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Final Report - Senior Design

1. AYWWIZZ E AYWWIZZ _ AS5304 _ AS5306 sd Le Pin 1 Identification 1 2 3 123 D p D Pin 1 Identification 2 18 Mw eL des 8 m 2 Revision 1 6 www austriamicrosystems com Page 3 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Dimensions Marking AYWWIZZ A Pb Free Identifier Y Last Digit of Manufacturing Year WW Manufacturing Week NI ELLO 005 0 15 0 002 0 006 ZZ Traceability Code 80 1 00 00 1 05 05 0031 031 0 039 _ 0 041 Ci fare eo JEDEC Package Outline Standard MO 153 AC raze ose Thermal Resistance Rin j a 89 K W in still air soldered on PCB 0 252 0 65 0 0256 s ew 5 580 0287 0258 0260 E s ur IC s marked with a white dot or the letters ES denote 6 3 Electrical Connection The supply pins VDD VDDP and VDDA are connected to 5V Pins VSS and TEST_GND are connected to the supply ground A 100nF decoupling capacitor close to the device is recommended VDD 5V 4 10 AS5304B gt gt
2. AYWWIZZ E AYWWIZZ _ AS5304 _ AS5306 sd Le Pin 1 Identification 1 2 3 123 D p D Pin 1 Identification 2 18 Mw eL des 8 m 2 Revision 1 6 www austriamicrosystems com Page 3 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Dimensions Marking AYWWIZZ A Pb Free Identifier Y Last Digit of Manufacturing Year WW Manufacturing Week NI ELLO 005 0 15 0 002 0 006 ZZ Traceability Code 80 1 00 00 1 05 05 0031 031 0 039 _ 0 041 Ci fare eo JEDEC Package Outline Standard MO 153 AC raze ose Thermal Resistance Rin j a 89 K W in still air soldered on PCB 0 252 0 65 0 0256 s ew 5 580 0287 0258 0260 E s ur IC s marked with a white dot or the letters ES denote 6 3 Electrical Connection The supply pins VDD VDDP and VDDA are connected to 5V Pins VSS and TEST_GND are connected to the supply ground A 100nF decoupling capacitor close to the device is recommended VDD 5V 4 10 AS5304B gt gt AS5306B ONLY Lo Ead AS5304A Quadrature AS5304B NE Posi
3. Figure 4 Sensor in package Die Tilt Tolerance 1 Revision 1 6 www austriamicrosystems com Page 2 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection 6 1 Pin Description PinName Pin Type Notes Pin 5 12 13 14 17 18 19 910 11 5 5 5 O D austriamicrosystems DO_OD Incremental quadrature position output A Short circuit current limitation VvDP 8 Peripheral supply pin connect to VDD DO OD Incremental quadrature position output B Short Circuit Current Limitation TE A VD test pins must be left open Positive supply pin DO_OD Index output active HIGH Short Circuit Current Limitation test pins must be left open 5 Analogue Output Used to detect low magnetic field strength AIO S S Hall Bias Supply Support connected to VDD TEST_GND W test pin must be connected to VSS VDDA Hall ZPZmskdis Test input connect to VSS during operation PIN Types supply pin AO analogue output AIO analog input output DI digital input DO OD digital output push pull or open drain programmable 6 2 Package Drawings and Markings 20 Lead Thin Shrink Small Outline Package TSSOP20
4. Sig 11 3 Appendix C Experimental Pulse Data TUE NOV 29 09 14 37 2011 req No signal Avg XNo signal Setup Info Invert Grat 22 Palette Color LI Figure 11 Drop Height 8 5 cm Damper Thickness 3 mm Peak Acceleration 210 g Pulse Duration 3 7 ms Press to Save s Agilent Technologies TUE NOV 29 09 19 05 2011 q No signal 00 XNo signal Figure 83 Drop Height 8 5 cm Damper Thickness 6 mm Peak Acceleration 51 g Pulse Duration 11 ms GE Agilent Technologies TUE NOV 29 09 15 54 2011 B 100v B 4 No signal Avg 1 No signal Setup Info Invert Grat I Color Press to Save Figure 72 Drop Height 15 5 cm Damper Thickness 3mm Peak Acceleration 272 g Pulse Duration 3 7 ms TUE NOV 29 09 22 16 2011 Figure 14 Drop Height 15 5 cm Damper Thickness 6 mm Peak Acceleration 77 g Pulse Duration 9 5 ms 11 4 Appendix D Team Budget Item Description Item QTY Unit Cost Fees A Shipping Total Avail Budget 7000 Back up Funds 1000 6000 Accelerometer 3 axis 356 24 1 1034 1 0 55 1069 1 4910 9 Data Acquisition DAC 1 700 0 35 135 4175 9 Linear Motor 1 1 50 0 50 1800 2315 9 Linear Bearings 1 2 697471 2 17 84 0 10 45 68 2330 22 Li
5. 16 Bit C T Out 0 Bi Counter Timer Gate 0 Analog Inputs sour Digital le Out la gt DOUT 0 lt DIN 7 Digital le External A D Clock In je Clock External Trigger A D Trigger ESD Buffered to 4000 V USB 2 0 Port Input FIFO ESD Buffered to 4000 V Figure 3 Block Diagram of the DT9816 Series Modules WWW DATATRANSLATION COM US Canapa 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 Digital vo 15 Di Digital vo 14 WO Digital vo 13 Digi l Digital vo 12 Gr 11 Digital yo 24 Digital VO 51 Sung 10 Reserveg Digital 10 Digita vo Di bs VO 9 2 81 Digital Digital VO 23 gital O g 4 0 7 Digital VO 22 Ground VO 8 Digital vo 21 Digital vo 7 Digita T Digital O VO 4 DT98 D 4 Digital vo 19 1 7 Digital VO 5 _ Ti m Sita 0 3 3 Digital VO 1 Digital VO 4 gt r D Digit 1 git al Tie Digital VO 2 C r 00 gt igita i 01 2 Digital y al VO 17 Counter Digital VO 16 8 Ti mer Digital VO 2 Dio 1 Digital yo 1 Digital i Figure 5 Connect sensors directly to the screw terminal of the module Screw terminals can accept AWG 26 to AWG 16 size wire Figure 4 Connect to a host computer using the standard USB 1 1 or 2 0 plug in connector on the ECONseries module The USB connector provides power to the module eliminating the need for an exter
6. Figure 4 Sensor in package Die Tilt Tolerance 1 Revision 1 6 www austriamicrosystems com Page 2 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection 6 1 Pin Description PinName Pin Type Notes Pin 5 12 13 14 17 18 19 910 11 5 5 5 O D austriamicrosystems DO_OD Incremental quadrature position output A Short circuit current limitation VvDP 8 Peripheral supply pin connect to VDD DO OD Incremental quadrature position output B Short Circuit Current Limitation TE A VD test pins must be left open Positive supply pin DO_OD Index output active HIGH Short Circuit Current Limitation test pins must be left open 5 Analogue Output Used to detect low magnetic field strength AIO S S Hall Bias Supply Support connected to VDD TEST_GND W test pin must be connected to VSS VDDA Hall ZPZmskdis Test input connect to VSS during operation PIN Types supply pin AO analogue output AIO analog input output DI digital input DO OD digital output push pull or open drain programmable 6 2 Package Drawings and Markings 20 Lead Thin Shrink Small Outline Package TSSOP20
7. Status Active HTS 8503 00 9526 MIN DSM DAL 09A HOU 18A 11A CHI 12A STL 12M STL 13A IND 14A MEM 15A DET 18A 17A CLE 18A ATL 19 214 GBO 22 AUB 23A PHL 27A PIT 37A BAL 38A SLC ABA BOS 00C 886 OSH DOK SMI QOL LIT OON CLM OOT TRO PTL 02A LAX 3B PHX CO CO CO CO CD O3 OD pu a Time for LIs 5 DIE DE x x kk k k k K eee L n short net CIIFTE yt MOT datar k A m _ ri hl E IE 2027 00 n T1 1 090 EAE 545 ot 000 199 400 20 1 4 99 MASS IOC UNLESS c FLU 0 3 PLC DEC i 005 ANG t 5 REV DESC NEW REV LTR COCHE 009220683 VERSION 00 TOR 000000432896 FILE NLADX00007X238 REVISED 11 36 45 06 06 2007 BY HALL EFFECT ASSY LMCF 11 12 Appendix M Linear Encoder Spec Sheet 212 austriamicrosystems 4 PRELIMINARY DATA SHEET 1 General Descr
8. magnetization tooling 1500 1700 1900 2100 2300 2500 Pole Length um Figure 9 Additional error caused by pole length variation AS5304 AS5306 Systematic Linearity Error caused by Pole Length Deviation However when using a ring magnet see Figure 1 the pole 140 length differs depending on the measurement radius For 120 optimum performance it is therefore essential to mount the 100 such that the Hall sensors are exactly underneath the 80 S dd magnet at the radius where the pole length is 2 0mm 5 40 AS5304 1 2mm AS5306 see also 8 1 2 20 a Note that this is additional error which must be added to 900 1000 1100 1200 1300 1400 1500 the intrinsic errors INL see 7 3 and DNL see 7 4 Pole Length um Figure10 Additional error caused by pole length variation AS5306 Revision 1 6 www austriamicrosystems com Page 7 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 7 4 Dynamic Non Linearity DNL The DNL dynamic non linearity describes the non linearity of the incremental outputs from one step to the next In an ideal system every change of the incremental outputs would occur after exactly one LSB e g 25um on AS5304 In practice however this step size is not ideal the output state will change after 1LSB DNL The DNL must be lt 7 LSB to avoid missing code Consequently the incremental outputs will change when
9. Sponsor Sandia National Labs Advisor Dr Steven Beyerlein Graduate Mentor Kysen Palmer Team Members Nicholai Olson Travis Nebeker Mike Brewster Fernando De La Garza Cameron Hjeltness Senior Capstone Design Work University of Idaho Final Project Report May 10 2012 Sandia National Laboratories Sandia M A S T Miniature Automated Shock Tester Table Of Contents Ut a Oe 10 Conclusions 11 Appendices Executive Summary Background n Problem Definition ProjecttPla yu Concepts Considered 5 1 u uuu u wass 5 2 Testing Configuration 5 3 Structural Considerations 5 4 Reduction of Energy Loss 5 5 Lift Actugation ii rere va ren 5 6 Source of 5 7 Shock Level and Energy Dissipation Concept Selection Mechanical System Architecture 8 2 System Operation Procedure Detailed Design
10. 5 10 2012 02 02 Forcer Mount SLDPRT SandiaMAST PART 02 02 scale 1 1 OF 5 2X D 136 420 8 32 UNC Y 330 6x 070 243 43 R 063 PROPRIETARY AND CONFIDENTIAL 1 908 THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION ecu OF UNIVERSITY OF IDAHO ME DEPARTMENT IS N MATERIAL Printed Plastic pescripion Encoder Board Mount UNIVERSITY OF IDAHO ME DEPARTMENT PROHIBITED DEFAULT TOLERANCES FILE NAME ev Nicholai Olson DATE 5 1 1 201 2 prawney Cameron Hieltness DATE 5 9 2012 02 03 Encoder Board Mount SLDPRT SandiaMAST PART 02 03 scale 1 1 4 OF 5 175 971 797 R 063 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION ecu sandiaMAST OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF IDAHO ME DEPARTMENT IS DEFAULT TOLERANCES UNIVERSITY OF IDAHO ME DEPARTMENT 02 04 02 04 Encoder Spacer SLDPRT scale 1 sug 5 OF 5 Note Vibration Damping Bronze Sleeve Bearings McMaster Carr Part No 6364K32 NO 4 3 3 8 16X5 Fully Thread
11. 1 ACS 1T NIST traceable triaxial amplitude response 10 Hz to upper 5 frequency 1 Physical Sensing Element Ceramic Ceramic Sensing Geometry Shear Shear Housing Material Titanium Titanium Sealing Hermetic Hermetic Size Height x Length x Width 0 28 in x 0 47 in x 7 0 mm x 12 0 mm x 0 47 in 12 0 mm Weight without cable 0 11 oz 3 1 gm 1 Electrical Connector 8 36 4 Pin 8 36 4 Pin Electrical Connection Position Side Side Mounting Adhesive Adhesive Typical Sensitivity Deviation ws Temperature 5 2 E 04 21 2010 04 20 2010 04 20 2010 04 22 2010 4 20 mim 3425 Walden Avenue 100 50 0 50 100150 200 250 300 350 PIEZOTRONIC 5 Depew NY 14043 VIBRATION DIVISION UNITED STATES Phone 800 828 8840 Fax 716 684 0987 E mail info pcb com All specifications are at room temperature unless otherwise specified In the interest of constant product improvement we reserve the right to change specifications without notice ICP is a registered trademark of PCB group Inc Web site www pcb com 11 11 Appendix L Hall Effect Sensor Board Hall effect Sensor Board 04 27 2012 Hosni SHIP FROM LOCATION 08 48 45 Nbr EB2027A00SP Dutput x Alt 0000 Spec Nbr EE RM Pallet Qty 8 086 List Prc 264 00 Frame Weight 0 500 LB Mult Sym Enc Item Type ELECTRONIC CONTROL Plant LI K B Poles Class Nc SRE Gear Head Desc SF
12. 1 to 9000 Hz 1 to 9000 Hz Temperature Range Operating 65 to 325 F 54 to 163 C Frequency Range 10 0 5 to 12000 Hz 0 5 to 12000 Hz J Ground Isolated Resonant Frequency gt 45 kHz gt 45 kHz Electrical Isolation Base 10 Ohm 10 Ohm Broadband Resolution 1 to 10000 Hz 0 004 g rms 0 04 m s rms 1 Size Height x Length x Width 0 33 in x 0 47 in x 8 3 mm x 12 0 mm Non Linearity 1 96 1 96 3 0 47 in x 12 0 mm Transverse Sensitivity lt 5 lt 5 Weight 0 13 oz 3 7 gm Environmental Overload Limit Shock 10000 g pk 98100 m s pk Temperature Range Operating 65 to 250 F 54 to 121 C 2 2 Notes Electrical 1 Typical Excitation Voltage 18 to 30 VDC 18 to 30 VDC 2 250 F to 325 F data valid with HT option only Constant Current Excitation 2 to 20 mA 2 to 20 mA 3 Zero based least squares straight line method Output Impedance 200 Ohm 200 Ohm 4 See PCB Declaration of Conformance PS023 for details Output Bias Voltage 7 to 11 VDC 7 to 11 VDC Discharge Time Constant 1 0 to 3 5 sec 1 0 to 3 5 sec Settling Time within 10 of bias lt 10 sec lt 10 sec Supplied Accessories Spectral Noise 1 Hz 900 ug VHz 8820 um sec 1 034K10 Cable 10FT Mini 4 Pin To 3 BNC 1 Spectral Noise 10 Hz 250 ug AHz 2450 VHz 1 080A109 Petro Wax 1 Spectral Noise 100 Hz 100 ug VHz 981 um sec Hz 1 080490 Quick Bonding Gel 1 Spectral Noise 1 kHz 50 ug VHz 490 um sec
13. 1008 s to 200g s Messure shockin direction 1008 to 200 Oe ______ upon impact ww a S monitored acquisition device Performance Requirements DUT must not experience ringing Single pulse half sine wave Shock consistent results Safety Robustness Pinch Points Protected Physical Shielding x components month for a desired life of five years 1 0 Conclusions The goal of this project was to provide Sandia Labs with a reliable mechanical shock tester for their proprietary electronics within the operating conditions of 100 to 200 g s and limiting the applied shock to within 10 milliseconds While not the most complex task this design posed many challenges of its own that proved to be a good resource for future knowledge Machining some of the components such as the arm that mounts to the linear motor to transmit the force through the dual steel rods were tricky requiring a detailed machine plan and the know how to deriving the correct geometry within tolerances The electronic systems proved to be more complex than originally planned with many various parts Designing and fabricating the linear encoder boards involved large amounts of time planning each component Overall the project s goals were certainly met The accelerometer mounted to the surface of the device under test registered shocks within 175 g s which is within 12 596 of the intended upper range of operation The size was limited to be as
14. AS5306B ONLY Lo Ead AS5304A Quadrature AS5304B NE Position A 4 AS5306A O No Connect i 55306 O Connect Quadrature Position B O No Connect HOST uC No Connect O 5V O 1uF 10uF optional O No Connect Index i O No Connect No Connect O O No Connect No Connect O O No Connect Figure 5 Electrical connection of the AS5304 A85306 Revision 1 6 www austriamicrosystems com Page 4 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 7 Incremental Quadrature AB Output The digital output is compatible to optical incremental S N 5 N 5 encoder outputs Direction of rotation is encoded into two signals A and B that are phase shifted by 90 Depending on the direction of rotation A leads B CW or B leads A CCW T 1 1 Index Pulse A single index pulse is generated once for every pole pair One pole pair is interpolated to 40 quadrature pulses 160 steps so one index pulse is generated after every 40 quadrature pulses see Figure 6 Index The Index output is switched to Index high when a magnet is placed over the Hall array as shown in Figure 7 top graph the north pole of the magnet is placed over the left side of the IC top view pin 1 at bottom left and th
15. f denotes the polymer sample which is atop component g a mounting platform Figure 1 Prototype used for testing rq n EXPERIMENTAL DESIGN 1 Capstone math models A primary objective of this project is to verify the mathematical models for the capstone project This model demonstrates the necessary drop height for a gravity actuated system as well as what damping coefficient would be best for our design targets Equation 1 is the model used to describe the acceleration of the impact with respect to time y g Fa x 1 A list of the relevant variables for this equation is listed in Table 1 below Symbol Mass of Drop Table Displacement Velocity Acceleration of Table Acceleration of Gravity Spring Stiffness Damping Coefficient Table 1 List of relevant variables Figure 2 shows the output of this model y3 when run with values for the independent variables of 1 Appendix A contains the full code used to generate this plot Acceleration of Drop Table 800 600 400 Acceleration m 200 0 5 Time 8 d Figure 2 Mathematical model for shock response 2 Statistical Models For the statistical analysis two factors were analyzed The first factor was drop height This factor is directly proportional to the amount of acceleration an object experiences during free fall motion It is importa
16. Die C Tear Strength pli 100 ASTM D 624 IMPORTANT Shelf life of product is drastically reduced after opening Shrinkage lt 001 in in ASTM D 2566 Immediately replacing the lids on both containers after dispensing product will prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the shelf life of unused liquid urethane products Value measured after 7 days at 73 F 23 IMPORTANT Shelflife of productis reduced after opening Remaining product should be used as soon as possible Immediately replacing the lids on both containers after dispensing product will help prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the shelf life of unused liquid urethane products The Material Safety Data Sheet MSDS for this or any Smooth On product should be read prior to use and is available upon request from Smooth On All Smooth On products are safe to use if directions are read and followed carefully Be careful Part A is a TDI prepolymer Vapors which can be significant if material is heated or sprayed cause lung damage and sensitization Use only with adequate ventilation Contact with skin and eyes may cause severe irritation Flush eyes with water for 15 minutes and seek immediate medical attention Remove from skin with waterless hand cleaner followed by soap and water Pre
17. agent with a soft brush over all surfaces of the model Follow with a light mist coating and let the release agent dry for 30 minutes Because no two applications are quite the same a small test application to determine suitability for your project is recommended Shore A Hardness 70 CMS if performance of this material is in question Tensile Strength psi 750 ASTM D 412 MEASURING amp MIXING 100 Modulus psi 250 ASTM D 412 E Liquid urethanes are moisture sensitive and will absorb atmospheric Elongation Break 750 ASTM D 412 moisture Mixing tools and containers should be clean and made of metal or plastic Die C Tear Strength pli 200 IMPORTANT Shelf life of product is drastically reduced after opening Shrinkage lt 001 in in ASTM D 2566 Immediately replacing the lids on containers after dispensing product will prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the shelf All values measured after 7 days at 73 F 23 C di life of unused liquid urethane products IMPORTANT Shelflife of productis reduced after opening Remaining product should be used as soon as possible Immediately replacing the lids on both containers after dispensing product will help prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the shelf life of unused liquid uretha
