Vibration Test Rig USER’SMANUAL

Rochester Institute of Technology

Prepared by: P16103 -Melissa St. Preux-Peter Artuso, -Timothy Wilhelm-Brian Herzog-Richard Maroney

April, 2016

Revision Sheet

Release No. Date Revision DescriptionRev. 0 04/07/2016 User’s Manual CreatedRev. 1 05/03/2016 Update test rig set-up, usage, and breakdownRev. 2

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USER'S MANUAL

TABLE OF CONTENTS

Page #

1.0 GENERAL INFORMATION..........................................................................................................1-1

1.1 System Overview.........................................................................................................................1-1

1.2 Acronyms and Abbreviations....................................................................................................1-1

2.0 SYSTEM SUMMARY......................................................................................................................2-1

2.1 System Model...............................................................................................................................2-1

2.2 Pneumatics...................................................................................................................................2-2

2.3 Damping.......................................................................................................................................2-3

2.4 Sensors..........................................................................................................................................2-3

2.5 User Safety...................................................................................................................................2-5

3.0 GETTING STARTED......................................................................................................................3-1

3.1 System Configuration.................................................................................................................3-1

3.2 User Interface and Controls.......................................................................................................3-1

3.3 Setting Up LabVIEW..................................................................................................................3-1

3.3 Installing the Accelerometer......................................................................................................3-1

4.0 USING the TEST RIG......................................................................................................................4-1

4.1 System Set-Up..............................................................................................................................4-14.1.1 System Components..............................................................................................................................4-14.1.2 Step-by-step Instructions.......................................................................................................................4-14.1.3 P-Pod Configuration..............................................................................................................................4-14.1.4 LabVIEW Instructions..........................................................................................................................4-14.1.5 Accelerometer Installation....................................................................................................................4-1

4.2 Running the Test.........................................................................................................................4-2

4.3 System Break-Down....................................................................................................................4-24.3.1 Step-by-Step Instructions......................................................................................................................4-24.3.2 P-Pod Deconfiguration..........................................................................................................................4-24.3.3 Clean-Up...............................................................................................................................................4-2

4.4 Maintaining the Test Rig............................................................................................................4-24.4.1 Test Rig Top Assembly.........................................................................................................................4-24.4.2 Test Rig Bottom Assembly...................................................................................................................4-24.4.3 Chords and Tubing................................................................................................................................4-24.4.4 Sorbothane Damping Hemispheres.......................................................................................................4-2

4.5 Other............................................................................................................................................4-24.5.1 A............................................................................................................................................................4-24.5.2 B............................................................................................................................................................4-24.5.3 C............................................................................................................................................................4-2

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1.0 General Information

1.0 GENERAL INFORMATION

User’s Manual

2.0 System Summary

1.0 GENERAL INFORMATION

1.1 System Overview

The RIT-SPEX vibration test rig is a cost effective to run and is capable of simulating the launch environment of commonly used CubeSat launch vehicles (5-100Hz frequencies). A CubeSat is a small satellite, which often serves as a more cost effective means of testing space system technology

This test rig is integrated with a LabVIEW application that utilizes pre-written code that makes using the test rig more efficient. This application provides a simple use interface that allows the user to visualize all information and easily set up testing.

1.2 Acronyms and Abbreviations

SPEX – Space Exploration GroupMSD – Multidisciplinary Senior DesignP-Pod – Poly-Picosatellite Orbital DeployerDAQ – Data Acquisition E-Stop –Emergency Stop

User’s Manual

2.0 System Summary

2.0 SYSTEM SUMMARY

User’s Manual

2.0 System Summary

2.0 SYSTEM SUMMARY

2.1 System Model

The vibration test rig materials are all made from 6063-T83 aluminum. COMSOL structural analysis testing was done to the entire system and its individual parts to ensure that the rig could withstand the required frequencies. Each part and their respective part numbers are labeled below:

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2.0 System Summary

The system architecture of the vibration test rig is illustrated below:

2.2 Pneumatics

The piston system designed for the test rig is a pneumatic controlled piston. It includes a double-acting piston controlled by a solenoid valve and powered by a compressor. It meets the necessary requirements of reaching a frequency range of 5-100 Hz, its ability to lift 30 pounds, and reaching amplitude of 0.501 inches.

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2.0 System Summary

2.3 LabVIEWBlablablabla

2.4 Damping

Sorbothane 50 durometer hemispheres isolate the vibrations of the test rig from its tabletop. There are four hemispheres, one per each corner of the rig’s baseplate. The hemispheres are 2 inches in diameter and 1 inch in height. Each hemisphere has a load rating of 17-24 pounds. Sorbothane hemisphere mounts are visco-elastic polymers that provide a quick, cost-effective method of isolating small machinery and bench equipment. It combines shock absorption, good memory, long fatigue life and vibration isolation/vibration damping characteristics. Feasibility analysis was

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2.0 System Summary

done to ensure that the hemispheres are capable of damping the system (https://edge.rit.edu/edge/P16103/public/Detailed%20Design).

