Bishop Steering Technology II Precision Measurement Device Hong Zhu Kyle Powell David K. Spaeth Patrick Richardson.
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Bishop Steering Technology IIBishop Steering Technology II
Precision MeasurementPrecision MeasurementDeviceDevice
Hong ZhuHong ZhuKyle PowellKyle Powell
David K. SpaethDavid K. SpaethPatrick RichardsonPatrick Richardson
Reason for the DesignReason for the Design
Present measurement techniques are not Present measurement techniques are not accurate enough accurate enough Ensure consistent measurements between Ensure consistent measurements between the various tiers involved in the industrythe various tiers involved in the industryImproper measurement can result in a part Improper measurement can result in a part being accepted that will fail when the being accepted that will fail when the whole steering system is testedwhole steering system is testedProperly measured parts facilitate Properly measured parts facilitate cooperation between supplierscooperation between suppliersFewer returned parts will reduce costsFewer returned parts will reduce costs
Main RequirementsMain Requirements
Client needs two measurement systems to Client needs two measurement systems to measure components of a rack and pinion measure components of a rack and pinion steering system steering system
Measurements must not have a difference Measurements must not have a difference greater than +/- 3microns from true valuegreater than +/- 3microns from true value
Device must not be overly complicatedDevice must not be overly complicated
How Small is Three Microns?How Small is Three Microns?
The average skin cell is four microns in diameterThe average skin cell is four microns in diameter
The average human hair is 70 microns in The average human hair is 70 microns in diameterdiameter
Problems with poorly Problems with poorly measured shafts and sleevesmeasured shafts and sleevesIf the shaft and sleeve are not accurately If the shaft and sleeve are not accurately machined, the flow of hydraulic fluid machined, the flow of hydraulic fluid through them will not be eventhrough them will not be even
The car may turn even though the steering The car may turn even though the steering wheel is in the neutral (center) positionwheel is in the neutral (center) position
The car may be more difficult to turn in The car may be more difficult to turn in one direction than the otherone direction than the other
Increased costs due to repairs and bad Increased costs due to repairs and bad partsparts
Process ControlProcess Control
The measuring process must be The measuring process must be consistent consistent Because of the high accuracy required, Because of the high accuracy required, the test facility must be in a pristine, the test facility must be in a pristine, laboratory-like environmentlaboratory-like environmentThe environment must be controlled and The environment must be controlled and free of dust and other fugitive material that free of dust and other fugitive material that could be detrimental to the measuring could be detrimental to the measuring processprocess
Thermal ControlThermal Control
Any variation in temperature cause the Any variation in temperature cause the size of a shaft or sleeve to change by size of a shaft or sleeve to change by more than three micronsmore than three microns
Transfer of human body heat to the shafts Transfer of human body heat to the shafts and sleeves must be minimizedand sleeves must be minimized
The ambient room temperature must be The ambient room temperature must be kept constantkept constant
SensorsSensors
It is necessary to record both linear and It is necessary to record both linear and angular displacementsangular displacements
The challenge was to find a way to record The challenge was to find a way to record both displacements at the same timeboth displacements at the same time
Linear Distance SensorLinear Distance Sensor
For the shaft measurement we propose For the shaft measurement we propose the use of a Keyence LK-011 laserthe use of a Keyence LK-011 laser
Linear Distance SensorLinear Distance Sensor
For the sleeve we propose the Philtec Fiber For the sleeve we propose the Philtec Fiber Optic linear displacement sensorOptic linear displacement sensor
Angular Displacement SensorAngular Displacement Sensor
The angular encoder can measure the angular The angular encoder can measure the angular rotation of a shaft to within 0.00005° accuracyrotation of a shaft to within 0.00005° accuracy
Sensor MountingSensor Mounting
Sensors are very sensitive, and must be Sensors are very sensitive, and must be stationary stationary
So, the shafts and sleeves must be rotated So, the shafts and sleeves must be rotated
so all the notches can be measured by the so all the notches can be measured by the sensorssensors
Why not design one device that holds both Why not design one device that holds both sensors stationary and measure both shafts sensors stationary and measure both shafts and sleeves?and sleeves?
