P16601: Glass Cutting Machine:Guide Rollers
/public/

Integrated System Build & Test with Customer Demo

Table of Contents

Team Vision for Week 11

Mechanical

Electrical

Current State of Design

3D Model

Full Assembly

Full Assembly

Installation of Guide Roller

Installation of Guide Roller

Basket

Debris Catch

Debris Catch

Basket

Basket

Frontside Sight

Frontside Sight

Motorside Sight

Motorside Sight

Finite Element Analysis

Summary

Images

Finite Element Analysis Results

Finite Element Analysis Results

Finite Element Analysis Results

Finite Element Analysis Results

Finite Element Analysis Results - Magnified Singularity

Finite Element Analysis Results - Magnified Singularity

Finite Element Analysis - Cumulative Effective Mass Participation Factor

Finite Element Analysis - Cumulative Effective Mass Participation Factor

Finite Element Analysis - Cumulative Effective Mass Participation Factor

Finite Element Analysis - Cumulative Effective Mass Participation Factor

Finite Element Analysis - Mode Shape of First Natural Frequency

Finite Element Analysis - Mode Shape of First Natural Frequency

A link to a full report detailing the results of the analysis can be found here

Assembly Instructions

Step 1: Assemble Angle Plates

Step 1: Assemble Angle Plates

Step 2: Install Bearing Housing

Step 2: Install Bearing Housing

Step 3: Attach the Motors

Step 3: Attach the Motors

Step 4: Install Debris Catch

Step 4: Install Debris Catch

Step 5: Assemble Guide Rollers

Step 5: Assemble Guide Rollers

Step 6: Install Guide Rollers

Step 6: Install Guide Rollers

Step 7: Install Shielding

Step 7: Install Shielding

Step 8: Assemble Basket Door

Step 8: Assemble Basket Door

The full assembly instructions can be found here

Motor Verification

Efficiency Analysis

Last phase the RDB-B21529 was selected in terms of consuming the least amount of power. With a lot more algebra and math, the efficiency was estimated at 4 different operating points. Below are 4 plots resulting from a Matlab script at 300 cuts and 900 RPM.

Acceleration

Acceleration

Velocity

Velocity

Torque

Torque

Power

Power

It was discovered that allowing time for Jerk (the derivative of Acceleration) reduced the peak power amount. Also, another interesting result of the matlab simulations was that by simulating the DS-264 at 900 RPM and 480 Nm (motors rated at 500 Nm and subtracting torque due to roller inertia) the peak power was exactly the motor size currently on the DS-264. This may lend some insight on how the motors were sized or at the very least helps give merit to the simulations.

DS-264 Power

DS-264 Power

Here is the instantaneous power of the smaller machine at 716 RPM (12 m/s on the wire) and 30 cuts.

Smaller Machine Power at 30 Cuts

Smaller Machine Power at 30 Cuts

A table of the efficiency is below comapring the theoretical average power to the simulated average motor power by Rockwell's Motion Analyzer Software obtained last phase. Best case is 88% efficient which is not so good. This is surprising because there are not really any better choices with or without a gearbox.

RDB-B21529 Efficiency

RDB-B21529 Efficiency

The motor efficiency analysis and derivations can be obtained here

The matlab script can be obtained at the end of the Word document.

Motor Re-Selection

The RDB-21529 Motor finally selected and verified last phase was discovered to be in the end of life state. This means that in a short amount of time, the motor series will no longer be sold by Rockwell. Rockwell will still provide service for these motors afterward, but not for too long. Therefore, we have done some searching on some Kollmorgen motors to find a suitable replacement. The CH06x Cartridge Motor series look very promising but more research needs to be done. A motor specialist from Zeller will help take a look at our options and help make a good choice.

Some Candidates

Some Candidates

Kollmorgen Cartridge Motor Series

Kollmorgen Cartridge Motor Series

The Kollmorgen Cartridge Motor Catalog can be found here

The excel file of the motor comparisons chart can be found here

Zeller Visit

The quote provided by Zeller can be obtained here here

Purchasing

Mechanical

public/Reviews/MSD 2 Week 11 Review/P16601 MSD2 W11 Mechanical Purchasing Progress.JPG

Electrical

public/Reviews/MSD 2 Week 11 Review/P16601 MSD2 W11 Electrical Purchasing Progress.JPG

BOM

Mechanical

public/Reviews/MSD 2 Week 11 Review/P16601 MSD2 W11 BOM.jpg

Electrical

A link to the full bill of materials can be found here

Problem Tracking

public/Reviews/MSD 2 Week 11 Review/P16601 MSD2 W11 Problem Solving Process.jpg

A link to the live document can be found here

Plans for next phase

Week 11 Plans

Mechanical

Electrical

Individual Plans

public/Reviews/MSD 2 Week 11 Review/P16601 MSD2 W11 Individual Contributions.jpg

A link to the live document can be found here


Home | Imagine RIT | Final Technical Paper | Final Poster

Problem Definition | Systems Design | Subsystem Design | Preliminary Detailed Design | Detailed Design | Gate Review

Build & Test Prep | Subsystem Build & Test | Integrated System Build & Test | Integrated System Build & Test with Customer Demo | Customer Handoff & Final Project Documentation | MSD2 Gate Review