18. 0 1 2 or multiples of 30 5mm 1 2 for non standard tracks OPTIONAL HALL MODULE TRACK ASSEMBLY Y o amp e A 6 Track assemblies can be stacked for additional stroke lengths Forcer Primary Coil Assembly LMCF Secondary Track LTCF Catalas Number ui p MOI Standard cog free tracks include mm in mm in mm in Kg Lbs 610 mm 24inch 1036 mm 40 8 inch Size A 24 LTCF C40 73 7 2 20 82 40 64 1 17 LMCFO2A HCO 3 90 0 8 0 8 0 6 60 0 08 0 LTCF E24 LTCF E40 size B LTCF F24 LTCF F40 LMCF02B HC0 0 82 53 59 2 11 0 11 0 25 Other track lengths are available as custom LMCFO4B HCO 0 82 53 59 2 11 0 22 0 49 Size C Catalog Number LMCFO2C HCO 73 7 2 90 30 48 1 20 57 15 2 25 0 18 0 39 mm In LMCFO4C HCO 134 6 5 30 30 48 1 20 57 15 225 0 32 0 0 LTCF X04 122 4 8 LMCFO6C HCO 195 6 7 70 30 48 120 57 15 2 25 0 57 1 25 LTCF X07 183 7 2 LMCFOSC HCO 256 5 10 10 30 48 1 20 57 15 2 25 0 75 1 64 LTCF X09 244 9 6 Size D LTCF X12 305 12 0 LMCFO2D HCO 134 2 90 34 29 1 35 86 31 3 40 0 35 0 6 LTCF X24 610 24 0 LMCFO4D HCO 134 6 5 30 34 29 1 35 86 31 3 40 0 6 1 4 LTCF X40 1036 40 8 LMCFO6D HCO 195 6 7 70 34 29 1 35 86 31 3 40 0 9 2 0 LMCFOSD HCO 256 5 10 10 34 29 1 35 86 31 3 40 1 2 2 6 LMCF10D HCO 31
19. 17 8217913 Figure 16 quickDAQ acquires analog data from all devices supported by DT Open Layers for NET software at high speed plots it during acquisition analyzes it and or saves it to disk for later analysis Cross Series Compatibility Virtually all Data Translation data acquisition boards including the ECONSseries are compatible with the DT Open Layers for NET Class Library This means that if your application was developed with of Data Translation 5 software products you can easily upgrade to a new Data Translation board Little or no programming is needed User Manual Each data acquisition module includes a user s manual that provides getting started and reference information The manual is provided in electronic PDF format on the Data Acquisition Omni CD provided with the module Technical Support Application engineers are available by phone and email during normal business hours to discuss your application requirements Extensive product information including drivers example code pinouts a searchable Knowledge Base and much more is available 24 hours a day on our web site at www datatranslation com For more information about the ECONseries modules please visit http www datatranslation com info ECONseries Ordering Information All Data Translation hardware products are covered by a 1 year warranty For pricing information please visit our website or contact your local reseller MODU
20. 248 0 63 LMCF04D HCO 73 6 16 5 1 5 220 49 4 4 49 6 1 26 LMCF06D HCO 110 24 8 1 5 330 74 4 4 74 4 1 89 LMCF08D HCO 147 33 1 5 440 99 4 4 99 3 2 52 LMCF10D HCO 184 41 3 3 0 550 123 8 9 61 8 1 57 LMCF12D HCO 220 49 6 3 0 660 148 8 9 74 2 1 88 4 LMCF04E HCO 124 28 1 6 372 84 4 7 79 9 2 03 4 LMCF06E HCO 185 42 3 1 556 125 9 2 59 7 152 4 LMCF08E HCO 251 56 21 153 169 9 2 82 0 2 08 4 LMCF10E HCO 314 70 3 1 942 212 9 2 102 5 2 60 4 LMCF12E HCO 377 85 3 1 1132 254 9 2 123 0 3 12 4 LMCF14E HCO 440 99 3 1 1318 294 9 2 143 5 3 64 4 LMCFO4F HCO 191 43 2 6 578 130 7 8 74 4 1 89 4 LMCFOSF HCO 387 87 2 6 1152 256 7 8 148 4 3 78 4 LMCF12F HCO 578 130 3 9 1726 338 11 6 148 4 SA 4 LMCF16F HCO 771 173 5 2 2300 517 15 6 148 0 3 76 Notes specifications for reference only Technical data at 75 C rise over 25 C ambient 1 Addition of 254 x 254 x 25 4 mm 10 x 10 x 1 aluminum heat sink increases continuous force capability by 20 along with 20 more current 2 Addition of forced air cooling increases continuous force 12 12 more current 3 Liquid cooling option increases continuous forces by 25 and power dissipation by 50 Available only on motors with D E and F size codes 4 Standard Motor Linear Motors and Stages Cog free Brushless motors Dimensions COIL ASSEMBLY FORCER 2 47 u 60 9mm m OPTIONAL HALL LEADS MOTOR LEADS D 122mm 4 80 N 61mm 2 4 N
21. 9 1 Initial Prototy PING u Ry in u EO Recommendations u u U u l U U lal 11 1 Appendix A Project Timeline 11 2 Appendix B Statistical Significance of each factor 11 3 Appendix C Experimental Pulse Data 11 4 Appendix D Team Budget 11 5 Appendix E Report on Statistical Analysis 11 6 Appendix G Damping Materials 11 7 Appendix H Linear Encoder Spec Sheet 11 8 Appendix Linear Motor Spec Sheet 11 9 Appendix J Data Acquisition Spec Sheet 11 10 Appendix K Accelerometer Spec Sheet 11 11 Appendix L Hall Effect Sensor Board 11 12 Appendix M Linear Encoder Spec Sheet 11 13 Appendix N Thomson Rods and Linear Bearings 11 14 Appendix M Drawing Package 1 Executive Summary For our senior capstone project we have been tasked with designing a personal sized shock testing apparatus for Dr Scott Whalen of Sandia National Labs Shock occurs when two objects collide causing rapid deceleration for a minute period of time It 1s this impulse that Dr Whalen wishes to measure so that he may test his proprietary electronics under these conditions In order to accomplish this task we must first understand how to replicate these conditions with accuracy and precision as well as how to modify them according to his user inputs Sandia M A S T must produce shock wav
22. During the prototyping phase of the project we developed a series of models that helped us design the final shock tester The first was a large steel structure built to gain an initial understanding of the process It was constructed with ample vertical height to allow modifications as necessary Unfortunately assembly tolerances were very loose creating noise in the accelerometer responses and did not provide results that could be analyzed for peak accelerations and shock duration From this design we did learn however that a minimal height was needed rather than over 3 feet of vertical drop This in turn helped to initially validate our math model Our math model was further validated after moving to our next prototype a spring mass damper test fixture from a previous class It was much smaller in size and built with precision rods and linear bushings With this upgraded set of features we obtained cleaner data with significantly less noise We were able to determine statistical significance of the relationship between damping materials used and drop height applied Figure 12 Last Prototype The last prototype developed had an aluminum base precision rods and linear bushings much like the second prototype It was larger and more like the proposed final design This design helped us map our machine plans in simplifying the process and to realize that we needed higher tolerances In the end we used portions of this design
23. IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION ecu sandiaMAST OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF IDAHO ME DEPARTMENT IS DEFAULT TOLERANCES UNIVERSITY OF IDAHO ME DEPARTMENT Cameron Hjelfness bae 5 10 2012 aus 01 03 01 03 Motor Track Mount SLDPRT scale 1 5 sue 4 OF 5 ME DEPARTMENT ANY REPRODUCTION IN PART 2X D 141 THRU ALL PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INCHES RAR mrb ge SOndioMASI ME DEPARTMENT ANY REPRODUCTION IN PART OR 5 WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DEFAULT TOLERANCES pescription Encoder Rail UNIVERSITY OF IDAHO e Nicholai Olson DATE 5 10 2012 ME DEPARTMENT Cameron Hijeltness pate 9 10 2012 part 01 04 rename 01 04 Encoder Rail SLDPRT scale 1 5 sug 5 OF 5 2 0202 1 3 0205 EncoderBoar Mount 4 5 7 1 6 Vibration Damping Bronze Sleeve Bearing 2 7 HX SHCS 0 19 32 0 75 0 75 4 8 HX SHCS 0 164 32x0 625x0 625 N 2 PROPRIETARY AND CONFIDENTIAL wet AEDES ge SOndioMAST Notes 1 Vibration Damping Bronze Sleeve Bearings OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION McMast
24. Ib Table 3 Lansmount 152 Specs Figure 3 Lansmount 152 Shock Capacity 1000 g s to 3500 g s Shock Duration 0 3 to 1 ms 4 7 Desirable Capabilities Gravity actuation small footprint Footprint Size 0 694 ftA2 to 2 ftA2 Load Capacity 500 to 3300 Ib Table 4 LAB SD Series Specs Figure 4 LAB SD Series 3 Problem Definition A concise table of needs specs and targets can be viewed in Appendix A The design will be reliable and compact capable of measuring shocks up to 200 g s over a range of 1 10 milliseconds compliant with safety considerations and will be designed for 5 or more years of performance The device will be electrically powered and will take user input to deliver precise impulses to the device under test while monitoring the output through LabView software Resonance will be mitigated 4 Project Plan Team responsibilities are delegated amongst the team The following 15 a list of roles and responsibilities of each team member Team Lead Cameron Hjeltness Send out reminders for events action items Create meeting agendas Run and schedule meetings Manage timeline Coordinate with POC for client meetings Coordinate with documenter for monthly status reports Budget Manager Travis Nebeker Keep a record of expenditures Maintain a current balance of team funds Communicate with UI Department Manager Communicate with team about purchases Responsible for tracking orders Responsible
25. before impact After the impact the controller will once again be enabled to position the platform back to the starting point in preparation for the next test and to avoid any secondary shocks The systems uses a Balder Microflex e100 motor controller as the linear motor controller The controller is an off the shelf controller that takes in signals from the hall effect sensor mounted on the motor as well as a differential linear encoder to control the motor position The linear encoder is a custom mode module designed for the apparatus using an Austria microsystems AS5306A magnetic linear encoder chip The linear encoder module has 15 micron resolution and a differential quadrature encoder output A Data Translation DT9812A was used for the data acquisition 8 2 System Operation Procedure Step 1 Install Labview download evaluation version Step 2 Install drivers Step 3 Install Open Layers library from manufacturer Install LV Link from DAQ manufacturer Step 4 Set up Ethernet adapter Step 5 Plug in power cord to wall and into power plug in on back of device Plug in Ethernet cord Step 5 Open and run given Labview program Step 6 Input device address number of cycles desired impact velocity Hit the Go button cleaned _controller_panel vi Front Panel Edt Yew Operate Took Window Help Sl co M 135 Application Fork Faw ee abs 9 Detailed Design 9 1 Initial Prototyping
26. by zoos and museums for a variety of mold making display and exhibit applications It features a convenient mix ratio 2 1 by weight or volume and contains no mercury concrete molds casting waxes Smooth On rigid polyurethanes and epoxies and also for making a variety of special effects Other applications include making plaster block molds reproducing ornamental plaster architectural restoration pre cast for movies and theatre PROCESSING RECOMMENDATIONS START BY PREPARING YOUR MODEL Preparation Materials should be stored and used in a warm environment 73 F 23 C They also have a limited shelf life and should be used as soon as possible Wear safety glasses long sleeves and rubber gloves to minimize contamination risk Some Materials Must Be Sealed To prevent adhesion between the rubber and model surface models made of porous materials gypsum plasters concrete wood stone etc must be sealed prior to applying a release agent SuperSeal or One Step available from Smooth On are fast drying sealers suitable for sealing porous surfaces without interfering with surface detail A high quality spray shellac is suitable for sealing modeling clays that contain sulfur or moisture water based Thermoplastics polystyrene must also be sealed with shellac or PVA In all cases the sealing agent should be applied and allowed to TECHNICAL OVERVIEW completely dry prior to applying a release agent Mix Ratio 2A 1B b
27. for resolution of conflict with suppliers Webmaster Fernando De La Garza Maintains up to date status of project Designs and manages team website Responsible for website deadlines and content Generates team blog Documenter Michael Brewster Takes meeting minutes Maintains team project binder Digital file organization Check documented team deliverables Maintain team monthly reports Maintain confidentiality and legality of documentation Point of Contact Nicholai Olson Maintain contact with Mentor Client Advisor Facilitates smooth information flow between parties Relays client communication to team members and vice versa Notifies client on team progress A current project timeline is shown in Appendix B 5 Concepts Cons idered 5 1 Design Breakup Initial talks with our group concluded with eight different categories that we felt were the most important criteria for the shock tester Table 5 Table 5 Morphological Chart STRUCTURAL REDUCTION OF ENERGY LOSS TABLE LIFT ACTUATION RELEASE MECHANISM EXTERNAL SOURCE OF Category selection were broken down into Figure 5 Pneumatic Shock Testing Apparatus FOUR POST TWO POST NO VERTICAL VERTICAL VERTICAL SINGLE POST STABILIZATION BE ARINGS BUSHINGS NONE ROTARY MOTOR CABLE amp WINCH ACME SCREW LINEAR MOTOR ROTARY MOTOR ROTATIONAL AND BELT HAMMER LINEAR MOTOR SYSTEM NONE GRAVITY DROP FROM VARIOUS MOTOR SOLENOID VARY STIFFNESS HEIG
28. in the range of 5 to 60mT at the chip surface The Hall elements on the AS5304 AS5306 are arranged in a linear array By moving the multi pole magnet over the Hall array a sinusoidal signal SIN is generated internally With proper configuration of the Hall elements a second 90 phase shifted sinusoidal signal COS is obtained Using an interpolation circuit the length of a pole pair is divided into 160 positions and further decoded into 40 quadrature pulses An Automatic Gain Control provides a large dynamic input range of the magnetic field An Analog output pin AO provides an analog voltage that changes with the strength of the magnetic field see chapter 8 A B Quadrature Incremental Signal Processing amp Hall Array amp Frontend Channel Interface Amplifier coc amp He Amplifier T magnetic Automatic field alarm Gain Analog Control Output Figure 3 AS5304 AS5306 block diagram 6 Sensor Placement in Package TSSOP20 0 65mm pin pitch aoa ems cames 0 2299 0 100 e s eee 0 2341 0 100 Package Outline Lad poo d epo 75 ON de 0 7701 0 150 3 0475 0 235
29. it circuitry Each converter uses a common clock and trigger takes the A D to switch from track to hold mode is well matched for simultaneous sampling of all six analog input signals The at 5 ns across all six track and hold circuits virtually eliminating throughput rate varies depending on the model you choose the channel to channel skew that is associated with multiplexed inputs Amaximum aperture uncertainty of 1 ns the jitter or variance in aperture delay virtually eliminates phase noise in your data ENOB Effecive Number of Bits using DT9816 02 About Hook Up DATA DATA TRANSLATION Gain Key Features of the DT9816 Frequency Effective m High Speed Simultaneous Acquisition Acquire all number of bits 150000 six analog input channels simultaneously at up to 55H 50 kHz per channel DT9816 150 kHz per channel 1024 Point FFT using DT9816 02 DT9816 A or 750 kHz per channel DT9816 S m Input 3dB bandwidth is 4 MHz typical DT9816 Spurious free DT9816 A 40 MHz typical DT9816 S dynamic range m High Resolution Data 16 bit resolution for precision greater than 96 db measurements 60 000 Two Bipolar Input Ranges Input range of 10 V and 5 V signal for maximum flexibility m Digital 1 0 Functions 8 fixed digital outputs for controlling external equipment m Multifunction Counter Timer One 16 bit counter timer for event counting freq
30. on both the analog input analog output DT9812 2 5V has analog signal range of 0 2 44V m Generate sine rectangle triangle or DC waveforms with the analog outputs m Three versions of Digital 1 0 modules isolated non isolated and high current drive Monitor and control up to 28 digital I O lines m Perform event counting frequency measurement edge to edge measurement and rate generation continuous pulse output operations using 32 bit counter timer m Shielded rugged enclosure for noise immunity with built in screw terminals Low Cost USB DAO quickDAQ eso File Edit View Marker Strip Hep gt m TimeotDay 4 46 k C MuuickDAQDataNDataFile1hpf Recording Device Press the Record button to start recording data to disk 10000 Recording stopped at 15 25 17 8217913 Figure 1 The ECONseries provides economical multifunction data acquisition instruments for the USB bus Simply install the software connect your module to any USB port and measure m Easy signal connections the DT9812 10V OEM and the DT9816 OEM with two 20 pin connectors for all signals m All modules run off USB power supply no external power supply needed Features Summary Analog Resolution OEM version avail
31. on the final product These components included high precision Thompson rods and the impact base 1 3 Last Prototype 9 2 Final Assembly The final design Is shown In Figure 14 There 15 a large degree of similarity to Figure 9 displaying our conceptual design A shows the DUT fixture which mounts to hole pattern as specified by Sandia Labs B represents the Thomson rods allowing the drop table to shde smoothly with a high degree of mechanical tolerance D 15 the damping material mounted to component E which is a component derived from our third prototype F is our wooden base constructed of maple hardwood G shows our linear encoder which 9M relays information of the 4 table s position to within 15 d micron to component J the linear motor J 1s regulated by K the linear motor ___ controller Our specifications for the design were provided by the client and served to guide our design from beginning to end Listed with a description they are in the following table GENERAL NEED SPECIFIC REQUIREMENT TARGET VALUES Physical constraints Small Size Maximum base dimension of 30 square and height of 72 Standardized mounting interface 1 5 center 3 8 16 course thread Standardized DUT to contain Cylinder of diameter 5 cm length 8 cm proprietary electronics mass of 0 3 kg 12 Motors Solenoids ete MeasureshockinY direction
