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1. Automaton Explorer os Ele Bot Yer Teoh Operete Help a E hiy atem o Raa lt Tha bigip B Oets Heghborhood a gg Ab DAD Glebe Vitus Cheeses CPi Wai Tun bbituan Channel Maranan o i PDA Taki Q Deion and interfaces oe 4 FLIGINGTIE a G Ni GATAI DAGS 1 619037 DADI Modi 2 019TH DAL Meds 3 619217 cDAgi Mods 4 01 AgI Mod a Peers Dat i Sales 5 Software it Pvt Gere Tonig ation BS Remote Systems Tabia Dpr Tyg Chanm Ser awal 4 Stran Setup EF Settings E Oe E Calibration eee ee eae Seed Ure Fiar len Sir 7 Men Im oles ra Eai Fani E eci te Minik iris Et a Wee Baron eer Wale i San Conipr atin beinni ae z 5 Peal Diiia i Drian Seali hii Scale gt RA M DAQra Global Channel Oesenpton AA Connection Diagram On the settings tab input the minimum and maximum strain values as expected Configure the Gage Factor Gage Resistance Initial Voltage Vex Source Vex Value V Lead Resistance and Strain Configuration based on the sensor specifications Thus start the software input the required stroke 1mm 10mm time and frequency 1 10 hz Counterbalance the arm and press start test 4 1 8 Attach strain gauge wires to the DAQ Remove the SCXI 1314 card from the SCXI 1520 data acquisition module located underneath the computer monitor there are screws that fasten the card in place which should be loosened as seen in the red circle It is the 3rd port of the
2. SCXI 1520 and can be seen below the one with the tape Loosen the screws of the P QTR and S ports of channels 4 5 6 and 7 on the SCXI 1314 i es aoe we ew Be Ie ee CE CE RRA se Aa 5 f onm Yi nih f ahs iy ana oa Roca ney Connect the red wire of the gage leadwire labeled 4 to the P port of channel 4 Continue to connect the white wire to the S port and the black wire to the QTR port C SC XI 1314 Repeat for each gage in their respective labeled channel I SX k e Nees 13 HSS 000 E2 NX GR d 4 N e Ei S08 he ip a SCX1I 1314 NIVERSAL STRAIN Reconnect the SCXI 1314 card to the SCXI 1520 module 3 There is a sharpied X on the correct port 4 1 9 Run calibration procedure You may want two people to do this to make it faster In order to calibrate the strain gauges get to the grid version of LabView by pressing Ctrl E Navigate until you find the blue DAQ Assist box and double click it A new window will appear Before calibrating the settings should be as follows Channel Settings 2 Si Detais gt gt Strain Setup ES Settings MF Device 4 Calibration Strain_0 Signal Input Range Scaled Units Max Strain aml Min Am Gage Initial Factor _ Resistance Voltage i 2 08 120 0 Vex Source _ Vex Value V Strain Conf
3. armature x direction In order to set up the armature in the x direction start by unlocking the lock lift lock lever show pic of lock Depending on which direction you intend to use turn the clockwise depending on which direction you intend or counterclockwise direction keeping in mind that the maximum adjustability is 27mm After adjusting the armature in the desired direction be sure to lower the lock lever so that the system is in place pic of what the x direction is 4 1 2 Setup armature y direction In order to set up the armature in the y direction simply obtain an M4 torque wrench loosen the setscrew on the top of the counterbalance block Adjust in the y direction keeping in mind the maximum adjustability is 49mm After you decided how far you want to move retighten the set screw so that the system is in place pic of what y direction is 4 1 3 Setup specimen In order to set up the specimen holder note that if the specimen is under 10mm be sure to put the spacer onto the specimen holder Next place the specimen onto the holder then apply pressure to specimen tighten down the knob making sure the specimen does not rise off the specimen holder Says 4a bee es EED Ee p 4 1 4 Adjust height of pin In order to adjust the height off pin loosen setscrews on the side using an M4 torque wrench Next lower the specimen so that the whole system is level then tighten down the setscrews on the side pic of pin
