Bishop Steering Technology II Precision Measurement Device

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Bishop Steering Technology IIPrecision
MeasurementDevice

• Hong Zhu
• Kyle Powell
• David K. Spaeth
• Patrick Richardson

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Reason for the Design

• Present measurement techniques are not accurate
  enough
• Ensure consistent measurements between the
  various tiers involved in the industry
• Improper measurement can result in a part being
  accepted that will fail when the whole steering
  system is tested
• Properly measured parts facilitate cooperation
  between suppliers
• Fewer returned parts will reduce costs

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Main Requirements

• Client needs two measurement systems to measure
  components of a rack and pinion steering system
• Measurements must not have a difference greater
  than /- 3microns from true value
• Device must not be overly complicated

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How Small is Three Microns?

• The average skin cell is four microns in diameter
• The average human hair is 70 microns in diameter

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Input Shaft
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Input Sleeve
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How the Parts Interface
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How steering system works
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Problems with poorly measured shafts and sleeves

• If the shaft and sleeve are not accurately
  machined, the flow of hydraulic fluid through
  them will not be even
• The car may turn even though the steering wheel
  is in the neutral (center) position
• The car may be more difficult to turn in one
  direction than the other
• Increased costs due to repairs and bad parts

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Process Control

• The measuring process must be consistent
• Because of the high accuracy required, the test
  facility must be in a pristine, laboratory-like
  environment
• The environment must be controlled and free of
  dust and other fugitive material that could be
  detrimental to the measuring process

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Thermal Control

• Any variation in temperature cause the size of a
  shaft or sleeve to change by more than three
  microns
• Transfer of human body heat to the shafts and
  sleeves must be minimized
• The ambient room temperature must be kept
  constant

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Sensors

• It is necessary to record both linear and angular
  displacements
• The challenge was to find a way to record both
  displacements at the same time

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Linear Distance Sensor

• For the shaft measurement we propose the use of a
  Keyence LK-011 laser

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Linear Distance Sensor

• For the sleeve we propose the Philtec Fiber Optic
  linear displacement sensor

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Angular Displacement Sensor

• The angular encoder can measure the angular
  rotation of a shaft to within 0.00005 accuracy

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Sensor Mounting

• Sensors are very sensitive, and must be
  stationary
• So, the shafts and sleeves must be rotated
• so all the notches can be measured by the
  sensors
• Why not design one device that holds both sensors
  stationary and measure both shafts and sleeves?

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Device Stand
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Positioning and Alignment

• Measurement Position Alignment
• By definition, linear and angular measurements
  require exact positioning and alignment
• Precision measurement requires precision equipment

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X-Y Tables

• Micrometer driven tables allow for accurate
  positioning
• Movable on one or two axes

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Bellows Type Flexible Couplings

• Rotation of shaft or sleeve must be the same as
  rotation of encoder
• Unique design ensures that rotation is the same
  at top and bottom of coupling and that shafts are
  aligned

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Bearing

• Browning Spherical Roller Bearing
• Low radial runout of 1.5 microns

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Use of a Stock Motor and Gear Reducer

• Small motors capable of turning the shafts and
  sleeves at constant speed are common and
  available for purchase
• We will use a Parker Automation stepper motor and
  a Daedel gear reducer

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Data Acquisition and Analysis

• Both the Keyence laser and Philtec fiber optic
  sensor are sold with electronics that acquire and
  process the data
• Output is usually digital, but analog output
  devices with graphical displays are available

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Patents and Trademarks

• We have found no exact matches for the proposed
  designs
• There are patented designs for similar
  components, but no design that incorporates them
  into a single system
• The Laser Micro100 by BLUM is the closest in
  theory to what we are attempting

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Design Modeling

• This project called for research and design, but
  not the building of a prototype
• Pro-Engineer is a powerful software program that
  allows us to model the design
• The components in our design are only
  representations of the actual parts

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Gauge Plate Interface
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Sleeve Measurement
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Shaft Measurement
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Shaft Rear View
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Conclusion

• We met the engineering requirements for
• accuracy and surpassed our task of
• designing a machine that could measure
• either the shaft or the sleeve
• OUR DESIGN MEASURES BOTH!
• The technology to produce this
• measurement machine is available now

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Recommendations

• We suggest that a prototype of this design
• be made and tested.
• Possible alternatives to our method of adjusting
  the gauge plate be investigated.

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Consultants

• Dr. Jie Chen - IUPUI
• Jason Wou Bishop Steering
• Daniel Crafton Bishop Steering
• Andy Hartsock Parker Automation
• Dr. A.K. Naghdi IUPUI
• Sales Support Heidenhain
• Dr. Vermuri IUPUI, Physics Department

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References

• The Mechanical Design Process
• By David G. Ullman
• MCG, 2002
• Introduction to Laser Technology
• By Hitz, C. Breck, Hitz, Breck, Ewing, J.
  J.,Hecht, Jeff
• John Wiley Sons Inc, 2001
• An Introduction to Fiber OpticsBy R. Allen
  Shotwell, E. Stewart
• Prentice Hall, 1996 

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Electronic References

• www.keyence.com
• www.howstuffworks.com
• www.philtec.com
• www.newport.com/
• www.isotech.net
• www.scantron-net.co.uk/applications.htmfibres
• www.eng.warwick.ac.uk/espbc/index.htm
• www.microphotonics.com/
• www.beemerprecision.com/info.html
• www.hephaist.co.jp/e/index.html
• www.eminebea.com/usa/
• www.hansen-motor.com/
• www.mstores.umich.edu/