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MECH-311

MANUFACTURING / TESTING / ANALYSIS PROJECT

Objective:

A major challenge in delivering a successful design is to ensure that it is


manufacturable. This project deals with the design and manufacturing of a
device. Through this process, several manufacturing issues will be faced.
Once the deliverable is completed, it will be tested and data will be
collected on its various sub-systems. The results will be compared to the
theoretical knowledge gained in class to see how the manufacturing
limitations affect the theoretical design.

Design Procedure:

You are to design a crank / clutch mechanism (see Figure 1) where the
crank will work against an extension coil spring (Jones Spring part #310
or #312), and will be driven by a DC motor (Mabuchi model RF-500TB-
12560) or other supplied by prof. The power from the motor to the crank
will be transferred through a belt / pulley transmission and a clutch that is
activated by a compression spring (Jones Spring part #1620 or #1626).
Figure 2 shows clutch details. You are strongly encouraged to review
clutches by clicking here. Recall that tutorials on DC motors, springs, belt
/ pulley transmissions and more can be found in the Mechanical Work
Session document. The remainder of the construction materials must
come from what is available in the Hougen Lab.

BEFORE BEGINNING YOUR DESIGN, PLEASE FAMILIARIZE


YOURSELF WITH THE MATERIALS AVAILABLE. YOUR PARTS
MUST BE DESIGNED IN A WAY THAT THEY CAN BE BUILT
FROM AVAILABLE MATERIAL!
Your design must take the following into consideration:

1. The extension spring will be placed in a preloaded condition such


that its total deformation ranges from no less than 1/2-inch to no
more than 3-1/2 inches.
2. You will need to place a transmission (belts and pulleys) between the
motor and clutch and between the clutch and crank. To determine the
transmission ratios, you will need to complete crank mechanism
torque calculations. A tutorial is provided here if you need help. The
remaining process of determining design parameters MUST be
accomplished by following the guidelines below and by using the
Microsoft Excel design template provided.
3. Your device must fit inside a 14-inch by 8-inch by 7-inch box when
completely assembled so that it will be able to fit along with your
toolbox in your locker. No exceptions!
4. You are limited to two 12-inch pine boards and one 12-inch by 12-
inch sheet of either plywood or masonite.
5. The end of the connecting rod that attaches to the extension spring
must oscillate linearly.
6. You are to make a complete set of detailed drawings for making the
manufactured parts of your entire design. You must also make an
assembly drawing. The use of CAD to complete these is
REQUIRED. All dimensions, materials and bearing surfaces must be
specified.
Manufacturing Procedure:

Your drawings will be given to another team to be manufactured for you.


Similarly, you will manufacture parts for another team based on their
design drawings. Manufactured parts will be returned to their respective
design teams when completed. They should be checked to be sure they
are in specification and then assembled. Finally, test analysis must be
done. A design team will grade their manufacturing team based on the
quality of parts received, and the manufacturing teams will grade their
design team based on the completeness and quality of the drawings given
to them.

PROCEDURE TO DETERMINE DESIGN PARAMETERS (NOTE:


Do this in conjunction with the Microsoft Excel design template!)

1. Determine torque on the crank mechanism (Tcrank) when the crank


angle is 90 degrees:

• Choose an extension spring #312 or #310.


• Choose a spring preload between 1/2-inch and 1-inch.
• Choose a crank length A where 1/2-inch < A < 1-1/2 inch.
• Choose a connecting rod length B where 2*A < B < 10*A.

Use parameters you’ve chosen above to calculate Tcrank when the crank
angle is 90 degrees. NOTE: the torque calculations tutorial shows
calculations for a crank angle of 105 degrees. The computation for a
crank angle of 90 degrees is MUCH less complicated!

The Free Body Diagram of the interface between the connecting rod and
the spring slider shown below may be helpful to you. Keep in mind that
friction force should be kept as small as possible (ideally it should be
zero).