4. during operation System is safe to be around when running Rear aluminum block Front aluminium block Armature subsystem Mounting block linear shafts lead screw Sensor subsystem Strain gauges and Labview Reciprocating subsystem Specimen holder Linear guide Voice coil Encoder Motion controller 2 2 Environment With regards to the conditions for operation of the friction tester standard room temperature would be ideal for optimum performance 2 3 System Safety and precautions Enter the purpose of these precautions here 2 3 1 Strain Gauges The wires of the strain gages are extremely fragile and care must be taken whenever moving or dismantling the system It is important that there is always a little extra slack in the wiring to allow movement without putting taught pressure on the gage wires The taping of the gages or wiring interface should not be interfered with unless needed to remove the wiring or gage from the system When moving the system or dismantling the arm do not set the arm in such a way that the gages are making direct contact with the table or whatever you set it on 2 3 2 Encoder Always read through ENC A2 Series Assembly Instructions Guide before handling the encoder lt is imperative to know how the assembly goes together before handling this device ENC A2 ENC A2 Series Assembly Instructions Guide sold separately 7 step 1 Base Mounting Slip the base and centering tool sold s
5. holder 4 1 5 Adjust counterbalance In order to adjust the counterbalance turn the threaded mass till the arm is stable This ensures that the force exerted without any weight is zero 4 1 6 Add force weights to top of pin rod Add force weights based on desirability by simply sliding the weights on the top of the pin rod Weight N Weights required a C e C C SCi EC Ce Ck Ce 5 09220 Ee po ft 6 0 202 0 Ce pic of force weights w weight chart 4 1 7 Setup LabView First make sure labview is installed on the desired computer A labview program has to be in place for the strain measurements to take place Thus before connecting any signals locate your device pinout using these steps 1 Open measurement and automation explorer MAX and expand devices and interfaces 2 Right click on device name and select device pinouts Next configure a strain measurement following these steps 3 With MAX open select Data Neighborhood and click Create New 4 Select NI DAQmx Global Virtual Channel and click Next 5 Select Acquire Signals Analog Input Strain After the above steps select the physical channels which you intend to use to connect your strain gauge to your DAQ In this case 4 gauges are being used thus 4 channels a4 a7 will be selected Click next then enter a name for the global virtual channel Click finish and then you should see the following screen in MAX TE MyStasChannel Meaourement amp
6. it may warp Always handle the codewheel by the aluminum hub disk Work slowly and consider using small tweezers or needle pliers to hold the hub disk Once the hub disk is supported on the support shaft it can be pushed into place by the aluminum hub The centering tool can also be used to push the codewheel into place safely e When positioning the brown encoder module into place it should be given a slight angle so as to clear the codewheel The encoder module should sit into divots formed into the encoder base When the module is in place verify that the code wheel is centered relative to the crevice in the encoder module The encoder module will be held in place with the two Phillips head screws that also hold the cover on These should be snug but do not overtighten or damage to the encoder module may occur In addition if the motion controller is unable to send commands to the correct COM port show debug and select the correct COM port to fix it If the voice coil continues to run into the base reduce the starting location by showing the debug and increasing the control this being said if it comes off the rail reduce this number There are also stroke and frequency constants that can be changed if the proper stroke and frequency is not being met 6 Key Contacts Emeka Okoye nco2991 rit edu Chris Karamanos cbk3594 rit edu 7 Roles and Responsibilities Chris Karmanos Industrial Engineer Emeka Okoye Electrical Engineer Reba Co
7. lt P15662 Reciprocating Friction Tester gt Operations amp Maintenance Manual Version lt 1 01 gt Date lt 05 11 2015 gt TABLE OF CONTENTS 1 Introduction 3 1 1 Purpose 3 1 2 Audience 3 2 System Description 3 2 1 Key Features 3 2 2 Environment 4 2 3 Safety and Handling Precautions 4 3 Product Installation 8 3 1 First Time Users 8 3 2 Access Controls 8 3 3 Installation 8 3 4 Starting the System 8 3 5 Stopping the System 8 3 6 Suspending the System 8 4 System Usage 9 4 1 High Level Instructions 9 4 1 1 Setup the armature x direction 9 4 1 2 Setup armature y direction 9 4 1 3 Setup specimen 10 4 1 4 Adjust height of pin 10 4 1 5 Adjust counterbalance 10 4 1 6 Add force weights to top of pin rod 11 4 1 7 Setup LabView 11 4 1 8 Attach strain gauge wires to the DAQ 12 4 1 9 Run calibration procedure 15 5 System Maintenance 18 6 Key Contacts 20 7 Roles and Responsibilities 20 8 Regulatory Requirements 20 APPENDIX A KEY TERMS 21 APPENDIX B KEY TABLES 21 Introduction 1 1 Purpose The goal of this project is to design a reciprocating friction tester composed of the armature and base subsystem This subsystem has the purpose of providing a constant and accurate vertical normal force through a single point of contact This normal force must be variable up to 20N with a ON load release aka resting force This means the weight of the armature m
