January 11, 2013 UL Vibration Test Apparatus 1

Final Design

Linear Slider

• Keeps mechanisms enclosed for safety• Prevents contaminates from getting into

mechanisms• Polycarbonate maintenance hatches on top

and side of mechanism• 1” diameter extension rod allows for more

robust design without concern of buckling

January 11, 2013 UL Vibration Test Apparatus 2

January 11, 2013 UL Vibration Test Apparatus 3

Linear RailsLinear Bearings

Linear Slider Slider Frame

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Connecting Rod

Extension Rod

Adjustment Mechanism

Shaft Bearings

Drive Shaft

Baseplate

Rotating Disc

Shaft Flange

Rear CoverTop Cover

Adjustment Mechanism

• Allows for adjustment in eccentricity in order to account for tolerance stack-ups and wear

• Allows for verification and adjustment of deflection• Set screw used for fine adjustment• Alignment blocks allow for the measurement of

adjustment using calipers• Two socket head cap screws for locking the system in

place• Nord Lock washers to prevent loosening of

adjustment mechanismJanuary 11, 2013 UL Vibration Test Apparatus 5

January 11, 2013 UL Vibration Test Apparatus 6

Springs

Alignment Blocks

Clamping Bolts

Press-Fit Crankpin

Adjustment Screw

Upper Slider

Rotating Disc Notched Bed

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Press-Fit Crankpin

T-Block Clamps

Notched Bed

Upper Slider

Clamping Bolts

January 11, 2013 UL Vibration Test Apparatus 8

Connecting Rod• Peel-Away Brass Shaft Shims• Shaft collars for holding bearings in place

January 11, 2013 UL Vibration Test Apparatus 9

Frame Design

January 11, 2013 UL Vibration Test Apparatus 10

Frame Design

January 11, 2013 UL Vibration Test Apparatus 11

Advantages:• Allows for a single technician to mount the

luminaire• Extra support of U-channel decrease vibration

of system• Rubber pads in-between supporting beams help

in dampening the system• More space efficient than current design• Approximately 44” X 34” footprint

Lubrication

• Drive Shaft Bearings: Double sealed flange mount bearings with easy access grease zerk fittings.

• Linear Bearings: Double sealed closed bearings with easy access grease zerk fittings.

• Crank Arm Bearings: Double Sealed roller bearings pre-packed with grease . Easy access for lubrication by taking off Polycarbonate cover.

January 11, 2013 UL Vibration Test Apparatus 12

Test Plan• Test the deflection of the pipe• Dial gauge• Measure required torque using torque wrench• Flanged collar mechanism

January 11, 2013 UL Vibration Test Apparatus 13

Part Part Description Supplier Purchase # Qty. Pkg. Qty. Unit Price PriceDowel 1/2"D X2" Alloy Steel MSC MSC#73079030 2 1 4.34 8.68Dowel 1/4"D X 3/4" Alloy Steel MSC MSC#06024079 2 100 17.76 17.76Dowel 1/4"D X 1" Alloy Steel MSC MSC#06024103 13 100 20.56 20.56Dowel 1/4"D X 1.5" Alloy Steel MSC MSC#06024152 36 100 24.83 24.83Dowel 3/4"D X 2" Alloy Steel MSC MSC#00328922 2 1 8.09 16.18

Nut Grade 8 Steel Nylon-Insert Hex Locknut Znc-Yellow Pltd, 1/2"-13 Thrd Sz, 3/4" W, 19/32" H McMaster-Carr MMC#97135A250 4 10 4.44 4.44Nut Grade 8 Steel Nylon-Insert Hex Locknut Znc-Yellow Pltd, 3/8"-16 Thrd Sz, 9/16" W, 29/64" H McMaster-Carr MMC#97135A230 8 100 4.14 4.14

Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/2"-13 Thread, 2-3/4" Length McMaster-Carr MMC#91251A723 2 5 5.86 5.86Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/2"-13 Thread, 3" Length McMaster-Carr MMC#91251A724 2 5 5.94 5.94Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 2" Length McMaster-Carr MMC#91251A550 4 25 5.51 5.51Screw Black-Oxide Alloy Steel Socket Head Cap Screw 3/8"-16 Thread, 2-1/4" Length McMaster-Carr MMC#91251A633 8 25 9.21 9.21Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 3/4" Length McMaster-Carr MMC#91251A540 18 50 6.96 6.96Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 1" Length McMaster-Carr MMC#91251A542 19 50 7.58 7.58Screw Black-Oxide Alloy Steel Socket Head Cap Screw 3/8"-16 Thread, 7/8" Length McMaster-Carr MMC#91251A623 4 25 6.09 6.09Screw Black-Oxide Alloy Steel Socket Head Cap Screw 1/4"-20 Thread, 1-1/4" Length McMaster-Carr MMC#91251A544 16 50 11.03 11.03