32. output will switch back to Index low i when the magnet is moved by one LSB from position X 0 to X X1 as shown in Figure 7 bottom graph One LSB is 25um for AS5304 and 15 for AS5306 Index Note Since the small step size of 1 LSB is hardly recognizable in a correctly scaled graph it is shown as an exaggerated step in the bottom graph of Figure 7 Step 157 158 159 0 1 2 3 4 5 Figure 6 Quadrature A B and Index output 7 1 2 Magnetic Field Warning Indicator The 55304 can also provide a low magnetic field warning to indicate a missing magnet or when the end of the magnetic strip has been reached This condition is indicated by using a combination of A B and Index that does not occur in normal operation A low magnetic field is indicated with Index high A B low 7 1 3 Vertical Distance between Magnet and IC The recommended vertical distance between magnet and IC depends on the strength of the magnet and the length of the magnetic pole Typically the vertical distance between magnet and chip surface should not exceed 75 of the pole length That means for AS5304 having a pole length of 2 0mm the maximum vertical gap should be 1 0mm For the AS5306 having a pole length of 1 2mm the maximum vertical gap should be 0 6mm These figures refer to the chip surface Given a typical distance of 0 2mm between chip surface and IC package surface the recommended vertical distances between magnet and IC surface are the
33. pressure casting technique using a pressure chamber can yield totally bubble free molds Contact Smooth On or your distributor for further information about vacuum degassing or pressure casting POURING CURING amp PERFORMANCE Pouring For best results pour your mixture in a single spot at the lowest point of the containment field Let the rubber seek its level up and over the model A uniform flow will help minimize entrapped air The liquid rubber should level off at least 1 2 1 3 cm over the highest point of the model surface Curing Allow rubber to cure overnight at least 16 hours at room temperature 73 F 23 C before demolding Cure time can be reduced with mild heat or by adding Smooth On Kick It Cure Accelerator Do not cure rubber where temperature is less than 65 F 18 C Post Curing After rubber has cured at room temperature heating the rubberto 150 F 65 for 4 to 8 hours will increase physical properties and performance Using The Mold using as a mold material a release agent should be applied to the mold before each casting The type of release agent to use depends on the material being cast The proper release agent for wax liquid rubber or thermosetting materials i e Smooth On liquid plastics is a spray release made specifically for mold making available from Smooth On or your distributor Prior to casting gypsum plaster materials sponge the mold with a soap solution for better plaster flo
34. small as reliably possible This was not an explicit design constraint given to Sandia MAST however from talks with the client and other specs given it was evident that size was an issue Physically the shock tester was required to stay within 30 wide by 30 long by 72 tall The end design captured much less territory with dimensions of 14 x 7 75 by 22 In achieving the end goal of this project Sandia MAST has capably demonstrated that a mini shock tester 1s viable and produced a working model from which further designs can be fabricated Recommendalions Short Term Recommendations for Sandia National Labs are as follows l Replace the Hall effect sensor board as seen in Appendix L Fabricate more damping samples per manufacturer s instructions in Appendix G 21 Use damping caster and bases Re fabricate damping caster and bases per drawing package The old ones were discarded accidentally Never operate without damping sample Install photo gate interrupter to avoid crashes into underside of aluminum base on the up stroke Mill slot into base to include clearance for Hall effect sensor Long Term Reccomendation for Sandia National Labs are as follows 1 Lubricate Thomson rods with graphite powder as necessary WR WN The shock tester must be mounted to a solid workbench table to reduce noise Provide adequate safety measures to ensure no injuries are incurred during operation Do not operate without plexi gl
35. with motion specified by the control system For this option a linear encoder would likely be used A sensor reads a magnetic strip which allows the computer to recognize the linear motor s displacement The above options are dependent upon the control program that we will develop for LabView and supply to our customer per requirements REF Appendix A 5 6 Source of Acceleration Once the drop table is at its desired height it becomes necessary to accelerate to a specified velocity to impart the desired shock The shorter the distance the greater the acceleration needed To create this acceleration several options were considered These included the use of only gravity elastic materials a rotary hammer a linear motor as stated section 5 5 a solenoid or a motor and belt system Advantages of gravity and springs elastics included cost simplicity and availability but were lacking in repeatability The use of a linear motor had several advantages including the ability to accurately control and have constant feedback as well as the elimination of several other systems but was the most expensive option by a fair margin For all practical purposes the option of using a solenoid system was the same as a linear motor with the exception of being cheaper A rotary motor and belt system would be less reliable and more mechanically complex 5 7 Shock Level and Energy Dissipation Although pulse shapes were not a part of the pro
36. 03 01 03 01 Drop Table SLDPRT scale 1 4 sug 2 OF 4 5 250 1 4 20 UNC 875 8 000 10 000 375 0 250 1 4 20 UNC PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES SandiaMAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia Material not specified DEFAULT TOLERANCES Connecting Rod UNIVERSITY OF IDAHO e Nicholai Olson DATE 5 1 1 12 DEPARTMENT Cameron Hjeltness pate 0 9 2012 part 03 02 rename 03 02 Connecting Rod SLDPRT bonc dem 3 OF 4 R1 004 Y 100 0 375 THRU 900 2 000 3 500 4 000 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION ecu OF UNIVERSITY OF IDAHO ME DEPARTMENT IS MATERIAL 6061 T SS PROHIBITED DEFAULT TOLERANCES DESCRIPTION 3 8 1 Fully Thread Stud ev Nicholai Olson DATE 5 1 1 1 2 beawuev Travis Nebeker DATE 5 10 2012 rename 03 03 Hold Down Fixture SLDPRT SandiaMAST UNIVERSITY OF IDAHO ME DEPARTM
37. 19 6061K13 4 36 6061K429 439 87 6061K103 440 97 56061 23 4 67 107 6061K109 5 36 12 6061 33 6 98 147 6061 431 7 56 15 6061 335 6 09 16 6061 432 8 63 187 606143 9 53 207 6061K433 11 59 247 6061 53 1297 307 6061 79 1557 36 6061K63 19 01 42 6061K635 2207 487 GOG1KF3 2401 60 6O0671KS3 30 01 72 50561K83 36 14 847 5061kR213 4299 95 6061 314 51 87 11 14 Appendix M Drawing Package TE LENL ea 01 01 L3 4 L5 Magnetic Encoder Sip T 6 ABB Linear MotorTrack 1 7 M8 5 8DowePin 2 8 15 x1 2 Thomson Precison Rod 2 9 HXSHCS 0 3125 18x1 25x1 25 N 4 10 HXSHCS0 25 28x0 625x0 25 N 4 11 HXSHCSO0 375 16x1 25x1 27 N 2 12 SSFLATSKT 0 19 24x0 375 HX N 2 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION Gc ME DEPARTMENT ANY REPRODUCTION IN PART OR AS OLE WITHOUT THE WRITTEN PERMISSION R AS A WH OF UNIVERSITY OF IDAHO ME DEPARTMENT PROHIBITED MATERIAL V CITIOUS gt Notes 1 Cover frame with Plexi glass for safety DEFAULT TOLERANCES 2 ABB Linear Motor 9 6 inch Track Part ANGULAR ME DEPARTMENT No LTCF DO9 XXE ap XXXe000 N 4X 5 500 T
38. 4 A85306 use a fast interpolation technique allowing an input frequency of 5kHz This means it can process magnetic field changes in the order of 5000 pole pairs per second or 300 000 revolutions per minute However since a magnetic ring consists of more than one pole pair the above figure must be divided by the number of pole pairs to get the maximum rotation speed Maximum rotation speed 300 000 rpm number of pole pairs Example same as above multi pole ring with 22 pole pairs Max speed 300 000 22 13 636 rpm this is independent of the pole length 8 1 44 Maximum Linear Travelling Speed For linear motion sensing a multi pole strip using equally spaced north and south poles is used The pole length is again fixed at 2 0mm for the AS5304 and 1 2mm for the AS5306 As shown in 8 1 3 above the sensors can process up to 5000 pole pairs per second so the maximum travelling speed is Maximum linear travelling speed 5000 pole pair length Example linear multi pole strip Max linear travelling speed 4mm 5000 1 sec 20 000mm sec 20m sec for AS5304 Max linear travelling speed 2 4mm 5000 1 sec 12 000mm sec 12m sec for AS5306 Revision 1 6 www austriamicrosystems com Page 9 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 GENERAL DEVICE SPECIFICATIONS 9 1 Absolute Maximum Ratings Non Operating Stresses beyond those listed under Absolute Maximum
39. 5304 AS5306 are arranged in a linear array By moving the multi pole magnet over the Hall array a sinusoidal signal SIN is generated internally With proper configuration of the Hall elements a second 90 phase shifted sinusoidal signal COS is obtained Using an interpolation circuit the length of a pole pair is divided into 160 positions and further decoded into 40 quadrature pulses An Automatic Gain Control provides a large dynamic input range of the magnetic field An Analog output pin AO provides an analog voltage that changes with the strength of the magnetic field see chapter 8 A B Quadrature Incremental Signal Processing amp Hall Array amp Frontend Channel Interface Amplifier coc amp He Amplifier T magnetic Automatic field alarm Gain Analog Control Output Figure 3 AS5304 AS5306 block diagram 6 Sensor Placement in Package TSSOP20 0 65mm pin pitch aoa ems cames 0 2299 0 100 e s eee 0 2341 0 100 Package Outline Lad poo d epo 75 ON de 0 7701 0 150 3 0475 0 235
40. 6 DT9816 A and DT9816 S eliminate the phase shift between signals allowing you to correlate simultaneous measurements of multiple inputs The per channel sampling rate in this case is the maximum rate of the sampling clock 50 kS s for the DT9816 150 kS s for the DT9816 A and 750 kS s for the DT9816 S According to sampling theory Nyquist Theorem specify a frequency that is at least twice as fast as the input s highest frequency component For example to accurately sample a 2 kHz signal specify a sampling frequency of at least 4 kHz Doing so avoids an error condition called aliasing in which high frequency input components erroneously appear as lower frequencies after sampling Input Triggers A trigger is an event that occurs based on a specified set of conditions Acquisition starts when the module detects the initial trigger event and stops when the buffers on the queue have been filled or when you stop the operation The DT9812 DT9813 DT9814 and DT9816 Series modules support the following trigger sources m Software trigger A software trigger event occurs when the analog input operation is started the computer issues a write to the module to begin conversions Using software specify the trigger source as a software trigger m External digital TTL trigger An external digital TTL trigger event occurs when the module detects a high to low negative transition on the Ext Trigger In signal connected to t
41. 75 1250 3429 135 8631 340 15 32 Catalog Number Weight LMCF12D HCO 3785 1490 3429 135 8631 340 18 39 Kg m Lb in Size E LTCF AXX 3 6 0 20 LMCFO4E HCO 1346 530 3937 155 1143 450 077 1 7 LTCF BXX 55 0 31 LMCFOGE HCO 1956 770 3937 155 1143 450 1 1 25 LTCF CXX 81 0 45 LMCFOSE HCO 2565 10 10 3937 155 1143 450 1 5 32 LTCF DXX 11 6 0 65 LMCF10E HCO 3175 1250 3937 155 1143 450 18 4 0 LTCF EXX 172 096 LMCF12E HCO 3785 1490 3937 155 1143 450 20 48 LTCF FXX 34 190 LMCF14E HCO 439 4 17 30 3937 1 55 114 3 4 50 2 5 5 6 Size F LMCFO4F HCO 156 2 530 440 173 1524 600 165 36 NO 2 LMCFOSF HCO 2565 1010 440 173 1524 600 31 6 8 stroke min 3 inch 76 2mm LMCF12F HCO 378 5 14 90 44 0 1 73 152 4 6 00 45 9 9 11 9 Appendix J Data Acquisition Spec Sheet ECONseries Low Cost USB Data Acquisition Modules The ECONseries is a flexible yet economical series of multifunction data acquisition modules You choose the number of analog and digital channels the resolution you need and the signal range of your application Key Features m Ultimate flexibility with up to 24 analog inputs 2 analog outputs 28 digital and one 32 bit counter timer m 10 12 or 16 bit resolution m independent subsystem operation at throughput rates up to 750 kHz per channel m Simultaneous analog inputs on the DT9816 modules m Signal range of 10V
42. CAO Analogue Output Buffer Parameter Note Strong field min Minimum output voltage VoutRange field max VoutRange AGC Votfs Average short circuit current Operating Reduces maximum Temperature Capacitive load Revision 1 6 www austriamicrosystems com Page 11 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 6 Magnetic Input Parameter i i Note Magnetic pole length 2 AS5306 Magnetic pole pair length 5306 Magnetic amplitude Os pc wera ss mama m 3 1 w Table 1 5304 ordering guide Device Resolution Magnet Pole Length Digital Outputs Table 2 AS5306 ordering guide Device Resolution Magnet Pole Length Digital Outputs Revision 1 6 www austriamicrosystems com Page 12 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Contact Headquarters austriamicrosystems A 8141 Schloss Premstatten Austria Phone 43 3136 500 0 Fax 43 3136 525 01 www austriamicrosystems com Copyright Devices sold by austriamicrosystems are covered by the warranty and patent indemnification provisions appearing in its Term of Sale austriamicrosystems makes no warranty express statutory implied or by description regarding the information set forth herein or regarding the freedom of the described devices from pate
43. Displacement m 2x 1 2 Velocity m s for i 1 length yl gravity before impact Acceleration is equal to if 1 1 lt 0 else Q 5 Plots Subpiot 2 l 1 plot t yl title Displacement of Drop Table axis 0 0 01 min y1 max y1 legend xl ylabel Displacement subplot 3 1 2 plot t y2 title Velocity of Drop Table axis 0 0 01 min y2 max y2 ylabel Velocity m s subplot 3 51 3 plot t y3 title Accleration of Drop Table ylabel Acceleration m s 2 xlabel Time 5 axis 0 0 01 3 max y3 maxacc max y3 Maximum Acceleration of drop table REFERENCES 1 2 MIL S 901 Rev D http www everyspec com MIL SPECS MIL SPECS MIL S MIL S 901D_14581 3 H Egbert MIL STD 810F 2000 http www dtc army mil navigator 4 http www biomedcentral com 1471 2474 9 137 5 Gere James Mechanics of Materials 8 2009 26 Print 6 11 6 Appendix G Damping Materials PMC 746 EDA Polyurethane Rubber Compound T IU PRODUCT OVERVIEW PMC 746 was developed to make molds for casting gypsum plasters Like PMC 744 this product is well suited for use as a rubber case mold especially large case molds where extra rigidity is required Shore hardness is 60A Because of its durability and moisture resistant properties PMC 746 is also used
44. ENT part 03 03 scale 1 2 SHEET 4 OF 4 DESCRIPTION TY SHEET NO NUMBER SCRIPTIO 5 04 01 Dompener Bose 04 03 Damping Material 04 02 Dompener Mold PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d id MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION ME DEPARTMENT ANY REPRODUCTION IN PART OR AS WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DEFAULT TOLERANCES pescription Shock Dampener UNIVERSITY OF IDAHO 25 Vi Nicholai Olson pate 5 11 2012 ME DEPARTMENT XXE V Cameron Hijeltness pate 9 10 2012 part 04 00 Necessary fe 04 00 Shock Dampener SLDPRT Lon c dem OF EI 50 Note This assembly is molded using castable polyeurathane materials Place Dampener Mold Cap over top of Dampener Base and inject materials into opening in bottom Mold damper to height of 0 750 inches D 2 000 D 1 200 D 400 THRU D 127 THRU FILLET R 100 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d IQ MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION OZ ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED DEFAULT TOLERANCES
45. HRU 5 250 THRU 250 5 250 11 630 1 250 THRU PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d MAST D PROPERTY um OF IDAHO THIRD ANGLE PROJECTION DEPARTMENT ANY REPRODUCTION IN PART RU DENEN c SER ON OF UNIVERSITY OF IDAHO ME DEPARTMENT IS 14 000 _ PROHIBITED MATERIAL Hickory Note Construct Base from Hickory Stock 0 875 inches thick oss DEPARTMENT frame Cameron we 5 10 2012 01 01 01 01 Wooden Frame SLDPRT deem 2 OF 5 2X 5 500 THRU 2 2 2X REAM 501 THRU 2 050 Y 250 2X D 125 250 150 V 1 000 10 24 UNC y 380 902 2X 313 738 3 8 16 UNC 550 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d IQ MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION OZ ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS DEFAULT TOLERANCES Shock Tower Base UNIVERSITY OF IDAHO DUE ME DEPARTMENT Xi logy Travis Nebeker bue 5 10 2012 01 02 1 5 2X 375 THRU 5 750 AX 000 THRU _ 000 Y 000 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING
46. HTS CONTROLS OF BASE VISCOELASTIC LOC KING MOTOR SOLENOID ELECTROMAGNET DAMPERS MECHANISM CONTROLS SOLENOID IC STOPPER LIFT CONDUCTIVITY IN BASE LINE ENCODER COLLISION VELOCITY SENSING was based on necessary functions of current market offerings that we researched Systems mechanical electrical and electro mechanical classifications From this point we further divided the systems into quantifiable single function categories Safety standards as defined by Sandia National Laboratories restricted the team from exploring options involving pressurized fluids 1 hydraulics and pneumatics Many shock testers on the market employ the use of high pressure fluids to lift and or accelerate the drop tables Figure 5 This made market research on force input only marginally helpful 5 2 Testing Configuration Our group had to decide on form of our shock tester before we could quantify options to be considered We were provided limited spatial constraints Appendix A that caused our group to lean to a vertical drop device Based on our market research a vertical drop was unanimously chosen The final factor that helped our group decide on a vertical structure was gravity With a vertical design gravity would help in acceleration of the drop table if not provide the primary means of acceleration 5 3 Structural Considerations Based upon research of competitors in the market the structural design of the shock tes
47. IVERSITY OF IDAHO Vi Nicholai Olson pate 5 11 2012 ME DEPARTMENT rs Cameron Hjeltness pate 9 10 2012 part 05 00 rename 05 00 Electrical Housing SLDPRT ae OF MU 500 THRU 7 750 6 375 1 375 1 500 18 500 20 000 Note 1 Use Hickory stock 0 875 inches thick PROPRIETARY AND CONFIDENTIAL DIMENSIONS ARE IN INCHES 2 Attach to Electrical Housing using E e ndm ql 20 sandiaMAST ME DEPARTMENT ANY REPRODUCTION IN PART ecd wood screws 2 DEFAULT TOLERANCES pescripton Mounting Base UNIVERSITY OF IDAHO sy Nicholai Olson DATE 5 1 1 12 ME DEPARTMENT Travis Nebeker pate 9 10 2012 part 06 00 rename 06 00 Mounting Base SLDPRT SCALE 1 4 sug OF 1