2. Determine the torque output (Tslip) from the clutch:

• Choose a transmission (pulley diameter) drive ratio (Ratio1) where


2 < Ratio1 < 6.
• Calculate the torque output from the clutch (Tslip) where:

Tslip = Tcrank / Ratio1


3. Using the clutch equation, determine the clutch dimensions and
parameters required to produce your calculated Tslip:

• Use Ri = 3/8-inch
• Choose Ro where 5/8-inch < Ro < 1-inch.
• Experimentally determine the coefficients of friction (static and
dynamic) for masonite on masonite.
• Choose a compression spring (part #1620 or #1626)
• Choose a deformation distance (d) for this spring so that 1/4-inch <
d < 3/4-inch.
• Determine the clutch actuating force Fa developed by compression
of the spring.
• Use the clutch equation to calculate Tslip for your initial clutch
design. Modify parameters such as Ro and d until your calculated
Tslip matches the value of Tslip determined in Step 2 above.

4. Determine the motor torque (Tmotor) required to operate the


mechanism:

• Consulting the motor specification sheet, choose a value of Tmotor


so that
(0.3 * Tstall < Tmotor < (0.5 * Tstall)
• Choose a transmission (pulley diameter) ratio (Ratio2) so that
Ratio2 < 40:1.
• Assume an efficiency (η) for this system so that 0.2 < η < 0.5
• Adjust values of Ratio2 and η until:

Ratio2 * η = Tslip / Tmotor

When this condition is met, your design parameters are determined. You
may proceed to designing the actual parts now based on these parameters.
If this condition cannot be met, return to the Microsoft Excel design
template and modify various parameters in the yellow boxes (do only 1 or
2 at a time!) until the condition is met.

Testing and Analysis Procedure:

Once your project is assembled and functional, adjust the clutch spring
force (Fa) until the clutch slips due to insufficient torque to overcome the
maximum crank torque. The crank will not complete a full revolution
under this condition.

TEST 1

Determine the motor torque using two different methods and compare the
results:

1. Apply 3 volts (regulated) to the motor using a one-ohm resistor in


series between the motor and the voltage source. Measure the
voltage drop across the resistor. Using Ohm’s Law, show in your
Engineering Logbooks how this voltage measurement is equivalent to
the current being supplied to the motor.
2. Knowing the motor current, use the motor’s specification sheet to
determine the motor torque as a function of current.
3. Using an oscilloscope, measure the signal across the one-ohm resistor
and display it. Adjust the display until you observe a sequence of
impulses embedded in this signal. These impulses are “back EMF”
generated by the motor. Knowing that there are six pulses per
revolution of the motor, and using the oscilloscope to determine the
time between pulses, calculate the speed of the motor in RPMs.
4. Knowing the motor speed, consult the specification sheet again to
determine the motor torque as a function of speed.
5. Compare the results of your two torque determinations to the torque
value that your team predicted from calculations. Calculate percent
differences and comment in your reports.

TEST 2

Determine the clutch slip torque (Tslip) using two different methods and
compare results:

1. While the motor continues to operate under the conditions of Test 1,


adjust the compression spring until the crank angle is 90 degrees
when slipping. Measure the spring deformation and determine the
value of Tslip based on this.
2. Wrap a string around the driven part of the clutch, replacing the belt
drive to the crank. Use a spring scale tied to the string to measure the
actual force required to make the clutch slip. Calculate the
corresponding slip torque (Tslip) based on this measured force and
the clutch radius where the string is wrapped around. Make sure your
spring scale is calibrated for the angle for which it is being held.
3. Compare both experimental Tslip determinations to the calculated
value that your team used. Calculate percent differences and
comment in your reports.
Finally, using the results from Test 1 (Tmotor) and from Test 2 (Tslip)
and the drive ratio (Ratio2), calculate the actual efficiency and compare to
the value you assumed in the Microsoft Excel design template.

Deliverables: The following items must be delivered BY THEIR DUE


DATE (Late reports are SEVERELY PENALIZED on grades!):

1. Prepare a 6-8 minute team PowerPoint presentation describing all


aspects of your project including:
• Any manufacturing difficulties your team had to overcome, and
how you did it.
• Your theoretical calculations (including all units)
• The results of your tests
• Differences between theory and measurements

NOTE: Each team member must speak during this presentation. NOTE:
Large percent errors are expected – your job is not to “cover them up” but
identify the causes and discuss them!

2. Prepare a thorough report documenting the entire manufacturing


process and fully discuss your theoretical computation, your test results,
comparisons, etc. You MUST also include your Microsoft Excel design
template, all graphs, calculations and part drawings.

3. Include a sheet grading the manufacturing team that produced your


parts, as well as the quality of the drawings produced by the design team
that you manufactured parts for. Identify teams by team numbers only!

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