Preliminary Detailed Design
Quick Project Overview
Gleason currently uses a test fixture in which the load is manually applied to the arbor in one static direction. In the subsystem design phase we expanded upon our “Pivel Swivot” fixture, which was approved from the system design review. During that phase we performed various simulations and determined that the subsystems still needed to be modified in order to avoid interferences and withstand the load caused during operation. During the preliminary detailed design phase we finalized our subsystems so that they can withstand forces with a factor of safety of 2.0-2.5, while not interfering with any other components during operation. We have also put a larger focus on mitigating risks, so that we do not run into issues when we are building the device in MSD II.
Team Vision for Preliminary Detailed Design Phase
What We Planned to Do
- Big focus on our Risk Assessment Items
- Continue simulating forces on components and system as a whole as well
- Develop a preliminary procedure to build the device
- Request quotes from more vendors, finalize BOM, and prepare purchase orders
- Develop safety and operating procedures
- Create a problem resolution matrix to better understand risk mitigation progress
What We Did
- Most objectives on Gantt Chart were directly related to risks, thus we were able to mitigate several critical risks like interferences and ability to withstand load.
- Developed a list of safety precautions to mitigate risks.
- Requested quotes from more vendors for models from the beginning of the phase. (We still need to send out quotes for our finalized components)
- Created a problem resolution matrix (FMEA) to identify our progress on various risk management issues and better plan action items accordingly.
Drawings, Schematics, Flow Charts, Simulations
Whole System Design
Whole System Design Exploded View
Finalized Ram and Pump
Enerpac RSM-50. Dimensions in inches.
Discussion with Mike indicated that a system for supplying the hydraulic pressure, similar to the one pictured below, will be available for testing.
Overload protection will be provided by an adjustable relief valve, set to a desired pressure given the application.
Load Cell Housing
Finalized Load Cell
Ball Joint/Work Piece Components
GUIGUI produced using Microsoft Visual Studio.
Additional code required for program provided with DAQ.
Interferences with Moving Part Simulation
Applied Load Simulations
Load Cell Block
Whole System Simulations
The following illustrate the device loaded in only the X/Z direction. Displacement constrains are of zero displacement in X,Y,Z:
The following illustrate the device loaded in only the Y direction. Displacement constrains are of zero displacement in X,Y,Z:
The following illustrate the device loaded equally in only the X,Y, and Z directions. Displacement constrains are of zero displacement in X,Y,Z:
GUI Test Bench SimulationsAs the DAQ has not yet been able to be purchased, the testing of the GUI has been limited to verifying the math using LabView.
The current axis of the device is abitrary and will need to be determined based on final sensor positioning and load definitions.
Quotes ReceivedRIGHT CLAMP 1018 MATL $330.00
LEFT CLAMP 1018 MATL $275.00
INNER SOCKET 1018 MATL $240.00
OUTER SOCKET 1018 MATL $240.00
PIVOT PIN 1018 MATL $75.00
TOOLING BALL 4140 PH $100.00
Bill of Materials (BoM)
List of Purchase Orders CompletedLow Profile Hydraulic Cylinder- $319.00
Donut Load Cell 2000LB Capacity- $560.00
- Note that no purchases have been made
Test PlansTest Plans
Preliminary Usage/Safety Manuals
Users ManualTwo "User Manuals" will be provided, a generic one and one specific to the test hobber.
They will include five sections as follows:
1) Safety First.
2) The Device:
- How it works.
- That attachment points.
- Initial setup.
3) The Ram:
- Safety precautions.
- How it is operated.
4) The GUI:
- How the sensors work.
- How to set it up.
- How to use it.
5) A Test:
- How to perform 3 generic tests (X, Y, and XYZ loading).
Safety DocumentsAreas of Concern:
- Components breaking which leads to injury
- Pinch points as a heavy load is applied
- Damage to the hobbing machine
Applying a sticker to the device such as the one below is another option.
Image provided by mysafetylabels.com
Risk Assessment Chart
Areas we are still worried about
- Any outstanding issues that we might be overlooking?
- Is it ok for our clamp to be fully made of steel or do we need to have a piece of rubber or cloth between the clamp and the arbor.
- Cost may be getting a little out of hand. Any ideas on how to reduce cost without changing the design too much.
Plans for next phase
- Fix anything based on feedback we receive
- Create model that contains all wires and components
- Finalize calibrating procedures and test plans
- Finalize what parts to outsource, buy, or make our own
- Finalize Purchase Orders and BOM
- Finalize Users Manual and Safety Procedures
- Determine how to build individual components and assemble the part as a whole
- Prepare Preliminary MSD II Schedule
- We were a little overzealous with what we wanted to get done.
- Use one CAD modeling program only. Jumping from Creo to Solidworks and back to Creo is a task in itself.
- Create definitive meeting times (Say let's meet 2pm Sunday instead of sometime this weekend)