MULTIDISCIPLINARYENGINEERINGMULTIDISCIPLINARYENGINEERING @ R I T Senior Design ME RIT MULTIDISCIPLINARYENGINEERINGMULTIDISCIPLINARYENGINEERING @ R I T

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MULTIDISCIPLINARYMULTIDISCIPLINARYENGINEERINGENGINEERING


@ R I T

Senior Design Senior Design

MEMERITRITMULTIDISCIPLINARYMULTIDISCIPLINARY

ENGINEERINGENGINEERINGMULTIDISCIPLINARYMULTIDISCIPLINARY

ENGINEERINGENGINEERING@ R I T


MEMERITRIT

HIGH SPEED LANYARD RELEASE TEST HIGH SPEED LANYARD RELEASE TEST FIXTUREFIXTURE

PROJECT NUMBER 05423PROJECT NUMBER 05423

Michael Amos, Team Leader

Mechanical Engineer

Aaron Brechko

Mechanical Engineer

Joshua Carmer

Electrical Engineer

Justin Grigonis

Industrial & Systems Engineer

Lindsay LaRocca

Mechanical Engineer

Dr. Benjamin Varela, Faculty Mentor

Mechanical Engineer

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Topics of DiscussionTopics of Discussion

Who is Amphenol?Who is Amphenol? Project Mission StatementProject Mission Statement Customer NeedsCustomer Needs Design ObjectivesDesign Objectives Performance SpecificationsPerformance Specifications ConceptsConcepts

• UnfeasibleUnfeasible• FeasibleFeasible

Design FeasibilityDesign Feasibility Future GoalsFuture Goals

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Amphenol Aerospace Amphenol Aerospace Operations (AAO)Operations (AAO)

““Accepted leader in providing quality Accepted leader in providing quality connectors… to the Industrial, connectors… to the Industrial,

Military, and Aerospace markets” Military, and Aerospace markets”

www.Amphenol-Aerospace.comwww.Amphenol-Aerospace.com

Sidney, New YorkSidney, New York

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Project Mission StatementProject Mission Statement

To develop several feasible concepts, To develop several feasible concepts,

with supporting documentation, with supporting documentation,

for an actuation method for an actuation method

to test the separation of to test the separation of

AAO’s lanyard release connectors.AAO’s lanyard release connectors.

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Lanyard-Release Connector Lanyard-Release Connector AssemblyAssembly

Main Components Main Components • LanyardLanyard• Operating SleeveOperating Sleeve• Plug ShellPlug Shell• ReceptacleReceptacle

Main electrical Main electrical interface between interface between aircraft and its aircraft and its storesstores

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Connector Operation: Locked Position

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Connector Operation: Un-locked Position

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Current Drop TestCurrent Drop Test

High cycle timeHigh cycle time No data acquisitionNo data acquisition UnsafeUnsafe InaccurateInaccurate Low precisionLow precision ““Two-person” Two-person”

operationoperation

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Customer Needs / Customer Needs / Performance RequirementsPerformance Requirements

Meet new Military Specification MIL-DTL-Meet new Military Specification MIL-DTL-38999/31D38999/31D• High speed separation of connectorHigh speed separation of connector

30 ft/s ± 10%30 ft/s ± 10% Variable Test VelocityVariable Test Velocity ReliableReliable RepeatableRepeatable EconomicalEconomical Low-Cycle TimeLow-Cycle Time SafeSafe Size <30 ftSize <30 ft33

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Concepts Evaluated – Concepts Evaluated – Considered UnfeasibleConsidered Unfeasible

Use of Actual Charges and Bomb RackUse of Actual Charges and Bomb Rack• Numerous safety issuesNumerous safety issues

Propane ActuatorPropane Actuator• Safety issuesSafety issues

Electromagnetic Linear DC MotorElectromagnetic Linear DC Motor• Failed to meet velocity requirementFailed to meet velocity requirement

DC Motor A - Rack and Pinion SystemDC Motor A - Rack and Pinion System• Failed to meet velocity requirementFailed to meet velocity requirement

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Linear Motor MechanismLinear Motor Mechanism

Initial Design ConsiderationInitial Design ConsiderationAdvantages:Advantages:

•Clean, sleek Clean, sleek implementationimplementation•Precise control and Precise control and measurements without measurements without additional equipmentadditional equipment

