P17665: Rotating Dynamometer for Cutting Tools
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Detailed Design

Table of Contents

Team Vision for Detailed Design Phase

The main goal of Phase 4 was to finalize all documentation, analysis, simulation, and proof of concept for our device. Due to the design of our device and the time constraints on MSD, some of the original customer requirements had to be altered. This completed phase is comprised of all design considerations and is ready to be reviewed for final implementation.

Required Tasks:

Other Accomplishments:

Progress Report

Click here to view the Mid-Phase Progress Report.

Click here to view the Updated Mid-Phase Progress Report as of 12/6/16.

Mechanical

Force Equations

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Click here to download the force calculations PDF.

Deflection Analysis

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Click here to download the Deflection Analysis spreadsheet.

Natural Frequency Analysis

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Click here to download the Deflection Analysis in .xlsx form or PDF form.

Toolholder Adapter & Acceptor

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Click here to download the toolholder adapter inventor part file.

Click here to download the toolholder adapter inventor part file without the bolt holes used in the ansys models.

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Click here to download the toolholder inventor assembly file.

Click here to download the toolholder nut inventor part file.

Click here to download the toolholder backstop inventor part file.

Click here to download the toolholder retaining ring inventor part file.

Click here to download the toolholder body inventor part file.

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Click here to download the Tool Acceptor inventor acceptor file.

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Click here to download the toolholder adapter print.

Measurement Structure

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Click here to download the Measurement structure inventor part file.

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Click here to download the Measurement Legs print.

Strain Gauge Placement

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Housing

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Click here to download one portion of the housing.

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Click here to download the other portion of the housing.

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Click here to download the housing assembly.

Full Assembly

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Click here to download the full assembly inventor file.

Ansys simulation

Setup

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Mesh

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Stress

500N

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500N at 18 degrees

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Strain

50N

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500N

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500N at 18 degrees

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Total Deformation

50N

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500N

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500N at 18 degrees

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Electrical

Electrical System Overview

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Click here to download the Electronics overview pdf file.

Wheatstone Bridge Circuit

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Click here to download the wheatstone bridge circuit pdf file.

Amplifier Circuit

Analysis and Design

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Click here to download the amplifier circuit pdf file.

Software Simulation

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Hardware Testing

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Filter Circuit

Microcontroller

Program Flow

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Click here to download the microcontroller program flow pdf file.

UART Calculations

Sample Rate Timer Calculations

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Communications Protocol

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Click here to download the communication scheme pdf file.

Program Code

The Code Composer Archive File containing C code for the program outlined above is located at here.

Testing

The capture below shows the program functioning under a test environment. The RN-42 was connected to the MSP430 launchpad device and was successfully able to wirelessly transmit sampled data to a computer.

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A packet data loss test was also done to see if data is not being lost during transmission. This was done by sending sequential numbers at the prescribed sampling time from the MSP430.

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Wiring Diagram

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Click here to download the wiring diagram pdf file.

Power Consumption Study

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Click here to download Power Calculations in pdf format and here in xlsx format.

Bill of Material (BOM)

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Click here to download the Bill of Materials in pdf format and click here to download in xlsx format.

Test Plans

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Click here to download the Test Plan pdf file.

Risk Assessment

Current Risks

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Click here to download the Risk Assessment in xlsx format.

Risk Score vs Time

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Click here to download the Risk Score vs Time document in pdf format.

Key Takeaways

Action List Items and Meeting Notes

Meetings with Dr. Liu

11/24 Meeting Notes

11/29 Meeting Notes

12/01 Meeting Notes

Meetings with Dr. Kempski

Meeting Notes

SME Form

Meetings with Professor Slack

SME Form

Plans for next phase

Click here to view the MSD I Project Plan.

Click here to view the MSD II Project Plan.

Three Week Plans

Each team member has developed an individual plan for the first three weeks of MSD II. This will help ensure that important tasks are completed and that all milestones are reached on time for the Detailed Design Review.

JA Three Week Plan

EH Three Week Plan

ZR Three Week Plan

MI Three Week Plan

BC Three Week Plan


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