P16665: Gleason Hobbing Machine Force Applicator
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Integrated System Build & Test with Customer Demo

Table of Contents

At the end of our last phase, we ran into some issues that were critical to being able to test our device in the Gleason 400H hobbing machine. We solved these quickly and ordered the required material over spring break. However, we continued to run into new problems throughout this phase...

Team Vision for System Level Demo with Customer

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Issues and Resolutions

Clamping Issues

At the end of last phase we realized that our clamp was over sized and would not be able to clamp down on the arbor rod. To fix this, we ordered shaft collars with a 40mm ID and a 60mm OD. These shaft collars fit over the arbor rod perfectly, and all we needed to do was shave them down so that the clamp could clamp down on them.

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PICTURE OF SHAFT COLLARS INSTALLED

Using the Gleason 400H Hobbing Machine

Previous to this phase, we did not know how the hobbing machine worked. We asked Dr. Liu to come teach us how to turn the machine on and off, deal with various alarms, and ultimately be able to jog the machine to a desired location to be used for our device.

Omega Pump Issues

We had an issue with our pump where we could pump the system up to a certain pressure, but as soon as you stopped pumping, it would release pressure immediately and decline rapidly. We tried various techniques to combat this including various procedures outlined in the user manual to stop the bleeding, but with no success.

In order to ensure that the pump was bleeding, and we did not have something wrong with our load cell, we fixed the load cell into a clamp and simply tightened the clamp onto the load cell until it read out a force. We then made sure that force was static for about 10 seconds. We then added the ram and pump to the set up and ran the test again, but instead of clamping down on the load cell, we extended the ram using the pump, ultimately determining the pump was to blame.

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PICTURE OF LOAD CELL CHECK APPARATUS

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PICTURE OF LOAD CELL AND PUMP CHECK APPARATUS

On April 13, Peter brought the entire pump apparatus to The Gleason Works to address the issue. Working with our customer, Mike Walker, they were able to determine a solution to the issue. First, we elected to use a different hose, as we believed that the hose use was likely flexing too much under load, and thus causing the pressure to decrease. The second part of the solution was to add a needle valve close to the ram. That way, if the pump began to bleed again, we could cut close off the line ad keep the pressure in ram static.

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PICTURE OF HOSING NEW HOSING FIXTURE

Test Plans

Unfortunately, these issues constantly hindered us in completing our tests; We were able to start our testing, but as we started one of our connecting pieced in the hose broke, and we needed to put it on hold for a short time longer until we got the piece replaced.

Updated BOM

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Risk and Problem Tracking

Reduced and Eliminated Risks

Increased Risks

Risk Management

Problem Solving/Tracking

Plans for next phase

Team Schedule

Team Objectives

Individual Objectives

Peter

Joe

Vince

Nick

Adel

Lessons Learned


Project P16665 Work Breakdown
Requirements Definition Test Analysis Documentation Project Management Academic
Project Readiness Package

Project Summary

Project Description

Customer Requirements

Engineering Requirements

Test Plan and Summary Matrix

Test Plan Data Sheets

Test Results

Mechanical Simulations BOM

Functional Decomposition

Flow of Concept Selection

Subsystem Architecture

Drawing Package

Poster

Tech Paper

Operators Manual

Risk Management

Problem Solving

MSD I Project Schedule

MSD II Project Schedule

Values and Norms

POs

Gate Review

All items highlighted in red are not yet completed.


MSD I & II MSD I MSD II

Home

Project Management

Project Photos and Videos

Imagine RIT

Problem Definition

Systems Design

Subsystem Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Integrated System Build & Test with Customer Demo

Customer Handoff & Final Project Documentation