Disadvantages:Disadvantages:•Most Expensive Most Expensive electromechanical solutionelectromechanical solution

Show-Stopper: •Unable to reach 30 ft/s

Electromechanical Systems

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DC Motor Concept A – DC Motor Concept A – Rack & Pinion MechanismRack & Pinion Mechanism

1st Alternative Design1st Alternative DesignAdvantages:Advantages:

•Easily mount tooling on Easily mount tooling on pre-machined rackpre-machined rack•Handles Load RequirementHandles Load Requirement

Disadvantages:Disadvantages:•More expensive than belted More expensive than belted electromechanical solutionelectromechanical solution

Show-Stopper: •Large 25lb+ Rack can not be accelerated to 30 ft/s with available motors


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DC Motor A-Conveyor DC Motor A-Conveyor MechanismMechanism

Advantages:Advantages:• Proven parametersProven parameters• InexpensiveInexpensive

$30k$30k Disadvantages:Disadvantages:

• Optimize belt width Optimize belt width and velocityand velocity• Questionable wheel Questionable wheel treadstreads


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Belt Drive Design Belt Drive Design DetailsDetails


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Concepts Evaluated – Concepts Evaluated – Considered FeasibleConsidered Feasible

Hydraulic ActuatorHydraulic Actuator DC Motor B - Cable Driven SledDC Motor B - Cable Driven Sled DC Motor C - Chain Drive SystemDC Motor C - Chain Drive System Pneumatic ActuatorPneumatic Actuator

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Hydraulic Actuator ConceptHydraulic Actuator Concept

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Hydraulics - Major Hydraulics - Major ComponentsComponents

Actuator AssemblyActuator Assembly Servovalve, Manifold and AccumulatorServovalve, Manifold and Accumulator Position Sensor & High Speed Load Washer Position Sensor & High Speed Load Washer

Cell (and signal conditioning)Cell (and signal conditioning) Hydraulic Service ManifoldHydraulic Service Manifold Test StandTest Stand Hydraulic pump Hydraulic pump Controller & data acquisition systemController & data acquisition system Calibration, installation, etc.Calibration, installation, etc.

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HydraulicsHydraulics

Advantages:Advantages: Meets velocity Meets velocity

requirementrequirement Can withstand high Can withstand high

impulsive loadsimpulsive loads Parameters are Parameters are

known through known through control softwarecontrol software

VersatileVersatile

Disadvantages:Disadvantages: Extremely Extremely

Expensive Expensive ($140,000)($140,000)

MaintainabilityMaintainability• Certified TechnicianCertified Technician• Seal life / leakageSeal life / leakage

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DC Motor Concept B – Cable Drive

Item Item No.No. DescriptionDescription VendorVendor

Vendor Part Vendor Part No.No. QtyQty

11 DC MotorDC MotorReliance Reliance ElectricElectric

T18R1312 T18R1312 oror

T21T1342T21T1342 11

22 Rail-1000 mmRail-1000 mmMcMaster-McMaster-

CarrCarr 9685K119685K11 22

33 Rail- 400 mmRail- 400 mmMcMaster-McMaster-

CarrCarr 9685K119685K11 22

44Sled #1-To Be Sled #1-To Be

Custom FabricatedCustom Fabricated

55Sled #2-To Be Sled #2-To Be

Custom FabricatedCustom Fabricated

66 Guide BlockGuide BlockMcMaster-McMaster-

CarrCarr 9685K19685K1 44

Cable/PulleyCable/Pulley

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DC Motor Concept B – Cable Drive

Part Qty Unit Price Total Cost

Motor-T18R1312 1 $2,613.00 $2,613.00

Motor-T21T1342 1 $4,251.00 $4,251.00

Guide Block 4 $192.07 $768.28

Rail-400mm 2 $124.00 $248.00

Rail-1000mm 2 $310.00 $620.00

Estimated Additional Costs $1000.00

Reliance Electric Motors

http://www.reliance.com/mtr/prfchr.htm

T18R1312 T21T1342 Units

Winding Type Stab. Shunt Stab. Shunt

HP Rating 10.0 10.0 HP

Speed 1750 1750 RPM

Arm. Volts 240 500 V

Field Volts 150 300 V

Overall Cost

$6,887.28 – T21T1342

OR

$5,249.28 – T18R1312

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Cable DriveCable Drive

Advantages:Advantages: InexpensiveInexpensive Readily available Readily available

componentscomponents Easily serviced Easily serviced SustainableSustainable

Disadvantages:Disadvantages: Very low precision Very low precision Requires manual Requires manual

reset reset Needs external Needs external

braking system braking system Slower testing rateSlower testing rate

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Cable Drive - Action ItemsCable Drive - Action Items

