1. Acknowledgments
We thank AEM for being our Capstone
sponsor and providing us with support
through all the stages of our design. We
thank Dr. Yang Cao for providing support
for our project as our faculty supervisor. We
thank Durwin Bossy, Ryan Mantau,and
Russell LaMountain for support and
patience during the build phase.
Introduction
Anodyne Electronics Manufacturing
(AEM) proposed a Capstone project to
design and build a machine that will verify
the functionality of a proprietary crack
detection sensor.
Core machine objectives:
- Induce fatigue fractures through cyclic
axial and static torsional loading within
a one week test.
- Allow attachment of crack detection
device to aluminum coupon (thin,
rectangular plate).
- Allow for future software development
to stop test when crack is detected.
Structural Design
The structural design has several main
components summarized below.
Frame
- 6”x6” structural steel members
- CNC machined to ensure dimensional
accuracy.
Load Cell Adapter
- Attaches the load cell to the hydraulic
cylinder
Slider Channels
- Isolate torsional loading from the
hydraulic system and load cell (Fig.1)
Coupon Clamps:
- Top clamp attaches the test coupon to
the load cell (Fig. 1)
- Bottom clamp attaches the test coupon
to the rotation plate (Fig. 2)
Rotation Plate
- Allows user to apply a static torsional
load to the test coupon (Fig. 2)
Results
Core machine objectives were achieved:
- Induce in-plane and out-of-plane fatigue
cracks in aluminum coupons
- Crack coupons within a week of cyclic
fatigue loading
- Modular software design
- Built machine within a $10,000 budget
as shown in Fig. 6 and Table 2
Axial Torsional Cyclic Load Test Machine
Robbie Sharma, Rick Gostlin, Brendon Skow and Trevor Condon
Faculty Supervisor: Dr. Yang Cao, Industry Sponsor: Anodyne Electronics Manufacturing
Group 16
Fig. 1. Slider Channel isolates torsional
loading from hydraulic system and load cell.
Mechanical
Components
1. Frame
2. Hydraulic Cylinder
3. Load Cell Adapter
4. Load Cell (Force
Sensor)
5. Slider Channels
6. Test Coupon
7. Rotation Plate
8. Cross Beam
For further information
Please contact yang.cao@ubc.ca. More
information about Anodyne Electronics
Manufacturing can be found at http://www.aem-
corp.com/
Fig. 3. Test coupons (after testing)
Hydraulics Design
1. Determine tensile strength of aluminum
samples as shown in Fig. 3.
2. Determine elongation of aluminum
coupon at 12.5kN to 16kN axial
loading.
3. Calculate maximum velocity of piston
head cycling vertically at 20Hz.
4. Calculate peak flow rate and cylinder
differential pressure based on cylinder
bore size.
5. Size servo-proportional valve based on
pressure and flow rate.
6. Iterate through available and compatible
cylinder bore sizes and servo-
proportional valves.
7. Size pump for required operating
pressures and flow rates.
Hydraulic system summarized in Table 1.
Power System Design
- Pump and transformer operate at 208V.
- Transformer converts 208V to 24 VAC
- Switching power supply converts 24
VAC to required DC voltages.
- Line voltage components selected are
CSA approved as shown in Fig. 5
Table 1. Summary of hydraulic selection
Fig. 5. Electrical panel fully assembled
Fig. 2. Rotation Plate allows for static
torsional loading during tests.
Control
Update
+
Load Cell Reading
Desired Signal
Control System Design
- Arduino © microcontroller (uC)
provides digital closed-loop feedback
control
- uC processes force readings from the
load cell and sends a signal to the
hydraulic servo valve to induce loading.
- Host computer interfaces to uC via USB
for user control
- User can set operating parameters and
log sensor readings for analysis through
the host computer.
- Software is modular for future
development
Control Loop
Fig. 4. SolidWorks™ rendering of machine
Table 2. Budget and Cost Summary
Fig. 6. Machine fully assembled
Item Nominal Cost UpperCost Actual Cost
Electrical 347.13$ 436.15$ 270.55$
Hydraulics 4,270.66$ 5,673.06$ 4,465.78$
Load cell 1,375.40$ 1,375.40$ 1,388.90$
Test frame 1,070.98$ 2,010.59$ 1,160.80$
Misc -$ -$ 17.00$
Hardware 501.71$ 501.71$ 405.60$
Total 7,565.88$ 9,996.91$ 7,708.63$
Citations
Moog. "D633 and D634 Series Direct Drive
Technical Specifications." Catalog. 2009.
—. "D633-A Series User Manual." User
manual. 2008.
—. Electrohydraulc Valves... A Technical
Look. Technical . East Aurora: Moog, n.d.
Component Model
Cylinder H25C Royal Cylinder
2.5” Bore 1” Rod 4”
Stroke
Servo valve Moog D633-303B
Servo-proportional
control valve
Power unit 2 HP 115/230V AC
1.25GPM Gear pump
10 micron filtration