48. LES DT9810 m 019812 2 5 DT9812 10V DT9812 10V OEM DT9812A DT9813 10V DT9813A DT9814 10V DT9814A DT9816 DT9816 0EM DT9816 A DT9816 S 019817 DT9817 H DT9817 R ACCESSORIES m DIN Mount Kit SYSTEM REQUIREMENTS m Windows XP Windows Vista or Windows 7 m Available USB Port s 2 0 or 1 1 m CD ROM drive SOFTWARE OPTIONS m quickDAQ High performance ready to run application that lets you acquire plot analyze and save data to disk at up to 2 MHz per channel SP8501 CD FREE SOFTWARE m DAQ Adaptor for MATLAB Access the analyzation and visualization tools of MATLAB m LV Link Access the power of Data Translation boards through LabVIEW Copyright 2012 Data Translation Inc All rights reserved All trademarks are the property of their respective holders Prices availability and specifications are subject to change without notice WWW DATATRANSLATION COM US CaNADA 800 525 8528 Europe Asia 49 0 7142 9531 0 DATA TRANSLATION 11 10 Appendix K Accelerometer Spec Sheet Temperature F ACCELEROMETER TRIAXIAL Performance ENGLISH SI Optional Versions Optional versions have identical specifications and accessories as listed Sensitivity 15 96 10 mV g 1 02 mV m s for standard model except where noted below More than one option maybe used Measurement Range 500 g pk 4905 m s pk HT High temperature extends normal operation temperatures Frequency Range 5
49. Ratings may cause permanent damage to the device Parameter Symbol Min Max Unit Note Input current latchup immunity 100 D sss DCS 3 8 _ 92 Operating Conditions Parameter Symbol Positive supply voltage AVDD Digital supply voltage DVDD Power supply current AS5304 at tai A B Index AO unloaded Power supply current AS5306 current AS5306 K e HE Integral nonlinearit weal ErrMax ErrMin 2 Differential nonlinearity No missing pulses wau alignment mes LE T 93 System Parameters Parameter Symbol Min Max Unit Note Powers T Amplitude within valid range uds Interpolator locked A B Index enabled Time bet hange of input signal to Revision 1 6 www austriamicrosystems com Page 10 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 4 A B C Push Pull or Open Drain Output Push Pull Mode is set for AS530xA Open Drain Mode is set for AS530xB versions Parameter Typ M High level output voltage pf Push Pull mode m m m p Low level output voltage VoL 0 4 VSS VO C T Push Pull mode V V Short circuit limitation current 39 maximum operating temperature Q Js S Capacitive load 20 KES See Figure 13 A B Index from AS5304 6 1 20pF Figure 13 Typical digital load 95 CAO Analogue Output Buffer Parameter Note Strong field min Minimum ou
50. able 10 bit 12 bit DT9810 DT9812 2 5V 12 bit 12 bit 12 bit 12 bit 12 bit 12 bit 16 bit 16 bit 16 bit DT9812 10V DT9812A DT9813 10V DT9813A DT9814 10V DT9814A DT9816 DT9816 A DT9816 S DT9817 DT9817 H DT9817 R WWW DATATRANSLATION COM US Canapa 800 525 8528 Europe Asia 49 0 7142 9531 0 _ 0 305V 0 1525V __ spe 20 1 0 j 8 in 8 out Isolated High Drive DATA TRANSLATION DT9812 Block Diagram 2 5 V Reference 8 Channel Multiplexer ESD Protected 4000 V DAC 1 DAC 0 USB 2 0 or 1 1 Port q 1 12 Bit D A Converter 5 From USB gt m Port Counter Timer 17 lt lt C T In 0 A D Clock External Clock External Trigger DOUT7 12 Bit A D e Converter e el DOUTO Digital deg DIN7 lel DINO ESD Protected to 4000 V Input FIFO Note For the DT9812 10V DT9812 10V OEM and DT9812A modules the reference is 2 5 V For the DT9812 2 5V module the reference is 2 44 V Figure 2 Block Diagram of the DT9812 2 5V DT9812 10V DT9812 10V OEM and DT9812A Modules WWW DATATRANSLATION COM US Canapa 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 DT9816 Series Block Diagram 2 5 t From USB Port
51. ace the recommended vertical distances between magnet and IC surface are therefore AS 5304 lt 0 8mm AS 5306 lt 0 4mm Revision 1 6 www austriamicrosystems com Page 5 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Magnet drawn at X index position 0 CW magnet movement direction Hall Array Center Line Index High Pin 1 Chip Top view i eu st D gs 3 0475 0 235 l 25um AS5304 15 AS5306 X Magnet drawn at Ol Te I gt position 1 x exaggerated ON CO O SE 09 au CW magnet movement direction Hall Array Center Line N Index Low I N N I Russ unan luas B YES Chip Top view 1 ll lL Qu LO CO g lt 3 0475 0 235 I Figure 7 Magnet placement for index pulse generation 7 1 4 Soft Stop Feature for Linear Movement Measurement When using long multi pole strips it may often be necessary to start from a defined home or zero position and obtain absolute position information by counting the steps from the defined home position The AS5304 AS5306 provide a soft stop feature that eliminates the need for a separate electro mechanical home position switch
52. also commonly used to make rubber mechanical parts of varying configurations gaskets wheels and pullies as well as ball mill liners and vibration shock pads PROCESSING RECOMMENDATIONS START BY PREPARING YOUR MODEL Preparation These products have a limited shelf life and should be used as soon as possible Materials should be stored and used at room temperature 73 F 23 C Humidity should be low Wear safety glasses long sleeves and rubber gloves to minimize contamination risk Good ventilation room size is necessary Some Materials Must Be Sealed To prevent adhesion between the rubber and model surface models made of porous materials gypsum plasters concrete wood stone etc must be sealed prior to applying a release agent SuperSeal or One Step available from Smooth On is a fast drying sealer suitable for sealing porous surfaces without interfering with surface detail You can also use Sonite Wax A high quality Shellac is suitable for sealing modeling clays that contain sulfur or moisture water based In all cases the sealing agent should be applied and allowed to TECHNICAL OVERVIEW completely dry prior to applying a release agent Mix Ratio 2A 1B by weight or volume Non Porous Surfaces Metal glass hard plastics sulfur free clays etc require only a release agent Mixed Vi it 2 000 ASTM D 2393 Applying A Release Agent A release agent is necessary to facilitate Specific Gravity g c
53. an be seen below Table 6 FOUR POST TWO POST SINGLE POST HORIZONTAL STATIONARY BASE VERTICAL VERTICAL AND HAMMER COST MACHINABILITY _________ 500 0 606 240 Table 6 Decision Matrix for test apparatus structural orientation From the decision matrix it was determined that the two post vertical drop table would be the best option The four post design would be more difficult to manufacture and would have the potential for binding since there would be the posts have the possibility of being misaligned A single post option was deemed to not be repeatable enough since it would be hard to keep it oriented the same way for each test The horizontal slider option was deemed to have too large of a footprint The stationary base and hammer option would likely have more resonance problems and in addition would likely have a shorter life because key components would be subjected to higher shocks than in the other options After it was determined that a vertical tower would be used it was then required to find a way to create the table motion Ideally an actuation method would be easy to integrate into the design provide high controllability and would be relatively inexpensive Several options were considered and the results were compiled into Table 7 below ROTARY CABLE amp IACME LINEAR Table 7 Table Actuation Decision Matrix The linear motor solenoid options scored the hi
54. and 75 kHz Digital 1 0 Lines The DT9812 Series modules provide 8 dedicated digital input lines and 8 dedicated digital output lines The DT9813 Series modules provide 4 dedicated digital input lines and 4 dedicated digital output lines The DT9814 Series modules do not support digital I O operations The DT9812 2 5V DT9812 10V DT9816 DT9816 A and DT9816 S modules feature 8 digital input lines and 8 digital output lines The DT9813 10V provides 4 digital input lines and 4 digital output lines 079810 module provides 20 programmable digital 1 0 lines If you need more digital I O lines and do not need analog I O functionality select the DT9817 or DT9817 H module which provide 28 programmable digital 1 0 lines The DT9810 and DT9817 can source 4 5 mA and sink 10 mA The DT9817 H provides high drive capability and can source 15 mA and sink 64 mA The DT9817 R is a high performance relay version of the DT9817 and can switch up to 30 V at 400 mA The DT9817 R features 8 dedicated digital input lines and 8 dedicated digital output lines This module includes channel to channel isolation of up to 500 V 250 V between digital input channels that are paired in an opto isolator The DT9817 H and DT9817 R are ideal for solid state or mechanical relays Multifunction Counter Timers The DT9816 modules support one 16 bit counter timer channel All other modules feature one 32 bit counter timer 16 bits in rate generation mode The c
55. ariables in this experiment compared to the dependent variables of the shock amplitude and the pulse duration By compiling and analyzing data using a factorial ANOVA table comparisons the two were made allowing the discovery of which is more important to the dependent variables This analysis will tell the team which factor if any is significant to both the magnitude of the pulse and the duration for which the pulse lasts I will also be able to determine which material to use for a damping platform on the senior design project that will provide the optimum results with high accuracy and minimal resonance Should the analysis prove that no factor is statistically significant this will show that there is another physical phenomenon that needs explanation The more likely outcome is that one factor will emerge as the most significant This will drive the design choices and resources of my design team Sandia M A S T An accelerometer purchased from PCB Piezotronics is the sensing element utilized for this project The sensitivity is advertised online 10 mV g with an accuracy of 15 percent Our specific unit has sensitivity calibrations of 10 36 mv g 10 31 mv g and 10 29 mv g for the x y and z axes respectively In order to derive useful data to the rest of the University and to be able to apply it in industry tests adhere to current standards for performing shock tests Available at the team s disposal are military specifications t
56. ass panels installed If disassembled reassemble with blue Loctite on all metal to metal fasteners 11 Appendices 11 1 Appendix Project Timeline IT 5 tog SandiaM A S T Project Timeline an AQU ay sz tago r or HE yaam FF yaam IE OF any 62 S yaam lt yaam 52 yaam 52 yaam EZ yaam 22 yaam 1 yaam yaam ST yaam ST yaam e 9 Jagu 79 ar OM Sr Yay MOAN Sr lagu Yea ON ET y er Yan OM rr Jana ar yos Je Oje Design Phase 5 J lt 1 gt Project Understanding Research and brainstorming Establish Design Requirements Preliminary Design Test Validation Detailed Design Project Deliverable Phase i usdeus jousdeus jou sdeus IST Updated 12 11 11 2 Appendix B Statistical Significance of each factor ANOVA Peak Response Source dof MS A 1 20606 24 B 1 277913 6 AB 1 1324 709 Error 36 39 33587 Total 39 Fo Fcrit 523 8537 4 12 7065 143 4 12 33 67687 4 12 ANOVA Pulse Duration Source dof MS A 1 1 922 1 183 618 1 1 682 Error 36 0 057778 Total 39 Key Significant Very Significant Fo 33 26538 3178 004 29 11154 Fcrit 4 49 4 49 4 49 Sig
57. ated e Complete system on chip Hall elements for measuring linear or rotary motion using multi pole magnetic strips or rings This allows the usage of the AS5304 AS5306 in AS5304 AS5306 Integrated Hall ICs for Linear and Off Axis Rotary Motion De e High reliability due to non contact sensing e Suitable for the use in harsh environments applications where the Sensor IC cannot be mounted at the Robust against external magnetic stray fields end of a rotating device e g at hollow shafts Instead the 55304 55306 are mounted off axis underneath a multi 3 Key Features pole magnetized ring or strip and provides a quadrature incremental output with 40 pulses per pole period at High speed up to 20m s AS5304 speeds of up to 20 meters sec AS5304 or 12 meters sec 12m s AS5306 55306 Magnetic pole pair length 4mm 55304 or A single index pulse is generated once for every pole pair 2 4mm 55306 Resolution 25 AS5304 or 15um AS5306 Using for example 32pole pair magnetic ring the 55304 55306 provide a resolution of 1280 pulses rev which is equivalent to 5120 positions rev or e 40 pulses 160 positions per magnetic period e 1 index pulse per pole pair 12 3bit The maximum speed at this configuration is 9375 e Linear movement measurement using multi pole rpm magnetic strips The pole pair length is 4mm 2mm north pole 2mm south e Circular off axis movement
58. c 1 02 ASTM D 1475 demolding when casting into or over most surfaces Use a release agent made specifically for mold making Universal Mold Release available from Smooth On A liberal coat of release agent should be applied onto all surfaces that will contact the rubber Specific Volume cu in Ib 27 2 Pot Life 25 minutes 73 F 23 C ASTM D 2471 Cure time 48 hrs 73 F 23 C Color Light Amber IMPORTANT To ensure thorough coverage lightly brush the release agent with a soft brush over all surfaces of the model Follow with a light mist coating and let the release agent dry for 30 minutes Because no two applications are quite the same a small test application to determine suitability for your project is recommended Snore iii s or l if performance of this material is in question Tensile Strength psi 900 ASTM D 412 MEASURING amp MIXING 10096 Modulus psi 400 ASTM D 412 Liquid urethanes are moisture sensitive and will absorb atmospheric Elongation Break 700 ASTM D 412 moisture Mixing tools and containers should be clean and made of metal plastic Pri oi et D ASI IMPORTANT Shelf life of product is drastically reduced after opening Shrinkage lt 001 in in ASTM D 2566 Immediately replacing the lids on containers after dispensing product will prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the
59. d use of our product Additionally the outcome of this design will undoubtedly influence the net worth of the degrees of each team member Manuscript received December 13 2011 This work was supported in part by Sandia National Labs and the University of Idaho C B Hjeltness is with the University of Idaho mechanical engineering department Moscow Idaho 83843 USA Phone 208 819 2257 Email chjeltness gmail com M Brewster is with the University of Idaho mechanical engineering department Moscow Idaho 83843 USA Phone 425 765 6406 Email brewsterster gmail com playing a direct role our ability to be hired in the Industry or to move on to graduate school The aim of a senior design project is to be a showcase of the talents of each team member as an engineer Producing a product compliant to published industry standards that exceeds the expectations of my sponsor would have a great impact on my overall livelihood as well as that of the rest of my team mates and teams to come in the future METHODS 1 Data Analysis and Test Constraints To analyze the data a factorial regression using Microsoft Excel is to be performed A Factorial analysis is a common method of analyzing the importance and interaction of different factors of experimental data This allows testing of a hypothesis when there are two or more independent variables Drop height and the thickness of the viscoelastic material were the two independent v
60. de gains of 1 and 2 Effective Input Range Module Unipolar put Range Bipolar Iput Range 2 _ 4 s wax 2 a venum w _ _ o a sv DT9812 10V DT9812A DT9813 10V DT9813A DT9814 10V DT9814A Throughput Before selecting a module consider whether you need analog inputs and if so what kind of throughput you need Modules with multiplexed inputs such as the DT9810 DT9812 DT9813 and DT9814 modules provide only one A D converter that is shared by the inputs A multiplexer selects or switches the channel to acquire which introduces a settling time and phase shift between channels In a multiplexed architecture the total or aggregate throughput is the maximum rate of the sampling clock The DT9810 provides an aggregate throughput of up 25 kHz while the DT9812 2 5V DT9812 10V DT9813 10V and DT9814 10V provide an aggregate throughput of up to 50 kHz and the DT9812A DT9813A and DT9814A provide an aggregate throughput of up to 100 kHz The per channel rate is determined by dividing the maximum sampling rate by the number of inputs sampled For example if you are acquiring 8 inputs on a DT9812 10V the per channel rate is 6 25 kS s WWW DATATRANSLATION COM US CaNADA 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 In contrast modules that provide separate A D converters per channel such as the DT981
61. e pair length is 4mm 2mm north pole 2mm south e Circular off axis movement measurement using multi pole for the 55304 and 2 4mm 1 2mm north pole pole magnetic rings 1 2mm south pole for the AS5306 The chip accepts a e 4 5 to 5 5V operating voltage magnetic field strength down to 5mT peak e Magnetic field strength indicator magnetic field alarm Both chips are available with push pull outputs 4 i for end of strip missing magnet AS530xA or with open drain outputs AS530xB The AS5304 AS5306 are available in a small 20 pin TSSOP package and specified for an operating ambient 4 Applications temperature of 40 to 125 The AS5304 A85306 are ideal for high speed linear motion and off axis rotation measurement in applications such as e electrical motors X Y stages e rotation knobs e industrial drives Figure 1 55304 AS5306 with multi pole ring magnet Figure2 55306 AS5304 with magnetic multi pole strip magnet for linear motion measurement Revision 1 6 www austriamicrosystems com Page 1 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 5 Functional Description The AS5304 AS5306 require a multi pole magnetic strip or ring with a pole length of 2mm 4mm pole pair length on the 55304 and a pole length of 1 2mm 2 4mm pole pair length on the AS5306 magnetic field strength of the multi pole magnet should be
62. e south pole is placed over the right side of the IC Detail The index output will switch back to Index low i when the magnet is moved by one LSB from position X 0 to X X1 as shown in Figure 7 bottom graph One LSB is 25um for AS5304 and 15 for AS5306 Index Note Since the small step size of 1 LSB is hardly recognizable in a correctly scaled graph it is shown as an exaggerated step in the bottom graph of Figure 7 Step 157 158 159 0 1 2 3 4 5 Figure 6 Quadrature A B and Index output 7 1 2 Magnetic Field Warning Indicator The 55304 can also provide a low magnetic field warning to indicate a missing magnet or when the end of the magnetic strip has been reached This condition is indicated by using a combination of A B and Index that does not occur in normal operation A low magnetic field is indicated with Index high A B low 7 1 3 Vertical Distance between Magnet and IC The recommended vertical distance between magnet and IC depends on the strength of the magnet and the length of the magnetic pole Typically the vertical distance between magnet and chip surface should not exceed 75 of the pole length That means for AS5304 having a pole length of 2 0mm the maximum vertical gap should be 1 0mm For the AS5306 having a pole length of 1 2mm the maximum vertical gap should be 0 6mm These figures refer to the chip surface Given a typical distance of 0 2mm between chip surface and IC package surf