Develop external braking systemDevelop external braking system Implement sensorsImplement sensors Develop control schemeDevelop control scheme

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DC Motor Concept C – Chain DriveDC Motor Concept C – Chain Drive

Main Components

• DC Motor

• Drive Chains

• Mounting Block

• Guide Rail

• Sprockets

• Bearings

• Drive Shafts

Details

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Chain DriveChain Drive

Advantages:Advantages: InexpensiveInexpensive Readily available Readily available

componentscomponents Easily serviced Easily serviced SustainableSustainable Integrated braking Integrated braking

systemsystem

Disadvantages:Disadvantages: Low Precision Low Precision Slower testing rateSlower testing rate

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Chain Drive - Action ItemsChain Drive - Action Items

Select DC motorSelect DC motor Design braking systemDesign braking system Calculate most efficient chain pitch, length and Calculate most efficient chain pitch, length and

sprocket diametersprocket diameter Develop control and sensing systemDevelop control and sensing system

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Pneumatic ConceptPneumatic Concept

Main Components

• Actuator Assembly

• Control Valves

• Compressor

• Shock Absorption

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Pneumatic ConceptPneumatic Concept

Advantages:Advantages: High power densityHigh power density InexpensiveInexpensive Readily available Readily available

componentscomponents• Air compressor Air compressor • Pneumatic cylindersPneumatic cylinders• Control valvesControl valves• SensorsSensors

Meets specificationsMeets specifications

Disadvantages:Disadvantages: Requires some custom Requires some custom

fabrication.fabrication. Seal life / leakageSeal life / leakage

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Pneumatics - Action ItemsPneumatics - Action Items

Implement sensorsImplement sensors Develop control system Develop control system Study dynamics of the air cylinder systemStudy dynamics of the air cylinder system Determine cylinder dimensions and massDetermine cylinder dimensions and mass Develop shock absorption methodDevelop shock absorption method

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Design FeasibilityDesign Feasibility

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Comparison of Concepts to Baseline (Drop Test) 1 = much worse than baseline2 = worse than baseline3 = equal to baseline4 = better than baseline5 = much better than baseline.

How much will it cost to bring this concept to the customer? 3.0 0.5 2.0 2.0 2.0

3.0 5.0 4.0 4.5 5.0

3.0 5.0 3.5 4.0 4.5

3.0 5.0 3.5 3.5 4.5

3.0 5.0 5.0 5.0 4.0

3.0 1.0 1.5 1.5 4.0

3.00 3.62 3.58 3.62 3.92

100% 105% 121% 127% 123%

Mean Score

Normalized Score

Can this concept be easily controlled (variation of velocity)?

Can the concept be easily serviced considering cost?

How does this concept meet the top three needs of Amphenol Aerospace? Velocity requirement, accuracy, durability..etc.

Will this actuation mechanism allow Amphenol Aerospace to rapidly test connectors?

Is there potential for this actuation mechanism to be universally accepted by other connector manufacturers as the industry standard for testing this product line?

How much will it cost to bring this concept to the customer?

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Variable Test Velocity Reliable Repeatable Economical Low-Cycle Time Safe Size <30 ft3

In ConclusionIn Conclusion

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Future GoalsFuture Goals

For AAO’s Selected Concept:For AAO’s Selected Concept:• Complete bill of materialsComplete bill of materials• Component and assembly drawingsComponent and assembly drawings• Provide detailed analysis of fabricated Provide detailed analysis of fabricated

componentscomponents Stress AnalysisStress Analysis DFXDFX

• SafetySafety• SustainabilitySustainability• ReliabilityReliability• Etc…Etc…

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Special Thanks to Amphenol Special Thanks to Amphenol Aerospace for their supportAerospace for their support

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Questions or Comments?

