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Independent stress and rotation system design.

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 INTROTION
Just as the name of this report, we are going to design an independent stress and

rotation system within axiom theory. Before the formal opening it is necessary give

definitions about ³what design is´ and ³what axiom is´.

Design is interplay between what we want to achieve and how we want to achieve it.

Therefore, a rigorous design approach must begin with an explicit statement of µµwhat

we want to achieve¶¶ and end with a clear description of µµhow we will achieve it.¶¶

Once we understand the customer¶s needs, this understanding must be transformed

into a minimum set of specifications, which will be defined later as functional

requirements (FRs), that describe µµwhat we want to achieve¶¶ to satisfy the customers¶

needs. The descriptor of µµhow to achieve it¶¶ may be in the form of design parameters

(DPs). All of these are design activities.

What is common in all these activities is that the designers must:

1. Know or understand their customers¶ needs.

2. Define the problem they must solve to satisfy the needs.

3. Conceptualize the solution through synthesis.

4. Perform analysis to optimize the proposed solution.

5. Check the resulting design solution to see if it meets the original customer needs.
 
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Before the definition of axiom we should know that the design world consists of four

domains. As what discussed in the paragraph above, design involves interplay

between µµwhat we want to achieve¶¶ and µµhow we choose to satisfy the need (i.e., the

what).¶¶ To systematize the thought process involved in this interplay.

The figure above is about four domains of the design world, in which CA represents

customer attribute, FR represents functional requirement, DP represents design

parameter and PV represents process variable. The {XX} are the characteristic vectors

of each domain. During the design process we go from the domain on the left to the

domain on the right. The process is iterative in the sense that the designer can go back

to the domain on the left based on the ideas generated in the right domain.

The mapping from the FRs to DPs is the µµproduct¶¶ design. Then, we may go to the

process domain to come up with a manufacturing process in the case of product

design. The PVs are selected to satisfy the DPs. In mechanical engineering we usually

think of design in terms of product design and often hardware design.

The mapping process between the domains can be expressed mathematically in terms

of the characteristic vectors that define the design goals and design solutions. FRs

constitutes the DP vector. The relationship between these two vectors can be written

as

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Where [A] is called the design matrix that characterizes the product design. The

equation above is a design equation for the design of a product.

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 The independence axiom maintains the independence of the FRs.

 The information axiom minimizes the information content of the design.

The performance, robustness, reliability, and functionality of products and processes

are significantly improved when these axioms are satisfied. Conversely, design

axioms can be used to analyze why machines and processes are not working well and

to solve the problems by coming up with alternate designs. Obviously, we are going to

use 

here.

To satisfy the independence axiom, the design matrix must be either diagonal or
triangular. When the design matrix [A] is diagonal, each of the FRs can be satisfied

independently by means of one DP. Such a design is called an uncoupled design.

When the matrix is triangular, the independence of FRs can be guaranteed if and only

if the DPs are determined in a proper sequence. Such a design is called a decoupled

design. Any other form of the design matrix is called a full matrix and results in a

coupled design. Therefore, when several FRs must be satisfied, we must develop

designs that will enable us to create either a diagonal or a triangular design matrix.

 À


 

We want to develop an environmental station for the beam line at CLS (Canadian

Light Source), which can give required tensile stress and rotation to the specimen

independently. To design a mechanism to stretch the specimen with desired forces or

displacements, and avoid any axial displacement of the geometric center of the

specimen; specifically speaking, this device is included in an image testing system

which is aimed to obtain images of the deformation process of the specimen; therefore,

this device will only offer rotation and stress tensile as a component of the image

testing system. The system will take 900 images by synchrotron radiation x-ray

imaging method at the CLS around 180 degree of the specimen by 0.2 degree step.

Then the rotation is stopped and the specimen will be pulled by 1mm by the lead

screw. After stopping the pulling again we will take 900 images around 180 degree of

the specimen by 0.2 degree step and so on«This device we are now proposing will

only offer rotation and stress tensile as a component of the image testing system.