2.5 SensorsThe Adafruit 9-DOF is an accelerometer with an included gyroscope, which is hooked up to the emergency stop in LabVIEW (section 2.5). If any tip beyond five degrees is detected, the gyroscope will send a signal to the LabVIEW program to stop the device completely.

The accelerometer board is installed onto the rig prior to testing using a LabVIEW DAQ.

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2.0 System Summary

The sensor’s characteristics and specifications are listed below:

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2.0 System Summary

2.6 User Safety

The test rig uses a heavy-duty emergency stop button with a bottom panel that supports its wiring and switch. This button is mounted to the base of the structure where the vibration requirements are significantly lessened.In order to stop the program, the emergency stop button and a true/false case loop will be implemented. This loop will surround the entire control system and will stop the program from running. It is a simple and free way to make sure there is a way to end the program as needed.

In order to stop the program, the emergency stop button and a true/false case loop will be implemented. This loop will surround the entire control system and will stop the program from running. It is a simple and free way to make sure there is a way to end the program as needed.

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3.0 Getting Started

3.0 GETTING STARTED

User’s Manual

4.0 Using the Test Rig

3.0 GETTING STARTED

3.1 System Configuration

The diagram below shows an overhead view of the critical processes running the test rig. The processes are broken down into two sections: providing inputs to the system’s solenoid and control valves, and sampling/validating data.

3.2 User Interface and Controls

3.3 Setting Up LabVIEW

The LabVIEW program and associated myDAQ device are designed with the intent of near instantaneous response. Ensure that the myDAQ is plugged into the computer when starting up the LabVIEW program.To start the LabVIEW program:

1. First, start by running “LavVIEW”2. Click “ “ to open the code for the vibration testing

Etc..

3.3 Installing the AccelerometerThe LabVIEW program and associated DAQ device are designed with the intent of near instantaneous response.

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4.0 Using the Test Rig

4.0 USING THE TEST RIG

User’s Manual

4.0 Using the Test Rig

4.0 USING THE TEST RIG

4.1 System Set-Up

4.1.1 System ComponentsIn order to run the test the following components are required

Vibration test rig with Sorbothane dampers Latptop/Computer with charger myDAQ with USB cable Arduino and breadboard DC power supply Solenoid 3 1/8” tubing Pressure regulator with pressure gauge Shop air Emergency Stop

4.1.2 Step-by-step Instructions1. Install the pressure regulator to the shop air pipe2. Attach the longer 1/8” black tubing from the pressure regulator connection to the solenoid3. Attach the two shorter 1/8” black tubing from the solenoid connections to the piston inputs4. Plug the signal cable into the third connection of the solenoid

a. Note: Be careful of the three-pin connection 5. Connect the myDAQ to the computer with the USB chord6. Plug in the DC power supply and connect it to the

4.1.3 P-Pod Configuration1. Screw in the rails from the baseplate

a. Leave the screws loose2. Make sure all components are aligned using the calibration cube (see Fig)3. Screw in 4. Unscrew all four side walls of the P-Pod5. Pull out all dummy (spacer cubes) CubeSats from inside of the P-Pod6. Insert the actual CubeSat into the P-Pod using the rails7. Attach the P-Pod cover and fasten all four screws8. Tighten all P-Pod wall screws and ensure that all of the bolts are secured9.

4.1.4 LabVIEW InstructionsThe LabVIEW program is available on a flash drive owned by the SPEX team. Their space is located on the second floor of the Center for Micro-Engineering and & Computer Engineering (B17).

4.1.5 Accelerometer Installation The accelerometer is used to validate the required frequencies and amplitudes of the test rig. To install the accelerometer:

4.0 Using the Test Rig

4.2 Running the TestThe LabVIEW program can run three distinct tests:

1. 6 speed test at 15 seconds for each speed (5Hz,10Hz,20Hz,60Hz,80Hz,100Hz)2. B3. C

Once a specific program is chosen, the test can be started by hitting “run” on the LabVIEW Front Panel

4.3 System Break-DownUpon the completion of testing, the LabVIEW code will shut off automatically.

4.3.1 Step-by-Step InstructionsAfter a record has been loaded and information has been changed the user can update the record by clicking on “Update” under the “Student” menu.

4.3.2 P-Pod Deconfiguration1. Loosen the P-Pod wall screws2. Unfasten the P-Pod cover screws and take off the cover3. Release the CubeSat by sliding it up through the rails4.

4.3.3 Clean-UpAafejafjl

4.4 Maintaining the Test RigSince the test rig is built to be portable, the user can move the rig by hand. The rig is to be stored in the SPEX laboratory located on the second floor of Engineering Hall (building 17). When not in use, the test rig should be isolated from other objects in the lab. Items should not be placed on top of the rig.

4.4.1 Test Rig Top Assembly

4.4.2 Test Rig Bottom Assembly

4.0 Using the Test Rig

4.4.3 Chords and Tubing

4.4.4 Sorbothane Damping Hemispheres

4.5 Other

4.5.1 AWhat

4.5.2 BTo

4.5.3 COnce