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Project Sponsor: Hardinge Inc. Team Members: Brian Heeran (Team Leader) Owen Brown Matt Buonanno

Multidisciplinary Engineering Senior Design Hardinge Universal Turret Project 05412 2005 Critical Design Review May 13, 2005. Project Sponsor: Hardinge Inc. Team Members: Brian Heeran (Team Leader) Owen Brown Matt Buonanno Eric Newcomb Steven Paul Brice Wert Robert Yarbrough.

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Project Sponsor: Hardinge Inc. Team Members: Brian Heeran (Team Leader) Owen Brown Matt Buonanno

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  1. Multidisciplinary Engineering Senior DesignHardinge Universal TurretProject 054122005 Critical Design ReviewMay 13, 2005 Project Sponsor: Hardinge Inc. Team Members: Brian Heeran (Team Leader) Owen Brown Matt Buonanno Eric Newcomb Steven Paul Brice Wert Robert Yarbrough Team Mentor: Dr. James Taylor Kate Gleason College of Engineering Rochester Institute of Technology

  2. Background Information

  3. Senior Design 2 - Plan • Detailed Design (3/7 – 3/28) • Iterative Problem Solving (3/29 – 4/8) • Component Fabrication (4/12 – 4/29) • Prototype Assembly (4/27 – 5/11) • Hardinge Review (5/13)

  4. Project Intent • Sustain Hardinge Inc. as an industry leader in turret manufacturing. • New technology • Improved reliability and flexibility of future designs. • Fewer parts • Versatile motor

  5. Traditional Motors vs. Torque Motors Traditional drive with motor and gear box Gear box Motor Customer machine • Large outside diameter allows for more poles, and windings thus allowing for higher torques. • Large diameter means higher torque can be generated with the same power input. Direct drive with torque motor Customer machine 1FW3..

  6. Project Overview • Project Scope: • Establish the feasibility of Torque Motor Integration. • Design a Turret Index Model capable of being manufactured. • Design for adequate cooling of the Torque Motor.

  7. Technical Include the use of a torque motor. Design with as few parts as possible. Included current top plate locking mechanism used by Hardinge in their Quest series turret. Performance Equal or exceed current industry leader performance attributes such as index time, repeatability, and static stiffness. Demonstrate increased reliability of assembly. Incorporate adequate cooling of the torque motor. Desired Outcomes

  8. Final Design

  9. Analysis of Design • Output from finite element software based on an indexing load of 633 N-m Torque. • Max Von Mises Stress found to be 47.3 MPa. • Yield Strength of 1018- CD steel 370 MPa. • Factor of Safety of 7.8.

  10. Development of Machining Experience • Standard Stock Sizes & Availability • Bearing Lead Time & Availability • Availability of Fasteners & Taps • English & Metric • SHCS • Flat Head w/ Chamfer • Hex Head

  11. Assembly Components • Side Walls (2x) • Supports Torque Motor and Stator-Up Plate by securing it to the Base Plate

  12. Assembly Components • Stator-Up Plate • Affixes Torque motor and Side Walls to Base Plate • Main Drive shaft assembly passage

  13. Assembly Components • House Front • Supports part of locking coupler, exposure to CNC Environment

  14. Assembly Components • Interface Plate • Connects Top Plate to Main Drive Shaft

  15. Assembly Components • Main Drive Shaft • Shaft feature changes for manufacturability • Location and company with more aggressive machining capabilities than RIT • Final determination: Hardinge Inc.

  16. Assembly Components • Hydraulic Block • Supports Variable Axial Guide and locking coupler while including potential expandability features for Hardinge Inc.

  17. Assembly Components • Variable Axial Guide • Locates within Hydraulic Block • Provides bearing surface, bearing retaining attributes and centricity control for Main Drive Shaft

  18. Assembly Components • Bearing Block (Upper & Lower) • Second major bearing surface in line with Variable Axial Guide

  19. Final Assembly

  20. Torque Motor Implementation • Powering • Etel Inc. high voltage motor driver • Encoding • Sick/Stegmann incremental encoder • Thermal Overload Protection • Analog and Digital sensors within Stator, providing temperature feedback

  21. Torque Motor Cooling • Max power produced: 1000 W (approx) • Cooling options • Ventilation slots • Simple, inexpensive • Slots placed in base and top of housing • Small AC powered fans • Fans mounted on top of housing

  22. Torque Motor Cooling • Further Options • Custom heat pipes • Expensive • Decreased reliability • Cooling sleeve • Extremely Expensive • Electron Channel Technology

  23. Desired Preparation for pilot builds. Detailed Drawings Machining Cooling Torque Motor Integration Actual Completed prototype assembly. Further completed formal documentation for use by project sponsor for future builds and testing. Outcomes

  24. Recommendations for Project Sponsor • Develop detailed testing procedures for: • Cooling • Variable Tool load Conditions • Worst Case Scenarios • Stiffness • Investigate inverse torque motor operation (switching stator & rotor orientation).

  25. Conclusions • The project culminated with: • An assembled prototype. • Investigated cooling options. • Project poised for future investigations.

  26. Acknowledgements • Special Thanks to: • Dr. James Taylor (Faculty Mentor) • Dr. Jacquie Mozrall (Faculty Coordinator) • Mr. John Bonzo (ISE Facilities Manager) • Mr. Dave Hathaway (ME Facilities Manager) • Mr. Rob Kraynik (Senior Mechanical Technician) • Mr. Steve Kosciol (Senior Mechanical Technician)

  27. Questions

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