8. 4356 3 4108E 05 9 1 2 163384356 6 2355E 05 2 183384356 6 2931E 05 5 183384356 1 4940E 04 8 es 2 5 19 98 20 16338436 5 8116E 04 This column corresponds This column ENTER THIS to the is the weight VALUE INTO weight being added plus THE placed onto the weight CALIBRATION the hook of the hook SHEET
9. 962 1F 5 1 1834E 0 2 18354E 0 4 8486E 5 2 18336 0 5 1834E 0 1 1566E 4 5 18336 H T 1834E 0 1 6312E 4 7 18326 LO1S34E 1 2 2292E 4 LO18S1E4 1 1 51834E 1 toe 1 51830E 1 5 Machine Maintenance In order to properly manage the machine cleaning greasing and adjustments should be performed in addition to an inspection of the bearings ability to run and of possible wear Further the tester should be calibrated regularly and tested for functionality to ensure it is fit for future tasks Specifically for the encoder and voice coil the below steps should be noted with regards to handling and upkeep Encoder handling instructions Always read through ENC A2 Series Assembly Instructions Guide before handling the encoder It is imperative to Know how the assembly goes together before handling this device Link htips www anaheimautomation com manuals encoder L010742 20 20ENC A2 20Series 20Assembly 20 Instructions pdf Assembly tips e When fastening the encoder base leave the screws loose until the centering tool is pressed into place Tighten the screws to secure the base relative to the centering tool e The Allen key sized to the codewheel set screw can be used in absence of the spacer clip e Most importantly handle the codewheel with the utmost care Do not touch the clear plastic portion else skin oils will contaminate the reading surface Do not handle squeeze or use tools on the plastic portion of the codewheel or
10. Appendix B or the SGCal xlsx file which can be found in the software folder of the P15662 edge page to determine the strain constant that corresponds to the weight of the hook Commit the value Next add incremental weights to the hook by pressing the bottom hook together then slipping it through the center hole of the weight then reopening the hook arms Use the strain equation to determine the strain Be sure to correctly enter the negative sign if necessary Commit the value Do this for 0 245N 0 5N 1N 2N 3N 5N 7N 10N 12N 15N 20N at the minimum for each side Repeat this process from everything after committing the 0 value for the other side of the same strain gauge Note the values will be the opposite sign of what they were for the first time Select the second strain gauge and repeat the process In order to be certain do the pull check to verify the negative sign again however this is not necessary as the values will be opposite of the first gauge If you went over the voice coil and it was negative for the first gauge going over the voice coil will be positive for the second gauge The calibration results and data are illustrated below Mal tal Uncalibrated l l 2 0E L 2 0E 1 0 0E 0 LOE 1 2 0E 1 3 0E 1 Figure 3 Calibration Plot Figure 4 Strain results Reference Uncalibrated Difference 18338E 1 6 3 96E 6 L8 amp 339E 1 4 2838E 1 8 59 10E 6 4 2838E 1 6 8330E 1 1 5569E 5 6 833 E 1 1 1834E 0 2
11. alibration measurement a N fie i1 Enter the reference value of the measurement on the row indicated by the arrow When calibrating multiple channels all channels must have the reference value Wait for the reading shown in the Uncalibrated column to stabilize 3 Click Commit Calibration Value or press the Enter key to accept the colikestina colikrstinn mair W Commit the O value before starting Place the system on the corner of the table so that the perpendicular line to the pin is off of the table so both locations for calibration will be able to hang freely First setup the stand This requires tightening two blocks onto the edge of the base plate using a 3 16 torque wrench Place the rod atop the two blocks Attach the hook system to the bottom of the pin by loosening the set screw with a 5 64 torque wrench then retightening it down so it cannot slip off Next hang the hook by itself over the edge of the stand rod Spin the rod away from you to release any tension between the string and the rod Since the hook is dangling do not allow it to spin around keeping it confined to a small spin radius Go back to the computer and write down the value you see While looking at the computer pull on the armature to determine which way the strain is going If the strain goes down you will enter negative values for this side if it goes up you will enter positive values Use Table 1 located in
