Fatigue Life Testing Platform for Electroformed Bellows Customer

Fatigue Life Testing Platform for Electroformed Bellows Customer: Ni. Co. Form, Inc. Advisor: Dr. E. Debartolo EEEE Jadon Weinel Hector Vargas February, 2004 EMEM Richard Kraynik Zachary Eastman James Haschmann © 2003 -2004, Team 04035

Outline Introduction Goals Preliminary Design Redesign Fabrication – Mechanical – Electrical Software Flow Conclusion

Goals Design, fabricate and debug a fatigue life testing platform for electroformed bellows Deliver a technical data package that allows the sponsor to reproduce the platform

What Is a Bellows? Bellows are dynamic components requiring a combination of strength, elasticity and long cycle life. Consisting of stacked circular convolutions, bellows can facilitate axial, angular, and/or defected motion. Common uses: Hermetically sealed vibration dampeners Aligned and Offset axis torque couplings Pressure sensors activators Springs

Test Procedure Concept Place bellows into test platform Input desired data – Frequency – Displacement Start test – Pressurize bellows Run test Test ends when the PLC detects a loss of pressure in the system which indicates a failure in the bellows integrity.

Preliminary Design Base Tester Top Support Rods Solenoid Pressure Switch Isolator Feet Bellows Adapters Actuator Flange Bellows Adapter Flange

Redesign Minor cosmetic changes to the base Actuator flange Development of optical feedback system Addition of centering spider diaphragm Relocated the solenoid and pressure switch Top bellows adapter Tester top

Final Test Platform Design

Slide Hose fitting Upper bellows adapter Support rod Lower bellows adapter Spider collar Spider diaphragm Spacer Actuator and actuator collar Base Feet Exploded View

Test Platform Design Details O-rings seat in the recesses. One prevents the upper bellows adapter from falling. The other provides a seal between the bellows adapter and the slide. Here, the spider diaphragm and major components attached to the base can be seen.

Fabrication Conventional Methods – – Grinding Milling Turning Wire Electrical Discharge Machining Materials – 304 Stainless Steel Base, Slide, Support Rods, Coil Collar – Brass Bellows Adapters, Spider Collar

Optical Feedback System Circuit to drive the LED in the OPTEK 830 L Series optical chopper and also condition the return signal brought back by the optical detector to provide feedback to the BEI Inc. motion controller. OPTEK 830 L Series OPTEK Inc. 831 L 55 transmissive photo transistor package. Works with above circuit to provide position feedback of the motion of the actuator.

Electronics Cabinet Closed – Position for normal operation and storage when not in use. Open – For maintenance purposes and reprogramming of the PLC and Motion Controller.

Software Flow

Conclusion/Outcomes Completed Items Mechanical Components Electronics Cabinet Wiring of Electronics Cabinet Low Frequency Actuator Motion Critical Design Review Package To Be Completed Before Demonstration Receive Spider From Vendor Test Motion of Voice Coil at Higher Frequencies Install Optical Sensor

Questions or Comments! Visit: www. Ni. Co. Form. com