The significance of this design is that we know every material goes under stress from

µ0¶ to its ultimate strength before failure and deformed. This is so much related to the

safety in using material which goes under stress in any environment. So, we have to

know the internal structure and the behavior of the material after deformation. For

doing these tasks we are taking images of the material specimen by passing

synchrotron radiation through the specimen at CLS and then analyzing the image

contrasts by software. But CLS beam line does not have any facility to give stress on
the specimen. It needs an environmental station for the beam line which can give

stress and rotation independently on the specimen. This project will open a new world

of exploring the material internal structure at CLS beam line.

We will give tensile stress to the specimen by pulling it by using lead screw which

will be run by a high torque stepper motor. The force will be applied to the specimen

in both directions so that any axial displacement of the center of the specimen could

not occur. For doing this task the two halves of the lead screws will be threaded in

opposite directions (i.e. one half will be right handed and other half will be left

handed). The specimen will be rotated independently by another stepper motor so that

we can take the images from all directions. At all bearing supports thrust bearing will

be used so that all shafts could rotate freely under axial load.
   

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FR1 = Giving axial stress to the specimen.

FR2 = Giving stepping rotation to the specimen during loading condition.

FR3 = Avoiding any axial displacement of the center of the specimen after deforming

it.

  



DP1 = Pulling of the specimen.

DP2 = Experiment adaptable rotational arrangement.

DP3 = Pulling the specimen from both sides.

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This is an uncoupled design and of course this is the best design at level of decision

making.
 
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FR11 = Hold the specimen.

FR12 = Apart the holding support from each other.

  



DP11 = Attaching two ends of the specimen with two different plates.

DP12 = Attach two lead-screws with the two plates in such way that when lead-screw

rotates plates experience movement along the lead screws.

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This is a decoupled design and it is still available.

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FR121 = Meshing the lead-screw with the plates.

FR122 = Rotation of the lead-screw.

  



DP121 = Making internal thread at specific location in the plate and meshing it with

the lead-screw.

DP122 = Rotate the lead-screw using motor.


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FR21 = Rotation of the specimen.

FR22 = Hold the specimen such that it can rotate smoothly under loading condition.

FR23 = giving stepping rotation.

  



DP21 = rotate the specimen using motor

DP22 = Using thrust bearing support to hold the specimen.

DP23 = Using stepper motor.

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FR31 = Free movement of the end support of the specimen.

FR32 = Moving the end support in opposite direction.

  



DP31 = Using smooth guide ways for moving the end support.
DP32 = Making the thread in opposite direction (right handed and left handed) in the

each half of the lead screw and also in the meshing plates.

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As what seen above we finished the ADT (Axiomatic Design Theory) function

decomposition and there is a concrete design steps based on the decomposition in the

following parts.

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Stress system
 


This is the top-slider. It slides on the guide ways with the help of two sliding holes. It

also has two holes with internal left hand threads which will mesh with the lead-screw

left handed threading part. In the center of the slider there is a hole for mounting the

specimen and space for mounting a thrust bearing which will hold the specimen

during experiment and ensure the smooth rotation of the specimen under loading

condition. The sliding and threading holes are located at the same distance from the

center to minimize the unbalances during sliding.



This is bottom slider. It is totally similar to the top slider.

This is bushing. It is attached inside the hole of the slider which hole is used to slide

on the guide ways. Bushing is used along with the hole of the slider to increase the

surface contact area with the guide ways which decreases the tilting possibility of the

slider so that slider can move smoothly on the guide ways. The material of the

bushing has lower friction co-efficient so that it can slide smoothly on the guide ways.
This is the sliding part with rotational arrangement.


Guide ways is used to facilitate sliding mechanism of the top and bottom slider and

also support the whole system. The material of the guide ways is so chosen that it has

minimum frictional co-efficient so that slider can slide smoothly on the guide ways.




This is the lead-screw. Upper half of the lead-screw is threaded left handed which will

mesh with the internal thread of the top-slider and lower half is threaded right handed

which will mesh with the internal thread of the bottom slider. This is done for pulling

the specimen from both sides to avoid any axial displacement of the center of the

specimen.