63. ed Stud 4 4 Vibration Damping Bronze a Sleeve Bearing 6 HINUTO2500 20DN 4 7 HJNUTOS750 16 D N 8 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d IQ MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION OZ ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION N OF IDAHO DEPARTMENT IS DEFAULT TOLERANCES BI ME DEPARTMENT bee Cameron Hjelfness we 5 10 2012 03 00 f1 XXX 28X D 313 1 000 3 8 16 UNC 120 gt gt gt gt gt gt gt gt 2 E gt E gt E gt E 2X 5 999 THRU REAM FOR BEARINGS zh _ IN KT Zs MIN KT 25 _ IN KT MIN KT 21 WIN KT M _ _ _ dd l d d l d E gt gt E gt E 2 LY ET 25 MIN 25 MIN M 25 br _ MIN N 7 _ N N 7 _ 7 2 CONFIDENTIAL DIMENSIONS ARE IN INCHES Notes 1 Stock 0 875 inches thick SOS APPS NSP HRD ANGLEPROJECTION yea SANCIAMAST 2 Bolt pattern 1 1 2 inch centers D AS A WHOLE M OUT IE WITTEN 3 8 U N C threads An OF IDAHO ME DEPARTMENT IS DEFAULT TOLERANCES pescripton Drop Table UNIVERSITY OF IDAHO DEPARTMENT
64. en a protective steel shell and an SAE 841 bronze insert these bearings quiet dawn equipment by absorbing vibration The neoprene rubber also allows these bearings to accommodate shaft misalignment and adds resistance to shock loads suddenly applied loads The bronze insert which is impregnated with 20 SAE 30 oil makes them great hard to lubricate areas View tolerance information for these bearings Bearing Temperature Material Range P max 841 OFto225 F 2000 1200 50 000 For Shaft Dia Lg fA 19 B Each 3 8 17 17 7 8 6364K31 9 22 1 2 1 1 B364K32 TF7 5 8 1174 114 1118 5354K 33 11 41 3 4 1447 3144 1118 b364K34 10 22 1 158 172 138 6364K36 16 12 Hardened Shafts Shaft Dia Dia Tolerance H2 6009816 00013 shafts are case hardened and precision ground for exacting diameter and straightness tolerances They have a 2 rms micron finish unless noted for inch sizes 12 rms micron finish unless noted for metric sizes Straightness tolerance is 0 002 per foot for inch sizes 0 03 mm per 300 mm unless noted for metric sizes Ends are beveled See nur selection of shaft supports View minimum hardness depth for these shafts Inch Sizes Steel Shafts are 1566 steel theyre stronger than stainless steel shafts but are less corrosion resistant Case hardness is Rockwell C60 Lg Each 1 2 Dia 3 86061k426 3 94 4 6061k427 415 5 6061 428 4
65. er Carr Part No 6364K32 eroe LLL 2 ABB Linear Motor Forcer Part No LMCFO4D HCO oerurrocegavces UNIVERSITY OF IDAHO ANGULAR ME DEPARTMENT s 0 30 PRAWN BY Cameron Hjeltness be 5 10 2012 part 02 00 rename 02 00 Slider SLDPRT 1 5 8 500 7 750 6 700 5 700 1 500 750 2X 5 999 THRU R 300 ALL FILLETS REAM FOR BEARINGS 0 250 THRU PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES Note Depth of stock is 1 1 2 inches RUN RoANGEPRO CTON ge SOnCIOMAST OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED materia 6061 T6 SS bescarnon Slider UNIVERSITY OF IDAHO pate 5 11 2012 ME DEPARTMENT pate 0 9 2012 part 02 03 rename 02 01 Slider SLDPRT scale 1 2 sug 2 OF 5 165 THRU ALL 5 0 8 6H THRU ALL 2 3 055 2X 136 340 8 32 UNC 250 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION ecu OF UNIVERSITY OF IDAHO ME DEPARTMENT IS materia 6061 6 SS UNIVERSITY OF IDAHO ME DEPARTMENT PROHIBITED DEFAULT TOLERANCES FILE NAME ev Nicholai Olson DATE 5 1 1 201 2 Cameron Hjeltness _
66. es within ranges of 1to 200 g s in magnitude and 1 to 10 milliseconds in duration Dr Whalen will then use this apparatus that we develop and subject his electronics to these conditions testing their reactions and developing them accordingly Our proposal to date includes features prominent on current designs as well as other features that are unique to our design We have determined that a dual post shock tower with a drop table is the most appropriate for our client s needs To actuate this device a linear motor is to be used with the possibility of other solutions as a backup plan With the accuracy we plan to incorporate into our design Dr Whalen will have a tool that exceeds his needs and allows him to develop electronics for Sandia National Labs well beyond the scope of this project A sub group of our team has performed statistical analyses on the validity of our design features with the additional motivation of being able to apply our senior design work to another class external of this project This project has demonstrated to a 99 confidence level that the viscoelastic damping effects will play a very significant role in comparison to impact velocity of the shock table Through this experiment our math modeling experiments have been validated providing us with legitimate targets to shoot for in our conceptual designs and future work to be applied to this task 2 Background Safety protocol in Dr Whalen s lab does not permit him
67. etic field warning indicator see 7 1 2 together with the index pulse can be used to indicate a unique home position on a magnetic strip 1 First the AS5304 A85306 move to the end of the strip until a magnetic field warning is displayed Index high A B low 2 Then the AS5304 AS5306 move back towards the strip until the first index position is reached note an index position is generated once for every pole pair it is indicated with Index high A B high Depending on the polarity of the strip magnet the first index position may be generated when the end of the magnet strip only covers one half of the Hall array This position is not recommended as a defined home position as the accuracy of the 55304 55306 reduced as long as the multi pole strip does not fully cover the Hall array Revision 1 6 www austriamicrosystems com Page 6 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 3 Itis therefore recommended to continue to the next second index position from the end of the strip Index high A B high This position can now be used as a defined home position 7 2 Incremental Hysteresis Incremental output Hysteresis 1 LSB ce a m e mi a m cn ci i X 3 X 2 X 1 Magnet position X Movement direction X Movement direction X Figure 8 Hysteresis of the incremental output 7 3 Integral Non Linearity INL If the magnet is sitti
68. ghest due to their high controllability ease of installation and reliability The cable and winch option and the rotary belt and motor option scored very low due to complexity and reliability issues The ACME screw option had a relatively high score but the major drawback of this option was its complexity due to the many extra components that it would need Another benefit of the linear motor and solenoid options is the fact that they require no additional components to create a downward force in order to impart shocks of the required magnitudes These components can be easily programmed to produce different shocks In contrast all of the other options would likely need spring systems to create a downward force or require additional height In an attempt to minimize size and complexity of the system linear motors or solenoids will be used for table actuation We hope that this decision will also help increase the system reliability and life with less components to fail and wear down with use Mechanical System Architecture The structure of the testing apparatus will be composed of a two post vertical drop table A detailed sketch of the conceptual design is shown below in Figure 9 Component a refers to the support structure of the testing apparatus to provide rigidity for the structure as a whole Component b is a pair of guide rails specified from Thomson These guide rails are to be precision machined and press fit into the top and bott
69. he module Using software specify an external negative digital TLL trigger Analog Outputs DT9812 DT9813 and DT9814 Series modules provide two 12 bit analog output channels DACs The modules can output data from a single analog output channel or from both analog output channels The DT9812 2 5V module provides a fixed output range of 0 to 2 44 The DT9812 10V DT9812 10V OEM DT9812A DT9813 10V DT9813A DT9814 10V DT9814A modules provide a fixed output range of 10 V Through software specify the range for the entire analog output subsystem 0 to 2 44 V for the DT9812 2 5 V module or 10 V for the DT9812 10V DT9812 10V OEM DT9812A DT9813 10V DT9813A DT9814 10V and DT9814A modules and specify a gain of 1 for each channel Output Trigger A trigger is an event that occurs based on a specifled set of conditions The DT9812 DT9813 and DT9814 Series modules support a software trigger for starting analog output operations Using a software trigger the module starts outputting data when it receives a software command Waveform Generation Generate sine rectangle triangle or DC waveforms from one or both analog output channels You can select the frequency amplitude duty and offset cycle of the signal For the DT9812 10V DT9812 10V OEM DT9813 10V DT9814 10V the output frequency ranges between 30 Hz 50 kHz For the DT9812A DT9813A and DT9814A the output frequency ranges between 30 Hz
70. hey can be 40 manufactured exactly to specification using the proper 20 magnetization tooling 1500 1700 1900 2100 2300 2500 Pole Length um Figure 9 Additional error caused by pole length variation AS5304 AS5306 Systematic Linearity Error caused by Pole Length Deviation However when using a ring magnet see Figure 1 the pole 140 length differs depending on the measurement radius For 120 optimum performance it is therefore essential to mount the 100 such that the Hall sensors are exactly underneath the 80 S dd magnet at the radius where the pole length is 2 0mm 5 40 AS5304 1 2mm AS5306 see also 8 1 2 20 a Note that this is additional error which must be added to 900 1000 1100 1200 1300 1400 1500 the intrinsic errors INL see 7 3 and DNL see 7 4 Pole Length um Figure10 Additional error caused by pole length variation AS5306 Revision 1 6 www austriamicrosystems com Page 7 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 7 4 Dynamic Non Linearity DNL The DNL dynamic non linearity describes the non linearity of the incremental outputs from one step to the next In an ideal system every change of the incremental outputs would occur after exactly one LSB e g 25um on AS5304 In practice however this step size is not ideal the output state will change after 1LSB DNL The DNL must be lt 7 LSB to a
71. ication a multi pole ring magnet must be used Resolution diameter and maximum speed depend on the number of pole pairs on the ring 8 1 1 Resolution The angular resolution increases linearly with the number of pole pairs One pole pair has a resolution interpolation factor of 160 steps or 40 quadrature pulses Resolution steps interpolation factor x number of pole pairs Resolution bit log resolution steps log 2 Example multi pole ring with 22 pole pairs Resolution 160x22 3520 steps per revolution 40x22 880 quadrature pulses revolution 11 78 bits per revolution 0 1023 per step 8 1 2 Multi pole Ring Diameter The length of a pole pair across the median of the multi pole ring must remain fixed at either 4mm 5304 or 2 4mm AS5306 Hence with increasing pole pair count the diameter increases linearly with the number of pole pairs on the magnetic ring Magnetic ring diameter pole length number of pole pairs for AS5304 d 4 0mm number of pole pairs for 55306 d 2 4mm number of pole pairs Tr Example same as above multi pole ring with 22 pole pairs for AS5304 Ring diameter 4 22 13 14 28 01mm this number represents the median diameter of the ring this is where the Hall elements of the 55304 55306 should be placed see Figure 4 For the AS5306 the same ring would have a diameter of 2 4 22 3 14 16 8mm 8 1 3 Maximum Rotation Speed The AS530
72. ides ActiveX controls which allows access to the capabilities of an ECONseries module using Microsoft Visual Basic or Visual C DTx EZ complies with the DT Open Layers standard Adaptor for MATLAB Data Translation s Adaptor provides an interface between the MATLAB Data Acquisition toolbox from The MathWorks and Data Translation s DT Open Layers architecture m V Link This software is included on the Data Acquisition Omni CD Use LV Link to use the LabVIEW graphical programming language to access the capabilities of an ECONseries module WWW DATATRANSLATION COM US CaNADA 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 ete Jes Ed quickDAQ File Edit View Marker Strip gt 0 gt m Timeofday Collector Viewer Filename C quickDAQData Datafile 1 hpf 7 7 R P 4 4 R P P 1 9 9 R P 4 Ban E 1000 Channel Ai Channel name Dm s P 4 Ain 4 2 10 C 4 4989 a 1 Record a 844 E E DU Events m l im p Recording Device Press the Record button to start recording data to disk Stop Recording 7 Total Samples Time sec 100 Plot data type Voltage Sensor 7 On Event 7 Stop Button IRecording stopped at 15 25
73. incremental output 7 3 Integral Non Linearity INL If the magnet is sitting right at the transition point between two steps the noise in the system may cause the incremental outputs to jitter back and forth between these two steps especially when the magnetic field is weak To avoid this unwanted jitter a hysteresis has been implemented The hysteresis lies between 1 and 2 LSB depending on device scattering Figure 8 shows an example of 1LSB hysteresis the horizontal axis is the lateral position of the magnet as it scans across the IC the vertical axis is the change of the incremental outputs as they step forward blue line with movement in X direction and backward red line in X direction Note 1LSB 25 for AS5304 15um for AS5306 The INL integral non linearity is the deviation between indicated position and actual position It is better than 1LSB for both 55304 and 55306 assuming an ideal magnet Pole length variations and imperfections of the magnet material which lead to a non sinusoidal magnetic field will attribute to additional linearity errors 7 3 1 Error Caused by Pole Length Variations AS5304 Systematic Linearity Error caused by Pole Length Deviation 40 Figure 9 and Figure 10 show the error caused by non ideal 120 pole length of the multi pole strip or ring S 60 This is less of an issue with strip magnets as t
74. information contained in this bulletin is considered accurate However no warranty is expressed or implied regarding the accuracy of the data the results to be obtained from the use thereof or that any such use will not infringe a patent User shall determine the suitability of the product for its intended applications and assumes all risk and liability whatsoever in connection therewith DENEN SMmooTHIIN IMPORTANT Pre Mix the Part B before using After dispensing the required amounts of Parts A and B into mixing container mix thoroughly for at least 3 minutes making sure that you scrape the sides and bottom of the mixing container several times If Mixing Large Quantities 24 Ibs 11 kgs or more at one time we suggest using a mechanical mixer i e Squirrel Mixer or equal for 3 minutes followed by careful hand mixing for one minute as directed above Then pour entire quantity into a new clean mixing container and do it all over again Although this product is formulated to minimize air bubbles in the cured rubber vacuum degassing will further reduce entrapped air A pressure casting technique using a pressure chamber can yield totally bubble free castings Contact Smooth On or your distributor for further information about vacuum degassing or pressure casting POURING CURING amp PERFORMANCE Pouring For best results pour your mixture in a single spot at the lowest point of the containment field Let the r
75. ion risk Good ventilation room size is necessary Some Materials Must Be Sealed To prevent adhesion between the rubber and model surface models made of porous materials gypsum plasters concrete wood stone etc must be sealed prior to applying a release agent SuperSeal or One Step available from Smooth On is a fast drying sealer suitable for sealing porous surfaces without interfering with surface detail You can also use Sonite Wax A high quality Shellac is suitable for sealing modeling clays that contain sulfur or moisture water based In all cases the sealing agent should be applied and allowed to TECHNICAL OVERVIEW completely dry prior to applying a release agent Mix Ratio 2A 1B by weight Non Porous Surfaces Metal glass hard plastics sulfur free clays etc require only a release agent Mixed Vi it 3 000 ASTM D 2393 U Applying A Release Agent release agent is necessary to facilitate Specific Gravity g cc 1 04 ASTM D 1475 demolding when casting into or over most surfaces Use a release agent made specifically for mold making Universal Mold Release available from Smooth On A liberal coat of release agent should be applied onto all surfaces that will contact the rubber Specific Volume cu in 1b 26 5 Pot Life 30 minutes 73 F 23 C ASTM D 2471 Cure time 16 hrs 73 F 23 C Color Light Amber IMPORTANT To ensure thorough coverage lightly brush the release
76. ions about this material relative to your application Call Us Anytime With Questions About Your Application Toll free 800 762 0744 Fax 610 252 6200 The new www smooth on com is loaded with information about mold making casting and more 071910 JR 770 SMOOTHON Industrial Liquid Rubber m ma AA AT MMm a ma A l PRODUCT OVERVIEW PMC 770 is a Shore 70A addition to our line of industrial liquid rubber products such as PMC 780 and PMC 790 used for a variety industrial and casting applications Mixed two parts A to one part B by weight PMC 770 pours easily and cures at room temperature to a solid Shore 70A rubber that has exceptional performance characteristics and dimensional stability u It is suitable for production casting of abrasive materials such as concrete pre cast concrete making concrete stamping pads etc and gypsum plasters with high exotherms It is also suitable for rubber mechanical parts of varying configurations gaskets wheels pullies as well as ball mill liners and vibration shock pads PROCESSING RECOMMENDATIONS START BY PREPARING YOUR MODEL Preparation These products have a limited shelf life and should be used as soon as possible Materials should be stored and used at room temperature 73 F 23 C Humidity should be low Wear safety glasses long sleeves and rubber gloves to minimize contaminat