Set Screw Alloy Steel Flat Point Socket Set Screw 1/2"-13 Thread, 1-1/4" Length McMaster-Carr MMC#94105A715 1 5 9.87 9.87Die Spring Screw Die-Spring Screw Cap 9/16"-18 Thread, 1/4" Hex, 5/16" Thickness McMaster-Carr MMC#96235K700 2 1 2.54 5.08

Nylon Bushing Nylon Bearing Flanged, for 1/2" Shaft Dia, 5/8" OD, 3/8" Length McMaster-Carr MMC#6389K419 2 1 5.54 11.08Drive Shaft Fully Keyed Precision Drive Shaft W/Cert 1" OD, 1/4" Keyway Width, 12" Length McMaster-Carr MMC#8488T84 1 1 34.06 34.06

Shim Wide-Rim Zinc-Plated Steel Shim .075" Thick, 1" ID, 1-1/2" OD McMaster-Carr MMC#97669A330 2 25 5.82 5.82Key Steel Machine Key Oversized w/ Square Ends, 1/4" Square, 1" Length McMaster-Carr MMC#98870A395 1 10 5.1 5.1

Flanged Shaft Collar Mounting Flange One-Piece Steel Shaft Collar 1" Bore, 2" Collar OD, 1" Overall Width McMaster-Carr MMC#9684T4 1 1 38.13 38.13T Block Black-Oxide Steel Full-Thread T-Slot Nut 1/2"-13 Thread Size, for 5/8" Slot Width McMaster-Carr MMC#94750A584 2 1 3.17 6.34

Lock Washer Zinc-Coated Steel Wedge Lock Washer 1/2" Screw Size, .77" OD, .10" Thick McMaster-Carr MMC#91074A133 2 10 9.32 9.32spring Type 302 Stainless Steel Compression Spring .750" Length, .500" OD, .062" Wire Diameter McMaster-Carr MMC#1986K118 2 6 4.76 4.76

Shaft Collar Two-Piece Shaft Collar with Wrench Flats 1" Bore, 1-3/4" Outside Diameter, 1/2" Width McMaster-Carr MMC#9746T4 1 1 7.17 7.17Extension Rod Steel Drive Shaft 1" OD, 24" Length McMaster-Carr MMC#1346K38 1 1 40.82 40.82

Linear Rail Hardened Precision Steel Shaft 1" Diameter, 18" Length McMaster-Carr MMC#6061K45 2 1 21.18 42.36Linear Bearing High-Speed Pillow-Block Linear Sleeve Bearing Closed, for 1" Shaft Diameter McMaster-Carr MMC#6674K16 4 1 93.37 373.48

Pin Collar Two-Piece Clamp-on Shaft Collar Steel, 3/4" Bore, 1-1/2" OD, 1/2" Width McMaster-Carr MMC#6436K16 2 1 4.46 8.92Shaft Support Quick-Access Base Mount Shaft Support for 1" Shaft OD McMaster-Carr MMC#1865K6 6 1 24.57 147.42

Peel Away Shim 1 Peel-Away Brass Shim .032" Thick, 3/4" ID, 1-1/8" OD McMaster-Carr MMC#90805A164 3 1 6.8 20.4Peel Away Shim 2 Peel-Away Brass Shim .062" Thick, 3/4" ID, 1-1/8" OD McMaster-Carr MMC#90805A184 1 1 9.17 9.17

Ball bearing High-Load Steel Ball Bearing Dbl Sealed, for Shaft Dia 3/4" X 1-3/4" OD X 1/2" W McMaster-Carr MMC#2780T3 2 1 17.85 35.7Flange Mount Bearing Cast Iron Flange-Mounted Steel Ball Bearing 4-Bolt SQ-Flange, for 1" Shaft Diameter McMaster-Carr MMC#5967K84 2 1 41.97 83.94

1053.71

Hardware & Standard Parts

Hardware and Standard Parts Total:

Part Part Qty. Part Description Supplier Purchase # Qty. Unit Price PriceAlignment Block 1

Adjustment Screw Plate 1Spring Plate 1

Adjustment Base 1 12"X4"X1" 1018 Steel MSC MSC #03913977 1 55.32 55.32Adjustment Slider 1 12X4X1.5 1018 Steel MSC MSC #03915626 1 83.64 83.64

Circular Plate 1 8"D X 3/4" 304 Stainless Steel MSC MSC #75335299 1 154.7 154.7Side Plates 2 Multipurpose O1 Tool Steel Tight-Tolerance Flat Stock, 1/2" X 8", 1-1/2'L McMaster-Carr MMC#9516K718 2 163.23 326.46Front Plate 1 Low-Carbon Steel Sheet 1/2" Thick, 8" X 12", Ground Finish McMaster-Carr MMC#1388K371 1 88.1 88.1Support Rib 2 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 2-1/2" Width McMaster-Carr MMC#9517K526 2 29.96 59.92

