS .............................................................................................................. 34 7.1.1 Initial known parameters ....................................................................................................................... 34 7.1.2 Initial test parameters ........................................................................................................................... 36 7.1.3 Calculated parameters of model............................................................................................................ 37 7.1.4 Equations of motion for model .............................................................................................................. 38 7.1.5 Graphical representation of model dynamics ........................................................................................ 41 7.2 BOND GRAPH APPROACH ................................................................................................................................. 44 7.3 EXPERIMENTAL RESULTS ................................................................................................................................... 48 7.3.1 Pressure results ...................................................................................................................................... 48 7.3.2 Return stroke ......................................................................................................................................... 50 7.3.3 Outward stroke ...................................................................................................................................... 52 7.3.4 Short Spring...........................................................................................................................................
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