77. iption 2 Benefits The 55304 55306 single chip IC s with integrated e Complete system on chip Hall elements for measuring linear or rotary motion using multi pole magnetic strips or rings This allows the usage of the AS5304 AS5306 in AS5304 AS5306 Integrated Hall ICs for Linear and Off Axis Rotary Motion De e High reliability due to non contact sensing e Suitable for the use in harsh environments applications where the Sensor IC cannot be mounted at the Robust against external magnetic stray fields end of a rotating device e g at hollow shafts Instead the 55304 55306 are mounted off axis underneath a multi 3 Key Features pole magnetized ring or strip and provides a quadrature incremental output with 40 pulses per pole period at High speed up to 20m s AS5304 speeds of up to 20 meters sec AS5304 or 12 meters sec 12m s AS5306 55306 Magnetic pole pair length 4mm 55304 or A single index pulse is generated once for every pole pair 2 4mm 55306 Resolution 25 AS5304 or 15um AS5306 Using for example 32pole pair magnetic ring the 55304 55306 provide a resolution of 1280 pulses rev which is equivalent to 5120 positions rev or e 40 pulses 160 positions per magnetic period e 1 index pulse per pole pair 12 3bit The maximum speed at this configuration is 9375 e Linear movement measurement using multi pole rpm magnetic strips The pol
78. iteration This process was imitated at 15 5 cm with one pad of foam 8 5 cm and two pads of foam and finally at 15 5 cm and two pads 40 unique data points were collected Each data point collected further data on the two dependent variables and thus 80 data points in all were effectively gathered APPENDIX MATLAB CODE USED TO MODEL THE RESPONSE TO ACCELERATION PULSES Drop Table Simulation clear all close all Assumptions Structure of Drop table and supporting mechanisms is assumed to be rigid gt No energy is lost structures perfectly elastic collision gt Deformation in stopping object does not exceed material yield poing gt No deformation occurs in colliding body AP oO Parameters m 2 0 Mass of drop table kg d 0 08 Diamter of base m L 0 04 Length of base m A pi 4 d 2 Cross Sectional Area m 2 0 1 9 Young s Modulus of Rubber Pa 9 81 Acceleration of Gravity e k b A E L Spring stiffness N m c b 00 Damping Coefficient kg s m param m m param k b k b D param g g N 10000 tend 0 1 5 simulation at t 0 U1 seconds t linspace 0 dt t 2 1 1 0 5 Initial Position Im o 2 0 5 Initial Velocity m s ODE 45 Simulation t x eode45 G0 t xo dmpact t xo patram t xo Call ODE45 s Outputs MZ kg o9 o 00 cO l2x 1
79. ject specification Sandia M A S T wanted to pursue this as option in order to go above and beyond From the Senior Lab team s results based on the comparison of drop height and viscoelastic materials they concluded that damping materials between the table and the stopper during the shock were heavily significant to the shock peak and duration REF Appendix C The team used packaging foam approximately 3mm thick per sheet to soften the impact between the slider where the accelerometer was mounted and the stopper By reading voltage charts between one and two pieces of foam the team was able to change the pulse shape from a sharp parabolic graph to very soft sinusoidal graph REF Appendix D This along with changing the drop height changed the duration and amplitude of the shock Locking mechanisms were presented to dissipate the energy but the team believed that ringing was a problem 6 Concept Selection The first and most fundamental design decision was that of how to orient the shock tester and how to generate the required shock Several options were considered for this function One idea consisted of having a horizontal sliding base that would impact against a stationary wall Another idea was to have a stationary base hit by some sort of heavy device such as a hammer Yet another concept consisted of a vertical tower with a sliding table that would impact a stationary base at the bottom The structure and orientation decision matrix c
80. l with encoder resolutions 21 micron w Speeds to 2 5m s 100 in sec with encoder resolutions 1 micron High accuracy 2 5um 300m 0 0001 in ft encoder dependent High repeatability 1um 0 00004 in encoder dependent Unlimited stroke length Independent multiple coil operation with overlapping trajectories No metal to metal contact virtually maintenance free Modular magnet tracks The cog free motor is designed for unlimited stroke servo applications that require smooth operation without magnetic force variation or cogging A large range of motors are available to suit different applications These motors are supplied in kit form to be integrated into your machine They are used in closed loop servo systems and provide optimum performance For higher continuous forces air and water cooling options are available Baldor s cog free motors are ideally suited for applications requiring high accuracy with resolutions down to 0 1um and smooth movement Ordering Information Ee E 2 0 j TE L JL IE WINDING Blank Standard NO OF POLES 02 04 18 P Parallel TERMINATION O Flying Leads 3m 10 ft Std SIZE CODE mm inch A 40 1 6 D 86 4 3 4 B 53 6 2 11 E 114 3 4 5 57 2 2 25 152 4 6 0 COOLING Convection A Air Cooling W Water HALLS H Hall Effect Sensors No Effect Sensors The motors can be con
81. m of around 50 g s suitable for the given range of experimental accelerations This variable was determined at a confidence of 95 Table 3 below summarizes the independent variables Drop Height Viscoelastic Thickness Factor A Factor B Low 8 5 cmj Piece 3 mm j High 15 5 cm 1 Piece 3 mm Low 8 5 2 Pieces mm High 15 5 cm 2 Pieces Table 2 Dependent variables and the applied ranges IV Experimental Procedure 1 Equipment used Below is a list of equipment utilized during the experiment e Digital Multi meter Oscilloscope e Accelerometer Foam pads 1 by 1 e Mounting platform for foam e Drop test device e Measuring tape e Mounting wax 2 Setup The experimental setup was fairly basic and had only a few steps First the drop test device was secured such that 1t would not move to maintain test consistency Next the measuring tape was secured next to the drop tester and secured The accelerometer was affixed with the mounting wax and connected to the oscilloscope The settings on the oscilloscope were set at 1 00 volts per vertical division and 2 milliseconds per time division 3 Procedure The table of the drop tester was raised to a height of 8 5 cm from the initial position atop one pad of foam With the oscilloscope ready to capture data the table was released and a pulse was recorded This was repeated 10 times replacing the foam for every
82. measurement using multi pole for the 55304 and 2 4mm 1 2mm north pole pole magnetic rings 1 2mm south pole for the AS5306 The chip accepts a e 4 5 to 5 5V operating voltage magnetic field strength down to 5mT peak e Magnetic field strength indicator magnetic field alarm Both chips are available with push pull outputs 4 i for end of strip missing magnet AS530xA or with open drain outputs AS530xB The AS5304 AS5306 are available in a small 20 pin TSSOP package and specified for an operating ambient 4 Applications temperature of 40 to 125 The AS5304 A85306 are ideal for high speed linear motion and off axis rotation measurement in applications such as e electrical motors X Y stages e rotation knobs e industrial drives Figure 1 55304 AS5306 with multi pole ring magnet Figure2 55306 AS5304 with magnetic multi pole strip magnet for linear motion measurement Revision 1 6 www austriamicrosystems com Page 1 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 5 Functional Description The AS5304 AS5306 require a multi pole magnetic strip or ring with a pole length of 2mm 4mm pole pair length on the 55304 and a pole length of 1 2mm 2 4mm pole pair length on the AS5306 magnetic field strength of the multi pole magnet should be in the range of 5 to 60mT at the chip surface The Hall elements on the AS
83. meter of 2 4 22 3 14 16 8mm 8 1 3 Maximum Rotation Speed The AS5304 A85306 use a fast interpolation technique allowing an input frequency of 5kHz This means it can process magnetic field changes in the order of 5000 pole pairs per second or 300 000 revolutions per minute However since a magnetic ring consists of more than one pole pair the above figure must be divided by the number of pole pairs to get the maximum rotation speed Maximum rotation speed 300 000 rpm number of pole pairs Example same as above multi pole ring with 22 pole pairs Max speed 300 000 22 13 636 rpm this is independent of the pole length 8 1 44 Maximum Linear Travelling Speed For linear motion sensing a multi pole strip using equally spaced north and south poles is used The pole length is again fixed at 2 0mm for the AS5304 and 1 2mm for the AS5306 As shown in 8 1 3 above the sensors can process up to 5000 pole pairs per second so the maximum travelling speed is Maximum linear travelling speed 5000 pole pair length Example linear multi pole strip Max linear travelling speed 4mm 5000 1 sec 20 000mm sec 20m sec for AS5304 Max linear travelling speed 2 4mm 5000 1 sec 12 000mm sec 12m sec for AS5306 Revision 1 6 www austriamicrosystems com Page 9 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 GENERAL DEVICE SPECIFICATIONS 9 1 Absolute Maximum Ra
84. nal power supply while providing complete enumeration for all data flow Easy to Hook up Shielded rugged Pd enclosure provides noise immunity Standard USB Connector IPM EN ES MT I c A etn I LED indicator Built in signal screw terminal provides USB status connectors Figure 6 ECONseries modules provide easy signal and USB connections in a shielded rugged enclosure WWW DATATRANSLATION COM US CaNADA 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 ECONseries Design Advantages Prevents Measurement Errors Operates Reliably 1K Source Impedance R2 Electro Static Discharge ESD protection up to 8000V Input Signal Vin 10 MO Input Impedance R1 B ONSE 4000V Touch and 8000V Gap ESD Protection Ri R2 R Input Error OTHER MODULES ECONseries Ri R2 _ 144k 1KO _ Ri R2 _ 10M 1KO _ a Ri 10MO Figure 7 The ECONseries provides 10 MOhms of input impedance Figure 8 The ECONseries provides 4000 V touch and 8000 V gap for virtually error free analog input measurements ESD protection circuitry for superior noise immunity Performs Simultaneous Operations Analog Input INDEPENDENT Digital Input Output INPUT OUTPUT Functions Counter Timer Functions OPERATIONS Analog Output Figure 9 The ECONseries provides 4000 V touch and 8000 V gap ESD protection circuitry for superior noise immunity Detects Edges for Pulse Width Frequency Pre
85. ne products The Material Safety Data Sheet for this or any Smooth On product should be read before using and is available upon request All Smooth On products are safe to use with proper handling and precautions Read and follow directions carefully Be careful Part A is TDI prepolymer Vapors which can be significant if prepolymer is heated or sprayed may cause lung damage and sensitization Use only with adequate ventilation Contact with skin and eyes may cause severe irritation Flush eyes with water for 15 minutes and seek immediate medical attention Remove from skin with soap and water Prepolymers contain trace amounts of TDI which if ingested must be considered a potential carcinogen Refer to the MSDS for this product Avoid skin contact by wearing long sleeve garments and latex gloves If skin contact is made remove immediately with soap and water If eye contact is made flush eyes with water for 15 minutes and seek immediate medical attention Important The information contained in this bulletin is considered accurate However no warranty is expressed or implied regarding the accuracy of the data the results to be obtained from the use thereof or that any such use will not infringe a patent User shall determine the suitability of the product for its intended applications and assumes all risk and liability whatsoever in connection therewith DENEN SMmooTHIIN IMPORTANT Pre Mix the Part B before
86. near Bushings 1 2 953313 2 14 38 10 38 76 2291 46 Linear Bearings 5 8 2 21 10 52 2239 46 1 2 Drill Rod 8890 1 1 6 69 10 18 69 2220 77 2 8 Polished Rod 1 90 15 65 2155 7 Linear Encoder 1 AS5306a 2 5 31 D 15 62 2140 15 Linear Encoder 2 AS5306b 2 5 31 0 0 10 62 2129 53 Encoder strip 55000 4 0 24 2105 53 Aluminum Stock 1 200 0 0 200 1905 53 Steel Stock 1 200 0 0 200 1705 53 Signal Conditioning 1 400 0 10 410 1295 53 Viscoelastic Materiasl 1 500 0 50 550 745 53 Misc Hardware Safety 1 700 0 0 100 45 5299999999997 BUDGET REMAINING 45 529999999999 7 11 5 Appendix E Report on Statistical Analysis Shock Pulses and the Effects Contributed by Viscoelastic Damping Materials Submitted to Dr Denise Bauer 709 Deakin Avenue Moscow ID 83843 Submitted by Cameron Hjeltness Department of Mechanical Engineering University of Idaho Michael Brewster Department of Mechanical Engineering University of Idaho December 13 2011 Shock pulses and the effects contributed by viscoelastic damping materials December 2011 C B Hjeltness M Brewster Schoolof Mechanical Engineering University of Idaho Engineering Campus Idaho U S A Abstract Senior design team Sandia M A S T Miniature Accelerations Shock Tester has been tasked with designing a shock testing apparatus for Dr Scott Whalen of Sandia National Labs Shock occurs when two objects collide causing rapid deceleration for minute period
87. ng After rubber has cured at room temperature heating the rubber to 150 F 65 C for 4 to 8 hours will increase physical properties and performance Using The Mold If using as a mold material a release agent should be applied to the mold before each casting The type of release agent to use depends on the material being cast The proper release agent for wax liquid rubber or thermosetting materials i e Smooth On liquid plastics is a spray release made specifically for mold making available from Smooth On or your distributor Prior to casting gypsum plaster materials sponge the mold with a soap solution for better plaster flow and easy release In amp Out II Water Based Release Concentrate available from Smooth On is recommended for releasing abrasive materials like concrete Performance amp Storage Fully cured rubber is tough durable and will perform if properly used and stored The physical life of the rubber depends on how you use it Contact Smooth On directly with questions about this material relative to your application Call Us Anytime With Questions About Your Application Toll free 800 762 0744 Fax 610 252 6200 The new www smooth on com is loaded with information about mold making casting and more 012511 JR 11 7 Appendix H Linear Encoder Spec Sheet 212 austriamicrosystems 4 PRELIMINARY DATA SHEET 1 General Description 2 Benefits The 55304 55306 single chip IC s with integr
88. ng right at the transition point between two steps the noise in the system may cause the incremental outputs to jitter back and forth between these two steps especially when the magnetic field is weak To avoid this unwanted jitter a hysteresis has been implemented The hysteresis lies between 1 and 2 LSB depending on device scattering Figure 8 shows an example of 1LSB hysteresis the horizontal axis is the lateral position of the magnet as it scans across the IC the vertical axis is the change of the incremental outputs as they step forward blue line with movement in X direction and backward red line in X direction Note 1LSB 25 for AS5304 15um for AS5306 The INL integral non linearity is the deviation between indicated position and actual position It is better than 1LSB for both 55304 and 55306 assuming an ideal magnet Pole length variations and imperfections of the magnet material which lead to a non sinusoidal magnetic field will attribute to additional linearity errors 7 3 1 Error Caused by Pole Length Variations AS5304 Systematic Linearity Error caused by Pole Length Deviation 40 Figure 9 and Figure 10 show the error caused by non ideal 120 pole length of the multi pole strip or ring S 60 This is less of an issue with strip magnets as they can be 40 manufactured exactly to specification using the proper 20
89. nments The following software is available for use with all USB modules and is provided on the Data Acquisition Omni CD m ECONseries Device Drivers The device driver allows the use of the USB DAO module with any of the supported software packages or utilities m quickDAQ application An evaluation version of this NET application is included on the Data Acquisition Omni CD quickDAQ acquires analog data from all devices supported by DT Open Layers for NET software at high speed plots it during acquisition analyzes it and or saves it to disk for later analysis Note quickDAQ supports analog input functions only DT9817 and DT9835 modules are DIO only and are not supported m Quick DataAcq application The Quick DataAcq application provides a quick way to get up and running using an ECONseries module Using this application verify key features of the module display data on the screen and save data to disk m DT Open Layers for NET Class Library Use this class library if you want to use Visual C or Visual Basic for to develop application software for an ECONseries module using Visual Studio 2003 2005 2008 the class library complies with the DT Open Layers standard DataAcq SDK Use the Data SDK to use Visual Studio 6 0 and Microsoft C or C to develop application software for an ECONseries module using Windows the DataAcq SDK complies with the DT Open Layers standard DTx EZ DIx EZ prov
90. nt infringement austriamicrosystems reserves the right to change specifications and prices at any time and without notice Therefore prior to designing this product into a system it is necessary to check with austriamicrosystems for current information This product is intended for use in normal commercial applications Copyright 2008 austriamicrosystems Trademarks registered All rights reserved The material herein may not be reproduced adapted merged translated stored or used without the prior written consent of the copyright owner To the best of its knowledge austriamicrosystems asserts that the information contained in this publication is accurate and correct However austriamicrosystems shall not be liable to recipient or any third party for any damages including but not limited to personal injury property damage loss of profits loss of use interruption of business or indirect special incidental or consequential damages of any kind in connection with or arising out of the furnishing performance or use of the technical data herein No obligation or liability to recipient or any third party shall arise or flow out of austriamicrosystems rendering of technical or other services Revision 1 6 www austriamicrosystems com Page 13 of 13 11 13 Appendix N Thomson Rods and Linear Bearings Thompson Rods And Vibration damping Sleeve Bushings vr Bronze Sleeve Bearings With a flexible layer af neaprene rubber sandwiched betwe