Platform Plate 1 Multipurpose 4140/4142 Alloy Steel Oversized Sheet, 1/2" Thick, 10" X 12" McMaster-Carr MMC#4473T13 1 84.78 84.78Back Support Rib 2 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 2" Width McMaster-Carr MMC#9517K524 2 27.01 54.02

Riser Block 4 Low-Carbon Steel Tight-Tolerance Rect Bar 1" Thick, 1" Width McMaster-Carr MMC#9517K595 1 52.76 52.76Polycarbonate Sheet 1 1Polycarbonate Sheet 2 1

Crank Arm 1 Low-Carbon Steel Tight-Tolerance Rect Bar 1/2" Thick, 3" Width McMaster-Carr MMC#9517K528 1 35.74 35.74Base Plate 1 Low-Carbon Steel Sheet 1" Thick, 24" X 24", Ground Finish McMaster-Carr MMC#1388K581 1 416.39 416.39

Extension Rod 1 Steel Drive Shaft 1" OD, 24" Length McMaster-Carr MMC#1346K38 1 40.82 40.82Pin Block 1 Low-Carbon Steel Sheet 1-1/2" Thick, 4" X 4", Ground Finish McMaster-Carr MMC#1388K704 1 44.76 44.76

1657

Raw Materials

Raw Material:

66.56

12"X4"X.5" 6061 Aluminum MSC MSC #86466356 1 93.03 93.03

Impact-Resistant Polycarbonate Sheet 1/4" Thick, 24" X 36", Clear McMaster-Carr MMC#8574K285 1 66.56

Part Description Supplier Purchase # Qty. Pkg. Qty. Unit Price Price1/2" x 2.5" 13 Bolt McMaster-Carr MMC#92327A308 36 1 4.11 147.96

1/2" 13 Nut McMaster-Carr MMC#90499A033 52 50 7.83 15.663/4" 10 Bolt McMaster-Carr MMC#92327A362 8 1 8.03 64.24

3/4" 10 Lock Nut McMaster-Carr MMC#90630A135 8 5 4.45 8.901/2" x 4" 13 Bolt McMaster-Carr MMC#92327A314 16 1 6.00 96.00

Pipe Flange McMaster-Carr MMC#6806K125 1 1 30.00 30.005/8" 11 Bolt McMaster-Carr MMC#92327A332 5 1 5.08 25.405/8" 11 Nut McMaster-Carr MMC#90499A832 5 50 12.04 12.04U Channel Metals Depot C21025 1 1 157.48 157.48

H Beam Metals Depot B2413 6 1 107.50 645.003' Crossbeam McMaster-Carr MMC#8910K58 5 1 102.87 514.35

Rubber Damper McMaster-Carr MMC#9023K26 2 1 20.47 40.94H Beam Feet McMaster-Carr MMC#8910K58 1 1 102.87 102.87

L Bracket McMaster-Carr MMC#8910K302 1 1 256.91 256.91

2117.75

Frame Components

Frame Components Total:

Part Part Description Supplier Purchase # Qty. PriceFlanged Shaft Collar Mounting Flange One-Piece Steel Shaft Collar 1" Bore, 2" Collar OD, 1" Overall Width McMaster-Carr MMC#9684T4 1 38.13

Socket Drive 3/8" Square Drive Socket 12-Point Std, 3/4" Sz, 1-1/8" L O'all, Black Fnsh McMaster-Carr MMC#5484A49 1 5.28Dial Indicator Mitutoyo Dial Indicator Continuous, 1-5/8" Dia, 0-0.250" Range, 1410S-10 McMaster-Carr MMC#2246A41 1 95.23

138.64

Test Materials

Test Material Total:

Part Part Description Supplier Purchase # PriceMotor 1Hp 3450RPM, 3PH, 60Hz, 230/460V Baldor M3545 472

Motor Base Adjustable NEMA Motor-Mount Base for NEMA 56 Frame McMaster-Carr MMC#62035K21 19.02

491.02

Motor Components

Motor Components Total:

-Brinkman Lab Machining: $90 per hour-Only part of the frame may be developed for test purposes-Unexpected tooling costs that may arise-Need for remaking parts (we are not expert machinists)

Cost Category CostHardware & Standard Components 1053.71Raw Materials 1657.00Frame Components 2117.75Test Materials 138.64Motor Components 491.02Est. Machining Costs 360.00Est. Unexpected Costs 300.00

Total: 6118.12

Cost Breakdown

January 11, 2013 UL Vibration Test Apparatus 19

January 11, 2013 UL Vibration Test Apparatus 20