12. eparately over f the shaft Adjust the base to align the base holes with the screw holes on the mounting surface Press down on the centering tool to secure it to the mounting surface Fasten the mounting screws to the mounting surface and remove the centering tool Step 2 Spacer Tool Installation For shafts less than 3 8 snap the space tool clip around shaft Figure A For shafts equal to or greater than 3 8 place spacer tool around the shaft Figure B Figure B Space Tool Figure A Spacer Clip Step 3 Codewheel Installation Slip the codewheel over the shaft with the disk side down until it touches the space tool Tighten the set screw with the provided hex wrench while pressing down on the hub of the disk Remove the spacer tool Step 4 Encoder Module Installation Slip the optical encoder module into position until the assignment pins slip into the holes of the module The pins should be on the bottom of the module facing out E Step 5 Cover Installation Place the cover over the assembly and secure the components in place with two 4 40 x 5 8 screws supplied with the kit When fastening the encoder base leave the screws loose until the centering tool is pressed into place Tighten the screws to secure the base relative to the centering tool The Allen key sized to the codewheel set screw can be used in absence of the spacer clip Most importantly handle the codewheel with the utmo
13. iguration __ Click the Add Channels button Internal jw 2 5 Quarter Bridge x to add more channels to Lead Resistance Custom Scaling the task fi 0 lt NoScale gt Timing Settings Rate Hz Once on this page Select the first gauge then press the Calibration tab then press Calibrate Channel Settings x petais gt gt Strain Setup a Strain_0 Calibrati alibration Date Calibrate Calibration Date 12 31 1903 Enable Calibration Expiration Date Delete Calibration 12 31 1903 When changing calibration settings verify that the Min and Max input ranges on the Settings tab are still valid Click the Add Channels button to add more channels to the task Timing Settings Acquisition Mode Samples to Read Rate Hz N Samples Another window will appear Type in your name and set the expiry date of the calibration to the beginning of the next semester Channel Calibration Wizard This wizard will guide you through a Calibrator s Name calibrating your channel s Make sure your system and signal Expiration Date reference measurement device are 5 21 2016 turned on and warmed up Fill in your name and the expiration date for this calibration After the calibration expires Apply the calibration and return a warning gt Do not apply the calibration and return an error Channel Calibration Wizard Collect c
14. nway Mechanical Engineer Eric Kutil Mechanical Engineer Kolby Irving Electrical Engineer Alexandra Woodward Industrial Engineer Matt Lebowitz Electrical Engineer Tyler Nigolian Electrical Engineer Ethan Hanson Mechanical Engineer sean Cummings Electrical Engineer 8 Regulatory Requirements This friction tester conforms to the specifications of multiple ASTM standards such as ASTM G 133 05 ASTM G 181 ASTM D 5706 05 and ASTM D 5707 05 APPENDIX A KEY TERMS Centering tool small aluminum hub with one conical end Used to ensure the encoder is centered upon the rotating shaft Codewheel Clear plastic disc mounted to a metal hub This is the most delicate part of the encoder Encoder support shaft Stainless steel rotating shaft supported by two bearings The encoder has a floating hub that mounts to this shaft Encoder base plastic plate with preformed ears and nut serts The positioning of the base is essential to ensuring accurate readings from the encoder wheel Encoder Module this unit contains all of the electronics of the encoder Spacer clip Small metal clip used to determine spacing between floating hub disk and encoder base can be substituted for appropriate allen key sized to hub set screw APPENDIX B KEY TABLES Table 1 Strain Input Table g n strain O 0 0000E 00 33 22 0 215746301 6 2184E 06 8 8 27 5 0 269682876 7 7730E 06 0 245 0 428384356 1 2347E 05 0 5 0 683384356 1 9697E 05 1 1 18338
