Project Readiness Package Rev 7/22/11
INTRODUCTION: Located in Syracuse, NY, Cooper Crouse-Hinds Industries is a leading manufacturer of luminaires for use in hazardous locations. These luminaires are used in severe environments where their ignition or explosion can have catastrophic consequences. For this reason these luminaires are strictly tested according to several standards such as UL844. The capacity to withstand vibration is among the several tests specified by this standard. A luminaire must pass a 35 hour test when subjected to a horizontal vibration consisting of a 1/32 inch horizontal displacement at a frequency of 2000 cycles per minute. Cooper Crouse-Hinds requires the design and building of a testing apparatus with the capacity to test luminaires according to UL844. The average weight of each luminaire is 100 lb and the apparatus must be capable to test luminaires in 4 different configurations. The size and components associated with this apparatus pose a constraint for its full design and testing in one senior design sequence. Some of the components, such as the ones associated with the drive system might have long lead times and will require the customer to place the purchase orders. The frame of the apparatus might require a large space in the MSDS floor and some of its elements might be too big and heavy to move them to the 4th floor. For the final testing all components must be in place and the machine anchored to the floor. For these reasons it was agreed that his apparatus can be build in several senior design sequences. In the first sequence ( winter/spring), the students will design and build only one subsystem of the apparatus. The chosen subsystem is the mechanism to vibrate a pendant mount luminaire. The students will also select the required drive system and associated components and provide engineering drawings for the fabrication and assembly of the whole apparatus . ADMINISTRATIVE INFORMATION:
Project Name (tentative): UL vibration test apparatus (Phase I)
Project Number, if known: P13471
Preferred Start/End Quarter in Senior Design: Fall/Winter Fall/Spring Winter/Spring
Faculty Champion: (technical mentor: supports proposal development, anticipated technical mentor during project execution; may also be Sponsor)
Name Dept. Email Phone Benjamin Varela ME [email protected] 5-4737
For assistance identifying a Champion:
Other Support, if known: (faculty or others willing to provide expertise in areas outside the domain of the Faculty Champion)
Name Dept. Email Phone
Project “Guide” if known: Benjamin Varela Primary Customer, if known (name, phone, email): Joe Manahan, 315-477-5768, [email protected] Sponsor(s): (provider(s) of financial support)
Name/Organization Contact Info. Type & Amount of Support Committed Cooper Crouse-Hinds Joe Manahan TBD
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PROJECT OVERVIEW: The ultimate goal of this project is to design, build and test a modern single axis vibration test apparatus complying with UL844 similar to the one shown in the following figure.
The apparatus must have a LabView interface and control capability. This goal will be achieved in several senior design sequences. This apparatus as the one shown in the figure above is composed by the following subsystems: a) Vertical support for 4 luminaire configurations b) Vibrating mechanism 3) Drive system 4) Frame 5) Control and Instrumentation
For senior design sequence I (winter/spring) the goal is to design and build a mechanism capable to vibrate a 100 Lb pendant mounted luminaire by applying a 1/32 inch horizontal displacement at a frequency of 2000 cycles per minute. The expectations for this phase of the project are: a) The team shall provide the customer with two designs capable of achieving the specifications given in the next section. a.1 One of the designs must be an eccentric shaft mechanism. This mechanism is composed of different elements such as the eccentric shaft as seen in the following figure, a connecting link, a slider, supporting pillow blocks and a sheave, to mention a few.
a.2 The customer is open to consider an alternative design. One possibility might be the traditional crank-shaft mechanism as shown next.
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b) The team will present both design to the customer and one will be selected for fabrication and testing c) Upon selection of the mechanism, the team shall purchase, machine and assemble the necessary elements to fabricate it. d) The team will build a steel frame that will support the mechanism and a vertical conduit according to the specifications given in the next section. The team is not expected to build the frame for the entire apparatus. e) The team shall calculate and select ( but not purchase) the required drive system (i.e. AC motor, speed reducer, sheaves, belts, etc.) to move the mechanism at a frequency of 2000 cycles per minute. e) The team shall select (but not purchase) a tachometer to verify the frequency of the mechanism e) The team shall design (but not fabricate) the frame for the whole machine. f) A complete set of engineering drawings is required.
Testing protocol for the mechanism: 1) A 100 lb weight shall be attached to the vertical conduit 2) The mechanism will be activated by some mechanical means ( a crank, a pulley with a weight, etc.) 3) The mechanism must provide a horizontal movement in each direction of motion of 1/32 inch at the location specified in the next section. 4) The total travel for each complete cycle is 1/16 inch. 5) The displacement will be measured using a dial indicator
NOTE: Ideally this test should be done at the 2000 cycles per minute frequency, but this will require the entire frame and drive system to be in place.
DETAILED PROJECT DESCRIPTION (PHASE I):
Customer Needs and Objectives: 1) The apparatus must be capable to vibrate a 2 inch NPT steel pipe according to the geometry given in the following figure:
2) The vertical conduit is to be attached to the machine frame using a flange. The flange shall be rigidly mounted to the frame and the conduit shall be removable. Page 3 of 6 Project Readiness Package Rev 7/22/11
3) The bottom part of the vertical conduit shall be NPT threaded. 4) The vertical conduit and flange shall be capable of supporting the configuration for stanchion, yoke and trunnion mounted luminaires as seen in the next figure:
4) The horizontal rod shall be attached to the vertical conduit using a removable collar 5) The horizontal rod/collar assembly shall be adjustable in the horizontal direction. 6) The horizontal rod/collar shall be assembled to the vibrating mechanism that will provide a 1/32 inch total horizontal displacement. 8) The mechanism shall be designed to operate at a frequency of 2000 cycles per minute for a total of 35 hours. 9) The deflection of the vertical conduit shall be checked using a dial indicator or other type of instrument
Project Deliverables:
o The mechanism as described before o Complete set of engineering drawings for the whole machine o Bill of Materials with estimated cost
Budget Estimate: This phase will cost approximately $3,000.00
Intellectual Property (IP) considerations: N/A
Other Information: The team must travel to customer’s site to witness the actual test and to present their mechanism design. Continuation Project Information, if appropriate: Customer must approve the concept before proceeding to fabricate the apparatus
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STUDENT STAFFING:
Skills Checklist: Complete the “PRP_Checklist” document and include with your submission.
Anticipated Staffing Levels by Discipline:
How Discipline Anticipated Skills Needed (concise descriptions) Many? EE 0 4 Design of Machine elements, ProE, Strength of Materials, material ME selection, machine systems CE 0 ISE 0 Other
OTHER RESOURCES ANTICIPATED: Describe resources needed to support successful development, implementation, and utilization of the project. This could include specific faculty expertise, laboratory space and equipment, outside services, customer facilities, etc. Indicate if resources are available, to your knowledge.
Resource Category Description Available?
Faculty
Environmen PC lab yes t
Machine Shop yes
Space in the 4th floor unknown
Equipment
Materials
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Other
Prepared by: Benjamin Varela Date: November 19, 2012
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