MALLARD MANUFACTURING

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MALLARD MANUFACTURING

• TECHNOLOGY 478
• Dr. Clifford Mirman

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THE MALLARD TEAM

• GUY ROBINSON
• JOE FRANKLIN
• NATE BOELKINS
• ALI TAHIR

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TEAM PICTURE
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PROJECT PROFILE

• PRODUCT DESCRIPTION
• Storage Handling Systems
• Time, Space, Energy, and Money Saving
• PROJECT DESCRIPTION
• TEST STAND FOR ROLLER BEARINGS
• APPLY VARING LOADS UP TO 500 LBS
• ROTATE BEARING AT SPEEDS UP TO 2000 RPM
• ACQUIRE AND RECORD DATA

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ROLLER BEARINGS
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APPLYING THE LOAD

• LOAD CELLS
• TWO LOAD CELLS ON X AND Y AXIS
• USE COMPRESSION TO VARY OUTPUT VOLTAGE
• TURN BUCKLE
• 3/8 DOUBLE ENDED THREADED ROD
• EXPANDS AND CONTRACTS
• POSTIONING THREADED ROD
• TWO POINT STYLES
• POINTED -- LOAD ON ONE POINT
• CURVED -- LOAD APPLIED ON CURVE OF BEARING

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LOAD MECHANISM
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ROTATING THE BEARING

• MOTOR
• 1/5 HP / 120 VAC
• MOTOR MOUNT
• SHAFT
• 1/2 HARDENED STEEL ROD
• MACHINING REQUIRED ON BOTH ENDS
• COUPLING AND MOUNTING
• UNIVERSAL JOINT
• BELL HOUSE BEARINGS

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FRAME DESIGN
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FRAME ASSEMBLY

• FRAME MATERIAL
• Aluminum Extrusion
• 30mm Square
• T-Slotted on all sides
• Joining Plates
• 3/16 Steel
• Fastened with T-Nut and Bolt

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FRAME ASSEMBLY CONT.

• ADVANTAGES OF MATERIAL
• Strength to Weight Ratio
• Versatility of Slot System
• Ease of Assembly

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FRAME ASSEMBLY CONT.

• SLIDES
• Used to Slide Load Mechanism
• Designed For Use With T-Slots
• ELECTRONICS HOUSING
• Shelters Sensitive Electronics
• 1/8 Aluminum Plating
• Fastens to T-Slots

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ELECTRICAL SYSTEM

• FORCE MEASUREMENT
• MOTOR SPEED CONTROL
• ROTATION SPEED MEASUREMENT
• DATA DISPLAY AND PRINT-OUT
• STAMP MICROCONTROLLER

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ELECTRONICS BLOCK DIAGRAM
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FORCE MEASUREMENT

• Load Cell
• mV output
• Instrumentation Amplifier
• Increases Voltage to 0-5V range
• Analog to Digital
• 0-5V Analog to Serial Output

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MOTOR SPEED CONTROL AND MEASUREMENT

• SPEED CONTROL
• Dayton 1/5 HP, 120 VAC Input
• Dayton Speed Control - Chopper Circuit

• Speed Measurement
• Infrared Detector and Emitter
• Breakable Light Beam is Created
• Tab on Shaft Breaks Beam
• 5V pulse is created

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DATA DISPLAY AND PRINTER

• DATA PRINTER
• Receipt Style Printer
• Serial Data Input
• Prints Every 10 Minutes

• DATA DISPLAY
• LCD Display
• Serial Data Input
• Continuously Updated
• Back-Lighting Capabilities

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THE MICROCONTROLLER

• BASIC STAMP 2SX
• 16 I/O Pins
• ??? of Memory
• Simplistic Programming
• Transmit and Receive Serial Data
• Pulse Counting

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LOAD ANALYSIS

• Transfer of Force
• Direct measurement Force by Electrical signal is
  Hard
• Can be done step by step
• Force applied (Turn buckle and point load)
• Stress-strain (Load Cell)
• resistance change and bridge output

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LOAD ANALYSIS CONT.

• Loads on Bearings
• Axial Load - Parallel to axis of the shaft
• Radial Load - Right angles to the axis of the
  shaft
• Reaction of the Motor (Torque)
• Point Load to minimize the result error
• Deflection
• Frame
• Point Loads and Shaft

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PROBLEMS ENCOUNTERED

• MOTOR VIBRATION
• Machining Difficulties
• Precision Alignment
• LOAD APPLICATION
• Applying Force
• Load Cells Spinning
• PROGRAMMING COMPLEXITY
• Subroutine Limits
• Serial Data Transmission

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THANK YOU

• MALLARD MANUFACTURING
• TECHNOLOGY FACULTY AND STAFF
• AL METZGER
• DR. MIRMAN

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FINAL PRODUCT