4th and 5th Axis Rotary Table Team: Dakota Bass Ricky Riedl Nicole Slagle Irene Yee Sponsors: Martin Koch Dr. Jose Macedo Mechancical Engineering Department California Polytechnic State University San Luis Obispo 2016 1 Statement of Disclaimer Since this project is a result of a class assignment, it has been graded and accepted as fulfillment of the course requirements. Acceptance does not imply technical accuracy or reliability. Any use of information in this report is done at the risk of the user. These risks may include catastrophic failure of the device or infringement of patent or copyright laws. California Polytechnic State University at San Luis Obispo and its staff cannot be held liable for any use or misuse of the project. 2 Contents Executive Summary ........................................................................................................................ 8 1. Introduction ................................................................................................................................. 9 1.1 Sponsor Background ............................................................................................................. 9 1.2 Formal Project Definition ..................................................................................................... 9 1.3 Objectives ............................................................................................................................. 9 1.4 Project Management ............................................................................................................. 9 2. Background ............................................................................................................................... 10 2.1 History................................................................................................................................. 10 2.2 Existing Products ................................................................................................................ 10 2.3 Patents ................................................................................................................................. 11 2.4 Component Research .......................................................................................................... 12 2.4.1 Backlash Reduction ..................................................................................................... 12 2.4.2 Motors .......................................................................................................................... 14 2.4.3 Bearings ....................................................................................................................... 19 3. Design Development ................................................................................................................. 20 3.1 Requirements/Specifications............................................................................................... 20 3.2 Concept Generation ............................................................................................................ 21 3.3 Initial Design Considerations .............................................................................................. 23 3.3.1 Support Design............................................................................................................. 23 4. Final Design .............................................................................................................................. 27 4.1 Overall Layout .................................................................................................................... 27 4.2 Detailed Design ................................................................................................................... 27 4.2.1 Cap ............................................................................................................................... 28 4.2.2 Housing ........................................................................................................................ 28 4.2.3 Platter ........................................................................................................................... 28 4.2.4 Shaft ............................................................................................................................. 28 4.2.5 Gear Preload................................................................................................................. 29 4.2.6 Worm Wheel ................................................................................................................ 29 4.3 Analysis Results .................................................................................................................. 30 4.3.1 Drive Shaft ................................................................................................................... 30 4.3.2 Driven Shaft ................................................................................................................. 30 3 4.3.3 Inertia ........................................................................................................................... 30 4.3.4 Worm Gear A and B .................................................................................................... 30 4.3.5 Bearings ....................................................................................................................... 30 4.3.6 Bolts ............................................................................................................................. 30 4.3.7 Summary ...................................................................................................................... 31 4.4 Cost Analysis ...................................................................................................................... 31 5. Product Realization ................................................................................................................... 32 5.1 Manufacturing ..................................................................................................................... 32 5.2 Design Edits ........................................................................................................................ 37 5.3 Recommendations for Future Manufacturing ..................................................................... 38 6. Design Verification Plan ........................................................................................................... 39 6.1 DVP&R ............................................................................................................................... 39 6.2 Vibration Testing ................................................................................................................ 39 6.3 Backlash Testing ................................................................................................................. 41 6.3 Tolerance Testing................................................................................................................ 41 6.4 Efficiency Testing ............................................................................................................... 44 6.5 Gear Wear Testing .............................................................................................................. 44 7. Conclusions and Recommendations ......................................................................................... 45 References ..................................................................................................................................... 46 Appendices .................................................................................................................................... 48 A: Specifications List ................................................................................................................ 48 B: Detailed Drawings ................................................................................................................ 48 C: Structured BOM ................................................................................................................... 48 D: Component Specification Sheets ......................................................................................... 48 E: EES Formatted Calculations ................................................................................................ 48 F: FMEA and Design Verification ............................................................................................ 48 G: Gantt Chart ........................................................................................................................... 48 4 List of Figures Figure 1. Haas OM-2 (Haas) ........................................................................................................... 9 Figure 2. Haas TRT 100 (Haas) .................................................................................................... 10 Figure 3. Nikken 5AX-130FA (Nikken) ....................................................................................... 10 Figure 4. Anti-Backlash Mechanism Patent Design (Mauro) ....................................................... 11 Figure 5. Rotary Table Bearing Patent Design (Bullard) ............................................................. 11 Figure 6. Rotary Table Apparatus Patent Design (Kato) .............................................................. 11 Figure 7. Manufacturers in Japan use blue ink to machine precision ground gears (Mitzubishi) 12 Figure