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Detailed FeasibilityFeasibility Assessment Project #05423

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3.0 1.0 5.0 4.0 2.0

3.0 1.0 3.0 3.0 2.0

3.0 0.5 2.0 2.0 2.0

3.0 0.5 4.0 4.0 5.0

3.0 5.0 4.0 4.0 4.5

3.0 5.0 4.5 4.0 5.0

3.0 5.0 4.5 4.0 5.0

3.0 5.0 4.0 3.5 4.5

This matrix is used to evaluate the baseline test fixture against the concepts that were developed. The following scoring system, was agreed upon by the entire team: 1 = much worse than baseline, 2 = worse than baseline, 3 = equal to baseline, 4 = better than baseline, 5 = much better than baseline.

How much will it cost to bring this concept to the customer?

Does the team possess the skills required to implement all aspects of the technologies for this concept?

Are all elements of the technology (components, materials, etc.) required to implement this concept available to the project team?

Does Amphenol have the financial resources to bring this product to the market?

Can this actuation mechanism help Amphenol rapidly improve their existing lanyard release connector’s performance?

Will the actuation test mechanism increase the connector’s marketability?

Will this actuation mechanism allow Amphenol Aerospace to rapidly test connectors?

Is there potential for this actuation mechanism to be universally accepted by other connector manufacturers as the industry standard for testing this product line?

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Detailed Feasibility cont.3.0 0.5 1.5 1.5 1.0

3.0 1.0 3.0 3.0 2.5

3.0 5.0 3.5 3.5 4.5

3.0 5.0 5.0 5.0 4.0

3.0 5.0 4.0 4.0 4.5

3.0 4.0 4.0 4.0 4.0

3.0 4.0 4.0 4.0 4.0

3.0 1.0 1.5 1.5 4.0

3.0 1.0 2.0 3.0 2.5

3.00 3.11 3.71 3.54 3.61

100% 104% 124% 118% 120%

Mean Score

Normalized Score

Can this concept be easily controlled (variation of velocity)?

Is the variability easily implemented?

How well does this concept reduce the risk of potential safety hazards?

How well can this concept be sustained? Required resources to run (spatial, human, energy)?

Can the concept be easily serviced considering cost?

How difficult is the concept to maintain?

Is there enough time to thoroughly analyze the concept and develop engineering specifications, drawings and bill of materials?

How does this concept meet the top three needs of Amphenol Aerospace? Velocity requirement, accuracy, durability..etc.

Is there enough time to receive and assemble all the necessary components of the concept, allowing for delivery, fabrication and assembly time?

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Detailed Weighted Feasibility

Evaluate each additional concept against the baseline, score each attribute as: 1 = much worse than baseline concept 2 = worse than baseline 3 = same as baseline 4 = better than baseline 5= much better than baseline

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Will this actuation mechanism allow Amphenol Aerospace to rapidly test connectors? 3.0 4.5 4 5 5 9%

Potential for actuation mechanism to be universally accepted as industry standard? 3.0 4 3.5 4.5 5 5%

How much will it cost to bring this concept to the customer? 3.0 2 2 2 0.5 14%

How well can this concept be sustained? Required resources to run (spatial, human, energy)? 3.0 4 4 4 4 9%

Will the actuation test mechanism increase the connector’s marketability? 3.0 4 4 5 5 2%

Enough time to thoroughly analyze the concept and develop engineering specifications, drawings and bill of materials? 3.0 3 3 2.5 1 16%

Can this concept be easily controlled (variation of velocity)? 3.0 5 4.5 4 5 12%

Can the concept be easily serviced considering cost?3.0 1.5 1.5 4 1 7%

Meet the top three needs of Amphenol Aerospace? Velocity requirement, accuracy, durability and force. 3.0 3.5 3.5 4.5 5 19%

Adequate team skills required to implement all aspects of the technologies for this concept? 3.0 5 4 2 1 7%

Weighted Score 3.0 3.5 3.3 3.6 3.1

Normalized Score 84.0% 98.7% 93.2% 100.0% 86.0%

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MULTIDISCIPLINARYENGINEERINGMULTIDISCIPLINARYENGINEERING @ R I T Senior Design ME RIT MULTIDISCIPLINARYENGINEERINGMULTIDISCIPLINARYENGINEERING @ R I T