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Final Design Report- Vibration Table for CVBT- VT4 Design Team

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    June 3 2010   Final Design Report: Vibration Table for CVBT- VT4 Design Team Thomas Bevan and Matthew Laurino Dr. Mello ME 428   Page | 2 Table of Contents: Executive Summary: ................................................................................................................................ 5 Introduction: ........................................................................................................................................... 6 Background: ............................................................................................................................................ 6 Objectives: .............................................................................................................................................. 8 Design Goals: ....................................................................................................................................... 8 Deliverables: ........................................................................................................................................ 9 Management Plan: ................................................................................................................................ 10 Design Development: ............................................................................................................................ 10 Tabletop: ........................................................................................................................................... 11 Spring Suspension System: ................................................................................................................ 13 Rubber Mount Suspension System: ................................................................................................... 17 Air Cushion Suspension System: ........................................................................................................ 17 Eccentricity Assembly: ....................................................................................................................... 18 Rheostat: ........................................................................................................................................... 20 Damping Mass: .................................................................................................................................. 21 Development Test Plan:......................................................................................................................... 22 Testing and Results: ............................................................................................................................... 25 VT4 Prototype Vibration Testing: ....................................................................................................... 26 Endurance Testing: ............................................................................................................................ 30 Final Design: .......................................................................................................................................... 31 Appendices: .......................................................................................................................................... 32 Gantt Chart........................................................................................................................................ 33 QFD House of Quality ........................................................................................................................ 36 Existing Products ............................................................................................................................... 37 Hand Calculations: ............................................................................................................................. 38 Four Spring Simulink Model ............................................................................................................... 39 Translational Spring Constant Matlab script ....................................................................................... 41 Tokushu Denso Motor Curves ............................................................................................................ 43 Prototype Testing Pictures ................................................................................................................. 44   Page | 3 Maintenance Log Sheet ..................................................................................................................... 46 Bill of Materials ................................................................................................................................. 47 VT4 Part Drawings ............................................................................................................................. 48 Operator’s Manual  ............................................................................................................................ 49   Page | 4 List of Figures: Figure 1: Drawing of VT4 final design ...................................................................................................................... 5 Figure 2: Horizontal motion design sketches, showing glide bearing locations and spring alignment for axial and transverse deflection. ........................................................................................................................................... 10 Figure 3: Design concept layout for various suspension systems. .......................................................................... 11 Figure 4: Deflection analysis of tabletop design, performed in Solidworks ............................................................. 12 Figure 5: Stress analysis of tabletop design performed in Solidworks..................................................................... 13 Figure 6: Simulink Plot of input force and tabletop displacement over time. The plot shows the reduced tabletop frequency with low k values and minimal damping. k=20 N/mm, C=0.001 N*sec/m, and me=0.00146 Kg*m ......... 14 Figure 7: Simulink Plot of input force and tabletop displacement over time. The plot shows the beat frequency apparent with high k values and minimal damping. k=2000 N/mm, C=0.001 N*sec/m, and me=0.00146 Kg*m ..... 15 Figure 8: Simulink Plot of input force and tabletop displacement over time. The plot shows the suppressed beat frequency apparent when moderate damping is used with high k values. k=2000 N/mm, C=10 N*sec/m, and me=0.00146 Kg*m ............................................................................................................................................... 16 Figure 9: Shear rubber mount configuration ......................................................................................................... 17 Figure 10: Vibco Electric Air Cushion Vibration Table (www.vibco.com Model US-RD-18X18) ................................ 18 Figure 11: Eccentricity assembly, with input shaft, housing, bearings, and eccentric mass. The eccentricity itself is a U-bolt which allows for an easy way to add mass and or change eccentric radius. This is accomplished by adding bolts to the free end of the U-bolt, and then using the threads to change the distance to the center. ................... 19 Figure 12: Eccentricity assembly, with input shaft, housing, bearings, and eccentric mass, showing the non-adjustable eccentricity chosen for the final VT4 design. ........................................................................................ 19 Figure 13: This plot shows the displacement of the table and input force from eccentricity vs. time. The spring constant = 2*106 N/m, c = 10 N*sec/m, m*e =.00248 kg*m, and input speed = 3800 RPM. .................................. 20 Figure 14: This plot shows the displacement of the table and input force from eccentricity vs. time. The spring constant = 2*106 N/m, c = 10 N*sec/m, m*e =.00248 kg*m, and input speed = 3700 RPM. Notice the large difference in displacement from the previous graph, due to a small change in input speed. .................................. 21 Figure 15: This figure shows a side view of the bike inner tube concept. ............................................................... 22 Figure 16: This figure shows the underside of the bike inner tube concept. ........................................................... 23 Figure 17: This figure shows the tabletop displacement of the bike inner tube concept when the concrete mass is 40kg and the eccentric and acceleration forces are assuming an eccentric mass of 0.00248 kg-m spinning at 3800 rpm. ..................................................................................................................................................................... 24 Figure 18: Fiber-reinforced rubber stabilizer assembly. ......................................................................................... 25 Figure 19: Final drawing of VT4 showing Damping Mass, made out of concrete, hanging from the vibration box. .. 29 Figure 20: Amplitude and frequency for each mold size tested with final design parameters of tube height, shaft alignment, eccentric size, and stabilization set. ..................................................................................................... 29 Figure 21: VT4 Final Design. .................................................................................................................................. 31 Figure 22: Martin Electric Vertical Spring Suspension Vibration Table .................................................................... 37 Figure 23: Patent Using Solid Rubber Mount as Pivot Point (www.freepatentsonline.com/4483621.pdf) ............... 37 Figure 24: CWC Hanging Tabletop With Horizontal Motion (www.cwc.org/gl_bp/gbp3-0403.htm) ........................ 37 Figure 25: Syntron Vibration Table with rubber shear mounts (located at Cal Poly) ............................................... 37 Figure 26: Tokushu Denso 2570-333 motor curves. ............................................................................................... 43
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