[ Second Generation ]
This design has the least pieces, it is the cheapest, easiest to build and least likely to fail. The design is universal and will work for all different sizes and applications. It is over 20x more powerful than last years design for less than 20% the price. More importantly, the customer liked the idea the most. After deciding on the on which design would be best we came up with this ideal pro/e render of how the system would look like in actual in closure.
For ease in ordering and construction the test apparatus frame was built using stainless steel parts like the center shaft (blue) from the previous year's system. The bearing (red), actuators (green), actuator controls (not shown), and the motor (orange) were all purchased from McMaster Carr.
Before construction the test frame was analyzed in FEM to ensure the system could handle the load specifications with an ample safety factor. Below shows a expected load of 2700lb on the system. This causes ®minimum stress on frame. We used Stainless Steel (Cold drawn) as our test metal.
An overload of 5400lbs, exaggerated model to see ®maximum stress on frame with structure failure.
To investigate the structure at a different point of view, a 2-D cross sectional design was made. The maximum displacement for 2700lbs was 0.001 inches. This data was conclusive with the 3-D, which was good enough to proceed with this design.
At this point the actuators, control box, switches, AC motor, and ball bearing orders that we placed with the Boeing sponsor came in. We photographed and tested the parts.
Once everything was plugged in and operational, we put together a mock test structure.
Finally we took all the parts and pieces to the machine shop for construction
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