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Drop Testing Apparatus

Drop Testing Apparatus. Team Members: Deatly Butler Mark Clouse Chris Dux Kris Honas Shaun Scott Drew Stephens. Client: Itron, Inc. Brian Priest. Technical Advisors: Steve Beyerlein Mike Severance.

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Drop Testing Apparatus

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  1. Drop Testing Apparatus Team Members: Deatly Butler Mark Clouse Chris Dux Kris Honas Shaun Scott Drew Stephens Client: Itron, Inc. Brian Priest Technical Advisors: Steve Beyerlein Mike Severance

  2. Presentation Overview • Customer Needs • Mechanical Components • Table Drop Design • Orientation Devices • Height Adjustment • Electrical Components • Data Acquisition • CPU • Interface • Software • Camera • Costs • Recommended Design • Work Remaining • Questions?

  3. Needs • Repeatable Impacts ( 45 +/- 5 deg) • Adjustable Drop Height (18-60 inches) • Portable (Wheels) • Short Setup time (<1 min) • Video Data Acquisition (automatically named and stored)

  4. Mechanical Components • Table Drop Design • Orientation Devices • Height Adjustment

  5. Table Drop Design Using Pneumatics • Fast Acceleration • Simple • Inexpensive • Non Electrical • Long Life

  6. Table Drop Design #1Frontside Pneumatic • PROS • One Pneumatic • Four Linear Bearings • CONS • Table Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects • No Initial Vertical Motion

  7. Table Drop Design #1Frontside Pneumatic

  8. Table Drop Design #2Backside Pneumatic • PROS • One Pneumatic Device • Four Linear Bearings • Pneumatic Does Not Interfere With Table Space • CONS • Table Only Rotates – Could Potentially Cause Slight Rotation On Dropped Objects • No Initial Vertical Motion

  9. Table Drop Design #2Backside Pneumatic

  10. Table Drop Design #3Double Pneumatic • PROS • Vertical Pneumatic Prevents Rotation on Test Device • CONS • More Linear Bearings • More Pneumatic Cylinders • Increased Chance of System Malfunction

  11. Table Drop Design #3Double Pneumatic

  12. Orientation DevicesCradle Block Design • PROS • Simple Block Design • Inexpensive • Simple Operation • Minimal Setup Time • Easily Removable • CONS • Works Best for Smaller Devices • Additional Testing Required to Confirm Functionality

  13. Orientation Device Design #1Edge Testing

  14. Orientation Device Design #2Corner Testing

  15. Orientation Device Design #2Corner Testing

  16. Height Adjustment Design #1Manual Hand Crank • Pros • Smooth Adjustment For Any Height • Able To Raise And Lower Heavier Loads. • Cons • Slow Adjustment • Involved Manufacturing Process • Increased Cost

  17. Height Adjustment Design #1Manual Hand Crank

  18. Height Adjustment Design #2Pin and Collar • Pros • Quick Adjustment • Predetermined Standard Heights • Secure Locking Mechanism • Cons • Operator Must Be Able To Support Weight Of Table And Mechanism

  19. Height Adjustment Design #2Pin and Collar

  20. Electrical Components • Data Acquisition • CPU • Interface • Software • Camera

  21. Importing to a PC • Video for each test will be imported to a PC by using GPIB interface. • Instrument controlled by Labview. • Automatically will name and store video clips for each test.

  22. CPU • Zero Footprint PC - $500 (w/o monitor) • LCD PC - $1000

  23. GPIB Interface • General Purpose Interface Bus • Standard interface between instruments and controllers from various vendors. • 8-bit parallel communication. • 5 bus management lines (ATN, EOI, IFC, REN, & SRQ) • 3 handshaking lines. • 8 ground lines.

  24. LabVIEW Software • Uses VI’s (Virtual Instrumentation) • Imitates physical instruments. • Cheaper than Hardware. • Modular Program design. • Will be used with GPIB to control the video.

  25. Video Camera • Handheld will fall in about 0.5 seconds • Video below 200 fps may be able to capture enough images

  26. Camera Option #1 Machine Vision System Pros High Speed Acquisition (>10000 fps) Cons Small Picture Area (1.5” x 1.25”) Designed as an Automatic Inspection Sensor Doesn’t capture video

  27. Camera Option #2 High Speed Video Camera Pros Easily interfaced and controlled with LabVIEW software Could be tested with lower quality cameras Cons High Cost Low Acquisition Speeds (< 500 fps)

  28. Mechanical Costs • Pneumatic Cylinder (1-3) $50ea • Shafts (1-2) $40ea • Raw Materials • Sheet Metal $70 • Metal Tubing $20 • Misc. Hardware $60 • Linear Bearings (2-6) $60ea • Spur Gear and Rack $200 • Valves and Fittings $100 • Compressor (Optional) $300 • Total ~$1400

  29. Electrical Costs • Computer ~$1500 • GPIB $300 • Misc. $200 • Camera ~$800

  30. Recommended Design • Single Pneumatic Operation (Back Side) • Track Mounted Block Orientation Device • Pin and Collar Height Adjustment • LCD PC or Laptop • GPIB Interface • LabVIEW Software

  31. Spring 2006 Detail Design: (Jan. 9th 2006 – Feb. 1st 2006) - Order parts. - Assess Drawing package. - Complete drawing package. Fabrication: (Feb 2nd 2006 – March 20th 2006) - Build product. Validation: (March 21st 2006 – April 20th 2006) - Debug and fix product. - Validate performance of product. - Draft final project report. Delivery: (April 21st 2006 – May 9th 2006) - Archive project documentation. - Deliver product. - Write final report. Work Remaining

  32. Our Questions for Itron • Will ~200 fps be enough for the video? • Computer? • Camera? • GPIB? • Labview license?

  33. Questions?

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