91. nt to note that this acceleration is different from the pulse experienced during impact however it is still vital for this experiment as it shows what input force 15 necessary to achieve the impact The second variable examined was the thickness of the damping material used Both independent variables they were measured with respect to the dependent variables pulse magnitude and pulse duration Foam was the damping material chosen for this experiment Specifically ESD Electro Static Dissipating foam it was readily accessible and abundant in quantity Its damping materials were deemed sufficient enough for prototyping and testing procedures Young s modulus for such foams is determined to be within a range of 0 08 to 0 93 MPa This means that it is a fairly soft material in comparison with Steel of 210 Pl and justified the decision to use it as a material with which to modify the pulse The values of this independent variable ranged from 3 mm thick for one pad to 6 mm thick for two pads This variable was determined at a confidence of 95 Drop height was chosen experimentally Tests were performed to conform to the design targets Thus at a maximum of two pads of foam a maximum drop height was determined to be 15 5 cm since the resulting maximum g s experienced by the accelerometer was 250 in amplitude With 15 5 cm as the maximum value for this variable the minimum value was set arbitrarily as 8 5 cm This resulted in a minimu
92. o guide the experiment MIL S 901D NAV Y describes shock test procedures 1 and MIL STD 810F describes test conditions such as temperature humidity and most importantly the accuracy to which shocks from acceleration are to be measured F1 2 Test Apparatus Figure 1 shows the conceptual design for the purposes of the designed experiment Component a refers to the top and bottom portion of the apparatus Constructed of inexpensive aluminum its function is to provide a solid base that 15 level and will restrict the level of permissible resonance Component b shows precision guide rails These will be costly with respect to the structural components because they will be machined to tight tolerances to avoid interference with components d Components c and h display the sensors associated with the system c shows the accelerometer the most costly component with which I will collect the primary data samples h is a conceptual component a magnetic linear encoder which provides exact calibrated position and velocity Included with h is a sensing magnet also shown in green I will use this data alongside a mathematic model to compare theoretical and experimental values Component d is the energy reduction system bushings which will allow smooth and repeatable drops Resonance is unacceptable and will be limited For these purposes I have chosen brass as a suitable material from which to construct component e or the drop table
93. om supporting structure for additional rigidity This design will be machined with tight tolerances to reduce friction loss and prevent any binding in the bearings e c 1s a linear motor which imparts the force to the drop table Component d 16 the device to be tested by the apparatus and it is mounted to the drop table f The device to be tested d will also include an accelerometer mounted to it This accelerometer will measure the shock that the device is subjected to An additional sensing unit the linear encoder 1 will provide feedback of the drop table motion Component g is the damping material to lessen the vibrations associated with the drop table impact while h 1 the damping material mount Figure 9 Conceptual drawing of the shock tester a b d e f g h 8 Electrical Systems The control system architecture can be seen in figure 10 The system consists of a host computer a motor controller a motor with Hall Effect sensors and a linear encoder In addition there 15 a data acquisition module will record the output from the accelerometer Mechanical System Servo Motor Drive Hall Sensor Linear Encoder Host PC Data Acquisition Module Accelerometer Figure 10 System Overview During a test the control system will first raise the table to a defined position It will then accelerate the platform to a desired impact velocity and disable the velocity control shortly
94. ons and prices at any time and without notice Therefore prior to designing this product into a system it is necessary to check with austriamicrosystems for current information This product is intended for use in normal commercial applications Copyright 2008 austriamicrosystems Trademarks registered All rights reserved The material herein may not be reproduced adapted merged translated stored or used without the prior written consent of the copyright owner To the best of its knowledge austriamicrosystems asserts that the information contained in this publication is accurate and correct However austriamicrosystems shall not be liable to recipient or any third party for any damages including but not limited to personal injury property damage loss of profits loss of use interruption of business or indirect special incidental or consequential damages of any kind in connection with or arising out of the furnishing performance or use of the technical data herein No obligation or liability to recipient or any third party shall arise or flow out of austriamicrosystems rendering of technical or other services Revision 1 6 www austriamicrosystems com Page 13 of 13 11 8 Appendix I Linear Motor Spec Sheet Linear Motors and Stages Cog free Brushless Servo Motors Standard and custom magnetic track lengths Peak forces from 16N 3 6 Lbs to 2300 N 517 Lbs High acceleration to 98m s 10g s High speeds to 10m s 400 in sec
95. or an optical light barrier switch to indicate the home position The magnetic field warning indicator see 7 1 2 together with the index pulse can be used to indicate a unique home position on a magnetic strip 1 First the AS5304 A85306 move to the end of the strip until a magnetic field warning is displayed Index high A B low 2 Then the AS5304 AS5306 move back towards the strip until the first index position is reached note an index position is generated once for every pole pair it is indicated with Index high A B high Depending on the polarity of the strip magnet the first index position may be generated when the end of the magnet strip only covers one half of the Hall array This position is not recommended as a defined home position as the accuracy of the 55304 55306 reduced as long as the multi pole strip does not fully cover the Hall array Revision 1 6 www austriamicrosystems com Page 6 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 3 Itis therefore recommended to continue to the next second index position from the end of the strip Index high A B high This position can now be used as a defined home position 7 2 Incremental Hysteresis Incremental output Hysteresis 1 LSB ce a m e mi a m cn ci i X 3 X 2 X 1 Magnet position X Movement direction X Movement direction X Figure 8 Hysteresis of the
96. ounter accepts a C T clock input signal pulse input signal and gate input signal and outputs a pulse signal clock output signal You can perform event counting frequency measurement edge to edge measurement not supported by DT9816 modules and rate generation continuous pulse output operations using this counter timer WWW DATATRANSLATION COM US CaNADA 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 Synchronizing Multiple Modules You can synchronize the analog input operations of multiple DT9812 DT9813 DT9814 and DT9816 Series modules by connecting the output of the counter timer from one module to the clock input of the next module as shown in Figure 15 xternal Clock Source i External Viodule 1 Tech Counter 0 External Clock In Counter 0 e Module N Figure 15 You can synchronize the analog operations of multiple modules by connecting them together External Clock In Easy Signal Connections Built in screw terminals on the module allow easy and direct signal connections No extra accessories are required Simply wire your signals to the module and you re all set For OEM users the board only versions of the DT9812 10V OEM and DT9816 OEM provide two 20 pin connectors to accommodate all I O signals Software Options Many software choices are available for application development from ready to measure applications to programming enviro
97. pescription Dampener Base UNIVERSITY OF IDAHO cuecxeo ay Nicholai Olson DATE 5 1 1 2012 ME DEPARTMENT Cameron Hieltness DATE 5 10 2012 part 04 01 av AS Necessary 04 01 Dampener Base SLDPRT scale 1 1 sue 2 OF 096 THRU ALL NZ Q 197 X 829 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO ME DEPARTMENT ANY REPRODUCTION IN PART DIMENSIONS ARE IN INCHES THIRD ANGLE PROJECTION sandiaMAST OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF IDAHO ME DEPARTMENT IS DEFAULT TOLERANCES UNIVERSITY OF IDAHO x ME DEPARTMENT Lane Cameron Hjelfness owe 5 10 2012 _ 0402 _ x As Necessdry menam 04 02 Dampener Mold Cap SLDPRT Lond d 3 OF 3 Notes 1 Construct housing out of 1 1 4 inch 90 degree angle iron 2 Considerations for fitting and mounting electrical components are necessary 3 Cover housing with Plexi glass for safety 4 ABB MicroFlex 100 Brushless Servo Control Part No MFE230AO003B 6 000 PROPRIETARY AND CONFIDENTIAL THE INFORMATION CONTAINED IN THIS DRAWING DIMENSIONS ARE IN INCHES S an d IQ MAST IS THE SOLE PROPERTY OF UNIVERSITY OF IDAHO THIRD ANGLE PROJECTION Gc ME DEPARTMENT ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF UNIVERSITY OF IDAHO ME DEPARTMENT IS PROHIBITED MATERIAL V CITIOUS DEFAULT TOLERANCES bescerron Electrical Housing Assembl UN
98. polymers contain trace amounts of TDI which if ingested must be considered a potential carcinogen Refer to MSDS Part B is irritating to the eyes and skin If contaminated flush eyes with water for 15 minutes and seek immediate medical attention Remove from skin with soap and water When mixing with Part A follow precautions for handling isocyanates Important The information contained in this bulletin is considered accurate However no warranty is expressed or implied regarding the accuracy of the data the results to be obtained from the use thereof or that any such use will not infringe upon a patent User shall determine the suitability of the product for the intended application and assume all risk and liability whatsoever in connection therewith ERES SMmMooTHIIN IMPORTANT Pre Mix the Part B before using After dispensing two Parts A and one Part B into mixing container mix thoroughly for at least 3 minutes making sure that you scrape the sides and bottom of the mixing container several times If Mixing Large Quantities 16 155 7 kgs or more at one time use a mechanical mixer i e Squirrel Mixer or equal for 3 minutes followed by careful hand mixing for one minute as directed above Then pour entire quantity into a new clean mixing container and do it all over again Although this product is formulated to minimize air bubbles in your the cured rubber vacuum degassing will further reduce entrapped air A
99. r the scope of this project a classical shock testing apparatus is to be built and implemented according to Dr Whalen of Sandia National Labs This implies a vertical drop table with a means of actuation and a vertical post construction The information gained from this experiment will supplement the current senior design team with informed data allowing the delivery of a precision instrument to Dr Whalen Being that this is the first time that this project has been instituted shock viscoelastic drop height factor factorial regression accelerometer this information will be forwarded onward to next year s design team who will repeat or carry onward with this design task building from what we accomplish this year The ability to have the information that we discover will save next year s team countless hours and reserve funds for proper allocation new developments on the project A basic understanding of physical phenomena is crucial to designing the shock tower to the specifications provided Dr Whalen will have other applications that he does not yet know of or that he does not currently realize If the solution delivered to him exceeds expectations he will no doubt find it significantly more useful than originally anticipated making the return on investments into these efforts worthwhile It is the desire of my team to deliver a product to Sandia National Labs that exceeds these expectations allowing Dr Whalen the continue
100. refore AS 5304 lt 0 8mm AS 5306 lt 0 4mm Revision 1 6 www austriamicrosystems com Page 5 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Magnet drawn at X index position 0 CW magnet movement direction Hall Array Center Line Index High Pin 1 Chip Top view i eu st D gs 3 0475 0 235 l 25um AS5304 15 AS5306 X Magnet drawn at Ol Te I gt position 1 x exaggerated ON CO O SE 09 au CW magnet movement direction Hall Array Center Line N Index Low I N N I Russ unan luas B YES Chip Top view 1 ll lL Qu LO CO g lt 3 0475 0 235 I Figure 7 Magnet placement for index pulse generation 7 1 4 Soft Stop Feature for Linear Movement Measurement When using long multi pole strips it may often be necessary to start from a defined home or zero position and obtain absolute position information by counting the steps from the defined home position The AS5304 AS5306 provide a soft stop feature that eliminates the need for a separate electro mechanical home position switch or an optical light barrier switch to indicate the home position The magn
101. s and linear bushings The use of bushings and bearings were both valid options for a guide rod based structure and only differed in price percent friction reduction and working load rating 5 5 Lift Actuation With a drop table there must be a lift mechanism to re set the drop table and gain the potential energy necessary There were a considerable number of ideas for this function one of which being a cable and winch Although this would be easy to control with LabView it would be mechanically complicated Another great idea presented was the ACME screw Figure 8 This screw would allow the table to lift and then to drop Although this 2 a pa af c c Figure 8 ACME Screw design idea is easy to build and would be cost effective it would need a coupling release mechanism and would only use gravity for the drop The acceleration would be dependent upon the amount of friction that 15 experienced from contact with the posts which will likely vary The third idea presented in the morphological chart was a rotary motor and belt system This design 15 not accurate although cost effective and would rely upon the mechanical advantage of a pulley system to provide acceleration The last idea a linear motor is the most expensive but highly accurate The linear motor will not only be able to lift the table but accelerate the table downwards because of the ability to move in either direction
102. s of time It is this impulse that Dr Whalen wishes to measure so that he may test his proprietary electronics under specific conditions of 1 to 10 milliseconds and up to 200 g s In order to accomplish this task an understanding of how to replicate these conditions with accuracy and precision as well as how to modify them according to his user inputs is to be gained Current published information lacks uniformity and reliability leaving the team with nothing better than educated guesses This paper publishes findings from an experiment testing how the thickness and properties of certain materials affect shock pulse duration and magnitude how height affects shock pulse duration and magnitude and which factor is more significant Statistical analyses of Factorial Regressions were performed determining that of the two selected for observation the thickness of the viscoelastic material used is the most important factor with a statistical confidence of 99 Key Words I INTRODUCTION HIS document describes the work done by members of Sandia M A S T for their senior capstone project Shock testers are used in industry to subject components or entire structures to shock over a regulated period of time They range in form function cost methods of actuation and applicable standards to which they apply There are multiple methods of accomplishing shock tests in industry including pyrotechnics hammer and classical shock testing Fo
103. shelf All values measured after 7 days at 73 F 23 C dnd life of unused liquid urethane products IMPORTANT Shelflife of productis reduced after opening Remaining product should be used as soon as possible Immediately replacing the lids on both containers after dispensing product will help prolong the shelf life of the unused product XTEND IT Dry Gas Blanket available from Smooth On will significantly prolong the shelf life of unused liquid urethane products The Material Safety Data Sheet for this or any Smooth On product should be read before using and is available upon request All Smooth On products are safe to use with proper handling and precautions Read and follow directions carefully Be careful Part A is TDI prepolymer Vapors which can be significant if prepolymer is heated or sprayed may cause lung damage and sensitization Use only with adequate ventilation Contact with skin and eyes may cause severe irritation Flush eyes with water for 15 minutes and seek immediate medical attention Remove from skin with soap and water Prepolymers contain trace amounts of TDI which if ingested must be considered a potential carcinogen Refer to the MSDS for this product Avoid skin contact by wearing long sleeve garments and latex gloves If skin contact is made remove immediately with soap and water If eye contact is made flush eyes with water for 15 minutes and seek immediate medical attention Important The
104. ter was limited to three categories first being a four post design This design is extremely stable and strong This allowed the reduction in diameters for the posts while keeping the strength that other designs may possess Although a four post is stable it would take longer to machine and would also cost more than other design considerations The table and posts would need to be perfectly square to keep the system from binding Another consideration was the single post design which was a less viable idea due to reliability and structural issues but allowed team members to compare ideas during the decision process Figure 6 The platform that held the DUT would have to be balanced to prevent from binding while being lifted and dropped for the shock The third idea that was presented was a two post design which most of the competitors used based on our preliminary market research Figure 6 This design is sturdier than the single post and will have less friction than the four post These design considerations were incorporated in our morphological chart and house of quality as is the case for all categories discussed below 5 4 Reduction of Energy Loss A major concern with respect to our design was reduction of friction between the Figure 7 Double Post Design posts and the drop table Our team researched several options to mitigate this loss Options considered included no device linear ball bearing