Positioning and AlignmentPositioning and Alignment
Measurement = Position +AlignmentMeasurement = Position +Alignment
By definition, linear and angular By definition, linear and angular measurements require exact positioning measurements require exact positioning and alignmentand alignment
Precision measurement requires precision Precision measurement requires precision equipmentequipment
X-Y TablesX-Y Tables
Micrometer driven tables allow for accurate Micrometer driven tables allow for accurate positioningpositioning
Movable on one or two axesMovable on one or two axes
Bellows Type Flexible CouplingsBellows Type Flexible Couplings
Rotation of shaft or sleeve must be the same as Rotation of shaft or sleeve must be the same as rotation of encoderrotation of encoderUnique design ensures that rotation is the same Unique design ensures that rotation is the same at top and bottom of coupling and that shafts are at top and bottom of coupling and that shafts are alignedaligned
BearingBearing
Browning Spherical Roller BearingBrowning Spherical Roller Bearing
Low radial runoutLow radial runout of 1.5 micronsof 1.5 microns
Use of a Stock Motor and Gear Use of a Stock Motor and Gear ReducerReducer
Small motors capable Small motors capable of turning the shafts of turning the shafts and sleeves at and sleeves at constant speed are constant speed are common and common and available for purchaseavailable for purchase
We will use a Parker We will use a Parker Automation stepper Automation stepper motor and a Daedel motor and a Daedel gear reducergear reducer
Data Acquisition and AnalysisData Acquisition and Analysis
Both the Keyence laser and Philtec fiber optic Both the Keyence laser and Philtec fiber optic sensor are sold with electronics that acquire and sensor are sold with electronics that acquire and process the data process the data Output is usually digital, but analog output devices Output is usually digital, but analog output devices with graphical displays are availablewith graphical displays are available
Patents and TrademarksPatents and Trademarks
We have found no exact matches for the We have found no exact matches for the proposed designs proposed designs
There are patented designs for similar There are patented designs for similar components, but no design that components, but no design that incorporates them into a single systemincorporates them into a single system
The Laser Micro100 by BLUM is the The Laser Micro100 by BLUM is the closest in theory to what we are attemptingclosest in theory to what we are attempting
Design ModelingDesign Modeling
This project called for research and This project called for research and design, but not the building of a prototypedesign, but not the building of a prototype
Pro-Engineer is a powerful software Pro-Engineer is a powerful software program that allows us to model the program that allows us to model the designdesign
The components in our design are only The components in our design are only representations of the actual parts representations of the actual parts
ConclusionConclusion
We met the engineering requirements forWe met the engineering requirements for
accuracy and surpassed our task of accuracy and surpassed our task of
designing a machine that could measure designing a machine that could measure
either the shaft or the sleeve…either the shaft or the sleeve…
OUR DESIGN MEASURES BOTH!OUR DESIGN MEASURES BOTH!
The technology to produce thisThe technology to produce this
measurement machine is available now measurement machine is available now
RecommendationsRecommendations
We suggest that a prototype of this design We suggest that a prototype of this design
be made and tested.be made and tested.
Possible alternatives to our method of Possible alternatives to our method of adjusting the gauge plate be investigated.adjusting the gauge plate be investigated.
ConsultantsConsultants
Dr. Jie Chen - IUPUIDr. Jie Chen - IUPUI
Jason Wou – Bishop SteeringJason Wou – Bishop Steering
Daniel Crafton – Bishop SteeringDaniel Crafton – Bishop Steering
Andy Hartsock – Parker AutomationAndy Hartsock – Parker Automation
Dr. A.K. Naghdi – IUPUIDr. A.K. Naghdi – IUPUI
Sales Support – Heidenhain Sales Support – Heidenhain
Dr. Vermuri – IUPUI, Physics DepartmentDr. Vermuri – IUPUI, Physics Department
ReferencesReferences
The Mechanical Design ProcessThe Mechanical Design Process By David G. Ullman By David G. Ullman
MCG, 2002MCG, 2002
Introduction to Laser TechnologyIntroduction to Laser Technology By Hitz, C. Breck, Hitz, Breck, Ewing, J. J.,Hecht, Jeff By Hitz, C. Breck, Hitz, Breck, Ewing, J. J.,Hecht, Jeff
John Wiley & Sons Inc, 2001John Wiley & Sons Inc, 2001
An Introduction to Fiber OpticsAn Introduction to Fiber OpticsBy R. Allen Shotwell, E. StewartBy R. Allen Shotwell, E. Stewart
Prentice Hall, 1996 Prentice Hall, 1996
Electronic ReferencesElectronic Referenceswww.keyence.comwww.keyence.comwww.howstuffworks.comwww.howstuffworks.comwww.philtec.comwww.philtec.comwww.newport.com/www.newport.com/www.isotech.netwww.isotech.netwww.scantron-net.co.uk/applications.htm#fibreswww.scantron-net.co.uk/applications.htm#fibreswww.eng.warwick.ac.uk/~espbc/index.htmwww.eng.warwick.ac.uk/~espbc/index.htmwww.microphotonics.com/www.microphotonics.com/www.beemerprecision.com/info.html www.beemerprecision.com/info.html www.hephaist.co.jp/e/index.htmlwww.hephaist.co.jp/e/index.htmlwww.eminebea.com/usa/www.eminebea.com/usa/www.hansen-motor.com/www.hansen-motor.com/www.mstores.umich.edu/www.mstores.umich.edu/
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