15. quired in order to use the computer connected to the friction tester so as to gain access to Labview 3 3 Starting the System In order to start the system it is important to make sure the machine is intact Confirm proper connection of the gauge to the DAQ card then to the computer Turn on the encoder After this add force weights to top of pin rod then start labview program on the computer in use Select the required DAQ assist input the parameters for labview then press start 3 4 Stopping the System In order to stop the system hit stop on the labview program and this bring the system to a complete halt 3 5 Suspending the System In order to suspend the system hit pause on the labview program and this brings the system to a halt 4 System Usage 4 1 High Level Instructions The items below represent an overview of the steps required to operate the system Notes items that may not be required every setup e Setup the armature x direction Setup armature y direction Setup specimen in specimen holder Adjust height of pin to be flat Adjust counterbalance to ensure no force is on pin Apply lubricant to to specimen in use Place specimen into specimen holder Add force weights to top of pin rod Attach strain gauge wires to the DAQ Start LabView on the computer Select DAQ Assist Run calibration procedure Select stroke length 1 10mm Select frequency 1 10 hz Select Time for the test to run then press start 4 1 1 Setup the
16. st care Do not touch the clear plastic portion else skin oils will contaminate the reading surface Do not handle squeeze or use tools on the plastic portion of the codewheel or it may warp Always handle the codewheel by the aluminum hub disk Work slowly and consider using small tweezers or needle pliers to hold the hub disk Once the hub disk is supported on the support shaft it can be pushed into place by the aluminum hub The centering tool can also be used to push the codewheel into place safely When positioning the brown encoder module into place it should be given a slight angle so as to clear the codewheel The encoder module should sit into divots formed into the encoder base When the module is in place verify that the code wheel is centered relative to the crevice in the encoder module The encoder module will be held in place with the two Phillips head screws that also hold the cover on These should be snug but do not overtighten or damage to the encoder module may occur 3 Product Installation 3 1 First Time Users For first time users it is important to understand that the machine is quite sensitive so should be handled with care especially when dealing with the sensors and also it works based on a Labview program which is used for the strain friction measurement thus proficiency in Labview is a strong requirement in order to operate the tester effectively 3 2 Access Controls Regular administrative privileges would be re
17. ust not effect or add to desired normal force The subsystem must be able to measure store and display the friction force and the normal force that is being applied to the plate specimen during testing The armature must be fully functional and securely attach to the reciprocating system which is being designed and developed in parallel The friction tester must conform to multiple ASTM standards ASTM G 133 05 ASTM G 181 ASTM D 5706 05 and ASTM D 5707 05 1 2 Audience This document is meant for Dr Patricia Iglesias Victoria and anyone she has authorized to use the Reciprocating Friction Tester System Description NO NO 1 Key requirements Components The key features of the system are listed below and are met in the design The components are also spelled out Requirements System must not exceed 4 x 6 Motor able to supply torque necessary for 20N applied normal load Base does not deform under a minimum of 20N applied normal load Device will withstand a 24 hour test duration Data acquisition system integrates with labview nterface armature system from P15660 team Base accepts variable sized specimens Device will accommodate for both dry and lubricated specimen tests Heats specimen to 200 C Variable stroke 2 10mm Variable frequency 1 10 Hz User repair manual included Easy to clean oil off base All data in SI units Labview program works for both rotating and oscillating test rigs Test rig must remain stationary

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