This is the top support. It holds the guide ways and lead screw. At the lead-screw

conjunction there is a thrust bearing to support if there any axial load exerted by the

specimen. There are also small holes with internal thread to attach the left and right

support by using screws. Fastening by using screw is easier than other method but the

only constraint is dimension should be precise.



This is the bottom support of the system. It is totally similar to the top support.
This is left and right support of the system. It holds all of the weight of the top support

and motor which is mounted on the top support and also makes the system stable. It

has small holes with internal thread on the top and bottom side to mount it with the

top and bottom support with the help of screw.

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uEMA 17, 23, and 34 frame sizes

Up to 1710 oz-in. (12.1 u · m) holding torque

3000 rpm max speed

1.8 deg step angle

Matched with P7000 drives for high performance

Stepper motors provide very precise, extremely cost-effective motion control. The

2-phase motors inherently move in small, precise, 1.8 degree increments at 200 steps /

revolution and are brushless and maintenance free. Stepping action is simple to

control and does not require complicated, expensive feedback devices. uational

Instruments also offers encoders matched to the motors for applications where

position verification is required. Stepper motors are available from uI in three

different uational Electrical Manufacturers Association (uEMA) frame sizes and with

either a single or a dual shaft. The motors provide optimum performance and easy

connectivity when matched with the P7000 series stepper drives available from uI.
 Àtepper Motor Drive
5 A continuous, 7.1 A peak current output, 20 to 75 V bus voltage

` Selectable 200 to 50,000 steps/revolution micro stepping

` Precision motion with encoder less stall detection, anti-resonance filtering, and

dynamic smoothing

` 20 to 75 VDC input voltage

` Easy connectivity to uI motion controllers

` Ability to match with uI stepper motors and motion controllers for best performance

The uI P70530 one-axis stepper power drive delivers the highest-performance

precision motion with micro stepping and anti-resonance filters for smooth motion

and encoder less stall detection to ensure reliable control.

 Micro-controller
A microcontroller (sometimes abbreviated C, uC or MCU) is a small computer on a

single integrated circuit containing a processor core, memory, and

programmable input/output peripherals. Program memory in the form of uOR

flash or OTP ROM is also often included on chip, as well as a typically small amount

of RAM. Microcontrollers are designed for embedded applications, in contrast to

the microprocessors used in personal computers or other general purpose applications.

Microcontrollers are used in automatically controlled products and devices, such as

automobile engine control systems, implantable medical devices, remote controls,

office machines, appliances, power tools, and toys. By reducing the size and cost

compared to a design that uses a separate microprocessor, memory, and input/output

devices, microcontrollers make it economical to digitally control even more devices

and processes. Mixed signal microcontrollers are common, integrating analog

components needed to control non-digital electronic systems.


 

A micro-controller is a single integrated circuit, commonly with the following

features:

ë central processing unit - ranging from small and simple 4-bit processors to

complex 32- or 64-bit processors

ë discrete input and output bits, allowing control or detection of the logic state of an

individual package pin

ë serial input/output such as serial ports (UARTs)

ë other serial communications interfaces like I²C, Serial Peripheral

Interface and Controller Area uetwork for system interconnect

ë peripherals such as timers, event counters, PWM generators, and watchdog

ë volatile memory (RAM) for data storage

ë ROM, EPROM, EEPROM or Flash memory for program and operating parameter

storage
ë clock generator - often an oscillator for a quartz timing crystal, resonator or RC

circuit

ë many include analog-to-digital converters

ë in-circuit programming and debugging support

This integration drastically reduces the number of chips and the amount of wiring

and circuit board space that would be needed to produce equivalent systems using

separate chips. Furthermore, and on low pin count devices in particular, each pin may

interface to several internal peripherals, with the pin function selected by software.

This allows a part to be used in a wider variety of applications than if pins had

dedicated functions.


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In our design we keep all the functional requirements independent to follow the

Axiom 1, the independence axiom. We decompose our functional requirements to find

out easier solutions. We used Micro-controller for controlling the motor drive which

makes the design cost effective and less complex and lighter because micro-controller

has different controlling capability in a single small chip. We used Atmel ATtiny861

micro-controller and we use µC¶ programming language to make the commands and

give the required pulses to diver to drive the motor as the requirement.


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