105. the magnet movement over the C is minimum 0 5 LSB and maximum 1 5 LSB s AS5306 DNL dynamic non linearity AS5304 DNL dynamic non linearity 1 LSB DNL 12 5 um 1 LSB DNL incremental output steps incremental output steps lateral magnet movement lateral magnet movement Figure 11 of 455304 left and AS5306 right 8 The AO Output The Analog Output AO provides an analog output voltage that represents the Automatic Gain Control AGC of the Hall sensors signal control loop This voltage can be used to monitor the magnetic field strength and hence the gap between magnet and chip surface e Short distance between magnet and IC strong magnetic field low loop gain low AO voltage e Long distance between magnet and IC weak magnetic field high loop gain high AO voltage For ideal operation the AO voltage should be between 1 0 and 4 0V typical see 9 5 Vao V weak field high AGC EE E E a a 3 45 70 recommended strong field range 1 4V low vertical gap Figure 12 output versus AGC magnetic field strength magnet to IC gap Revision 1 6 www austriamicrosystems com Page 8 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 8 1 Resolution and Maximum Rotating Speed When using the 55304 55306 in an off axis rotary appl
106. tings Non Operating Stresses beyond those listed under Absolute Maximum Ratings may cause permanent damage to the device Parameter Symbol Min Max Unit Note Input current latchup immunity 100 D sss DCS 3 8 _ 92 Operating Conditions Parameter Symbol Positive supply voltage AVDD Digital supply voltage DVDD Power supply current AS5304 at tai A B Index AO unloaded Power supply current AS5306 current AS5306 K e HE Integral nonlinearit weal ErrMax ErrMin 2 Differential nonlinearity No missing pulses wau alignment mes LE T 93 System Parameters Parameter Symbol Min Max Unit Note Powers T Amplitude within valid range uds Interpolator locked A B Index enabled Time bet hange of input signal to Revision 1 6 www austriamicrosystems com Page 10 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 4 A B C Push Pull or Open Drain Output Push Pull Mode is set for AS530xA Open Drain Mode is set for AS530xB versions Parameter Typ M High level output voltage pf Push Pull mode m m m p Low level output voltage VoL 0 4 VSS VO C T Push Pull mode V V Short circuit limitation current 39 maximum operating temperature Q Js S Capacitive load 20 KES See Figure 13 A B Index from AS5304 6 1 20pF Figure 13 Typical digital load 95
107. tion A 4 AS5306A O No Connect i 55306 O Connect Quadrature Position B O No Connect HOST uC No Connect O 5V O 1uF 10uF optional O No Connect Index i O No Connect No Connect O O No Connect No Connect O O No Connect Figure 5 Electrical connection of the AS5304 A85306 Revision 1 6 www austriamicrosystems com Page 4 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 7 Incremental Quadrature AB Output The digital output is compatible to optical incremental S N 5 N 5 encoder outputs Direction of rotation is encoded into two signals A and B that are phase shifted by 90 Depending on the direction of rotation A leads B CW or B leads A CCW T 1 1 Index Pulse A single index pulse is generated once for every pole pair One pole pair is interpolated to 40 quadrature pulses 160 steps so one index pulse is generated after every 40 quadrature pulses see Figure 6 Index The Index output is switched to Index high when a magnet is placed over the Hall array as shown in Figure 7 top graph the north pole of the magnet is placed over the left side of the IC top view pin 1 at bottom left and the south pole is placed over the right side of the IC Detail The index
108. to use any compressed fluids A large majority of devices on the market use pneumatics for lift actuation as well as a system to reduce resonance Additionally a large majority of these are for applications where the device under test is well beyond 300 grams Sometimes the capacity of the most basic tester is over 3300 pounds Dr Whalen has expressed the need for an electrically or an elastically actuated system to circumnavigate these constraints With such a system we feel that we will have greater controllability and reliability over other systems such as a gravity fed drop or a spring loaded system Complete data sheets for each system can be referenced in the appendix of the report Current competitor solutions include the following Shock Capacity 3 30 000 g s Shock Duration 0 012 ms to 100 ms Desirable Capabilities Able to produce three Ps types of pulse shapes Load capacity 50 to 200 Ibs Figure 1 Avex SM Series Table 1 Avex SM Series Specs LAB AutoShock Shock Capacity 500 600 g s Shock Duration SM 105 Table Asserr Hydraulic Power Supply Shock Progran Assembly Desirable Capabilities Safety interlock system Load Capacity 600 Ib Table 2 LAB AutoShock Specs Figure 2 LAB AutoShock Individual Airmount Floor Anchor Plates MN Shock Capacity 400 g s Shock Duration Desirable Capabilities Lift actuation and release mechanism un Load Capacity 2000
109. tput voltage VoutRange field max VoutRange AGC Votfs Average short circuit current Operating Reduces maximum Temperature Capacitive load Revision 1 6 www austriamicrosystems com Page 11 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 9 6 Magnetic Input Parameter i i Note Magnetic pole length 2 AS5306 Magnetic pole pair length 5306 Magnetic amplitude Os pc wera ss mama m 3 1 w Table 1 5304 ordering guide Device Resolution Magnet Pole Length Digital Outputs Table 2 AS5306 ordering guide Device Resolution Magnet Pole Length Digital Outputs Revision 1 6 www austriamicrosystems com Page 12 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems Contact Headquarters austriamicrosystems A 8141 Schloss Premstatten Austria Phone 43 3136 500 0 Fax 43 3136 525 01 www austriamicrosystems com Copyright Devices sold by austriamicrosystems are covered by the warranty and patent indemnification provisions appearing in its Term of Sale austriamicrosystems makes no warranty express statutory implied or by description regarding the information set forth herein or regarding the freedom of the described devices from patent infringement austriamicrosystems reserves the right to change specificati
110. trolled from any of Baldor s 3 phase brushless drive family including MicroFlex FlexDrive ll Flex Drive ll and MintDrive ll The motors are also compatible with the NextMove range of motion controllers for multi axis position control Baldor s cog free linear motors are nickel plated meeting ROHS compliance Baldor provides standard magnetic track lengths to optimize pricing for customers These standards include LTCF C24 LTCF E24 LTCF F24 and LTCF C40 LTCF E40 LTCF F40 Other track lengths are available as custom JEn Ee IL CODE FOR LENGTH OF MODULAR TRACK mn linch 04 121 9 4 8 07 182 9 7 2 09 243 8 9 6 12 3048 12 24 609 6 24 40 1036 40 8 SIZE CODE mm linch A 40 7 1 6 B 53 6 2 11 57 2 2 25 D 86 4 3 4 114 3 4 5 F 152 4 6 0 Indicates standard size and length Cog free Brushless Technical Data Technical Data Catalog Numbers Continuous Farce Continuous Petite BackeEMF Constant K o Duty N Lbs Amps N Lbs Amps V m sec V in sec LMCF02A HCO 53 1 2 1 7 16 3 6 54 3 1 0 08 LMCF02B HCO 13 8 3 1 2 1 41 8 9 4 6 3 6 7 0 17 LMCF04B HCO 27 8 6 2 2 1 83 3 18 7 6 3 13 2 0 34 4 LMCF02C HCO 29 6 5 1 9 86 8 19 5 5 7 15 2 0 39 4 LMCF04C HCO 58 13 1 9 173 39 5 7 30 4 0 77 4 LMCFO6C HCO 87 19 5 1 9 260 58 5 7 45 6 1 16 4 LMCFO8C HCO 116 26 1 9 347 78 5 7 60 9 1 55 LMCFO2D HCO 36 8 8 3 1 5 110 24 4 4
111. ubber seek its level up and over the model A uniform flow will help minimize entrapped air The liquid rubber should level off at least 1 2 1 3 cm over the highest point of the model surface Curing Allow the mold to cure at least 48 hours at room temperature 73 F 23 C before demolding Do not cure rubber in temperatures less than 65 F 18 C Cure time can be reduced with mild heat or by adding Smooth On Kick It Cure Accelerator Post Curing After rubber has cured at room temperature heating the rubber to 150 F 65 C for 4 to 8 hours will increase physical properties and performance Using The Mold If using as a mold material a release agent should be applied to the mold before each casting The type of release agent to use depends on the material being cast The proper release agent for wax liquid rubber or thermosetting materials i e Smooth On liquid plastics is a spray release made specifically for mold making available from Smooth On or your distributor Prior to casting gypsum plaster materials sponge the mold with a soap solution for better plaster flow and easy release In amp Out II Water Based Release Concentrate available from Smooth On is recommended for releasing abrasive materials like concrete Performance amp Storage Fully cured rubber is tough durable and will perform if properly used and stored The physical life of the rubber depends on how you use it Contact Smooth On directly with quest
112. uency measurement and continuous pulse output operations 20dB 40dB First Value 08 19916 View Frequency File In Cho 1025 Hertz File Out Chl Figure 14 This graph shows the outstanding quality of the DT9816 A for all error sources effective number of bits greater than 13 1 from all sources Note the absence of harmonic content and digital switching noise across the full spectrum WWW DATATRANSLATION COM US Canapa 800 525 8528 EuRoPE AsiA 49 0 7142 95310 Analog Inputs DT9810 provides 10 bit resolution while the DT9812 DT9813 and DT9814 modules provide 12 bit resolution For maximum resolution the DT9816 modules provide 16 bit resolution The DT9810 and DT9812 modules provide eight single ended analog input channels The DT9813 modules provide 16 single ended analog inputs The DT9814 modules provide 24 single ended analog input channels The modules can acquire data from a single analog input channel or from a group of analog input channels DT9810 and DT9812 2 5V modules feature a full scale input signal range of 0 to 2 44 V If you need a full scale input signal range of 10 V the 079812 079813 DT9814 and DT9816 modules are available The DT9816 modules also feature a full scale input signal range of 5 V The DT9812 2 5V provides gains of 1 2 4 8 and 16 the DT9812 DT9813 and DT9814 modules provide programmable gains of 1 2 4 and 8 and the DT9816 modules provi
113. um Rotating Speed When using the 55304 55306 in an off axis rotary application a multi pole ring magnet must be used Resolution diameter and maximum speed depend on the number of pole pairs on the ring 8 1 1 Resolution The angular resolution increases linearly with the number of pole pairs One pole pair has a resolution interpolation factor of 160 steps or 40 quadrature pulses Resolution steps interpolation factor x number of pole pairs Resolution bit log resolution steps log 2 Example multi pole ring with 22 pole pairs Resolution 160x22 3520 steps per revolution 40x22 880 quadrature pulses revolution 11 78 bits per revolution 0 1023 per step 8 1 2 Multi pole Ring Diameter The length of a pole pair across the median of the multi pole ring must remain fixed at either 4mm 5304 or 2 4mm AS5306 Hence with increasing pole pair count the diameter increases linearly with the number of pole pairs on the magnetic ring Magnetic ring diameter pole length number of pole pairs for AS5304 d 4 0mm number of pole pairs for 55306 d 2 4mm number of pole pairs Tr Example same as above multi pole ring with 22 pole pairs for AS5304 Ring diameter 4 22 13 14 28 01mm this number represents the median diameter of the ring this is where the Hall elements of the 55304 55306 should be placed see Figure 4 For the AS5306 the same ring would have a dia
114. using After dispensing the required amounts of Parts A and B into mixing container mix thoroughly for at least 3 minutes making sure that you scrape the sides and bottom of the mixing container several times If Mixing Large Quantities 24 Ibs 11 kgs or more at one time we suggest using a mechanical mixer i e Squirrel Mixer or equal for 3 minutes followed by careful hand mixing for one minute as directed above Then pour entire quantity into a new clean mixing container and do it all over again Although this product is formulated to minimize air bubbles in the cured rubber vacuum degassing will further reduce entrapped air A pressure casting technique using a pressure chamber can yield totally bubble free castings Contact Smooth On or your distributor for further information about vacuum degassing or pressure casting POURING CURING amp PERFORMANCE Pouring For best results pour your mixture in a single spot at the lowest point of the containment field Let the rubber seek its level up and over the model A uniform flow will help minimize entrapped air The liquid rubber should level off at least 1 2 1 3 cm over the highest point of the model surface Curing Allow the mold to cure at least 16 hours at room temperature 73 F 23 C before demolding Do not cure rubber in temperatures less than 65 F 18 C Cure time be reduced with mild heat or by adding Smooth On Kick It Cure Accelerator Post Curi
115. vents Measurement Errors and Period Measurements Built in Waveform Generator for generating sine ramp triangle square wave and DC signals start the measurement stop the measurement rising shown here falling shown here The interval is calculated Connect Signal and the count is returned to C T Gate 0 ae lt Triangle Pulse width of counts 24 MHz Frequency 24 MHz of counts Period 1 Frequency Figure 10 DT9812 2 5 V DT9812 10V DT9813 10V and the Figure 11 Programmable edges allow you to use the counter DT9814 10V modules provide 2 waveform DACs for generating timer of an ECONseries module to measure the pulse width sine ramp triangle square wave and DC signals frequency and period of a signal WWW DATATRANSLATION COM US CaNADA 800 525 8528 EuRoPE AsiA 49 0 7142 9531 0 DT9816 Design Advantages Six Simultaneously Sampled Analog Inputs Accurate Measurements Designed In Ext Trig Ext Clk Analog Input Sampled Data tap Aperture Delay of 35 ns tay Aperture Jitter Uncertainty of 1 ns The time between each channel Aperture Delay Matching Data Stream is 5ns maximum Figure 12 The DT9816 modules feature six independent Figure 13 The A D design of the DT9816 modules feature built successive approximation A D converters with track and hold in accuracy Amaximum aperture delay of 35 ns the time that
116. void missing code Consequently the incremental outputs will change when the magnet movement over the C is minimum 0 5 LSB and maximum 1 5 LSB s AS5306 DNL dynamic non linearity AS5304 DNL dynamic non linearity 1 LSB DNL 12 5 um 1 LSB DNL incremental output steps incremental output steps lateral magnet movement lateral magnet movement Figure 11 of 455304 left and AS5306 right 8 The AO Output The Analog Output AO provides an analog output voltage that represents the Automatic Gain Control AGC of the Hall sensors signal control loop This voltage can be used to monitor the magnetic field strength and hence the gap between magnet and chip surface e Short distance between magnet and IC strong magnetic field low loop gain low AO voltage e Long distance between magnet and IC weak magnetic field high loop gain high AO voltage For ideal operation the AO voltage should be between 1 0 and 4 0V typical see 9 5 Vao V weak field high AGC EE E E a a 3 45 70 recommended strong field range 1 4V low vertical gap Figure 12 output versus AGC magnetic field strength magnet to IC gap Revision 1 6 www austriamicrosystems com Page 8 of 13 AS5304 AS5306 Integrated Hall IC for linear and off axis rotary motion detection austriamicrosystems 8 1 Resolution and Maxim
117. w and easy release In amp Out Il Water Based Release Concentrate available from Smooth On is recommended for releasing abrasive materials like concrete Performance amp Storage Fully cured rubber is tough durable and will perform if properly used and stored The physical life of the rubber depends on how you use it Call Us Anytime With Questions About Your Application Toll free 800 762 0744 Fax 610 252 6200 The new www smooth on com is loaded with information about mold making casting and more 052511 JR PMC 780 Dry amp PMC 780 Wet Industrial Liquid Rubber Compounds p I PRODUCT OVERVIEW PMC 780 is a premium performance urethane rubber that offers exceptional strength durability and abrasion resistance PMC 780 DOES NOT CONTAIN MOCA a known cancer causing agent and hazard Mixed two parts A to one part B by weight PMC 780 pours easily and cures at room temperature with negligible shrinkage to a solid Shore 80A rubber Pick The One Best Suited For Your Application Original PMC 780 Dry does not exude oil New PMC 780 Wet contains a built in release agent to aid in demolding concrete Note wet rubber has a higher net shrinkage value over time vs dry rubber Both are used around the world for casting abrasive materials such as concrete pre cast concrete making concrete stamping pads etc and gypsum plasters with high exotherms PMC 780 Dry is
118. y weight or volume Non Porous Surfaces Metal glass hard plastics sulfur free clays etc require only a release agent n ASTM Applying Release Agent A release agent is necessary to facilitate Specific Gravity g cc 1 03 ASTM D 1475 demolding when casting into or over most surfaces Use a release agent made specifically for mold making Universal Mold Release available from Smooth On A liberal coat of release agent should be applied Specific Volume cu in Ib 26 9 onto all surfaces that will contact the rubber Pot Life 15 minutes 73 F 23 C ASTM D 2471 Cure time 16 hours 73 F 23 C Color Amber color may vary from batch to batch IMPORTANT To ensure thorough coverage lightly brush the release agent with a soft brush over all surfaces of the model Follow with a light mist coating and let the release agent dry for 30 minutes Because no two applications are quite the same a small test application to determine suitability for your project is recommended Shore A Hardness 60 ASTM D 2240 if performance of this material is in question Tensile Strength psi 700 ASTM D 412 MEASURING amp MIXING 100 Modulus psi 220 ASTM D 412 Liquid urethanes are moisture sensitive and will absorb atmospheric E 3 moisture Mixing tools and containers should be clean and made of Elongation Break 650 ASTM D 412 metal glass or plastic Materials should be stored and used in a warm

Final Report - Senior Design

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